SBIR Phase II: Long Fiber Thermoplastic Composites from Recycled Carbon Fiber

该小型企业创新研究第二阶段项目将开发基于回收碳纤维的长纤维热塑性（LFT）组合物。 在第一阶段，我们展示了基于（1）废碳纤维和（2）复合材料废料和报废热塑性和热固性碳纤维复合材料制造高质量LFT配方的能力。 这些复合材料的机械性能相似，在某些情况下，上级，那些原生碳纤维。 在这个项目中，我们将继续开发制造热固性和热塑性复合材料的制造能力。 在第二阶段的项目中，我们将研究以下技术问题：（1）研究新的再生纤维形式的使用，并将结果与先前的数据进行比较;（2）研究与LFT平坯“锻造”相关的成型参数;（3）优化LFT成分;（4）展示一致的成型性和机械性能;（5）研究与LFT平坯“锻造”相关的成型参数。和（5）证明模塑的LFT部件转化回LFT化合物以在再循环上“闭环”。 这项工作将与一家非营利复合材料实验室和另一家小企业建立合作伙伴关系，这两家公司在使用原始碳纤维开发LFT方面都有丰富的经验。 该项目更广泛的影响/商业潜力包括减少进入垃圾填埋场的碳纤维数量和降低温室气体排放。 全球碳纤维产量每年约为8000万磅，需求每年增长约15%。保守地说，这种纤维的20%最终在复合材料制造过程中成为废物（约1600万磅/年）并被填埋。 航空航天工业是这种材料的主要消费者（军用飞机，波音787和空客A380），但工业，汽车和娱乐市场也在增长。 然而，很少有复合材料制造工艺设计用于短切纤维，这是回收碳纤维的主要形式。 开发基于回收碳纤维的LFT将使我们能够通过消除垃圾填埋、降低相对于原始纤维的能源成本以及提高可持续性来实现“三度绿色”。 如果能够开发出以再生材料的典型形式使用再生纤维的制造方法，则存在重大的商业机会。 由回收/再生碳纤维制成的复合材料的潜在市场超过2亿美元。 最后，回收碳纤维所需的能量仅为制造原生纤维所需的4%左右，减少了相关的温室气体排放。

This Small Business Innovation Research Phase II project will develop long fiber thermoplastic (LFT) compositions based on recycled carbon fiber. In Phase I, we demonstrated the ability to make high quality LFT formulations based on (1) waste carbon fiber and (2) composites scrap and end-of-life thermoplastic and thermoset carbon fiber composites. Mechanical properties of these composites were similar to, and in some cases superior to, those for virgin carbon fiber. In this project, we will continue to develop manufacturing capabilities to make both thermoset and thermoplastic composites. In this Phase II project, we will look at the following technical issues: (1) examining the use of new recycled fiber forms and comparing the results to prior data; (2) investigating the molding parameters associated with the "forging" of flat blanks of LFT; (3) optimizing the LFT compositions; (4) demonstrating consistent moldability and mechanical properties; and (5) demonstrating the conversion of molded LFT parts back into LFT compound to "close the loop" on recycling. This effort will feature partnerships with a not-for-profit composites laboratory and another small business, both of whom have extensive experience in developing LFTs using virgin carbon fiber. The broader impact/commercial potential of this project includes a reduction in the amount of carbon fiber going into landfills and lower greenhouse gas emissions. Worldwide carbon fiber production is ~80 million pounds per year, with demand growing at ~15% annually. Conservatively, 20% of this fiber ends up as waste during composite manufacture (~16 million pounds/year) and is landfilled. The aerospace industry is a main consumer of this material (military aircraft, Boeing 787 and Airbus A380), but industrial, automotive, and recreational markets are also growing. However, few composite manufacturing processes are designed to work with chopped fibers, which is the primary form of recycled carbon fiber. Developing LFTs based on recycled carbon fiber will allow us to achieve "Three Shades of Green" by eliminating landfilling, reducing energy costs relative to virgin fiber, and improving sustainability. A significant business opportunity exists if manufacturing methods can be developed that use recycled fiber in the forms that are typical of reclaimed material. The potential market for composites made from recycled/reclaimed carbon fiber is more than $200 million. Finally, the amount of energy needed to recycle carbon fiber is only about 4% of that needed to make virgin fiber, reducing associated greenhouse gas emissions.