Application of recycled carbon-fibre-reinforced polymers as reinforcement for epoxy foams

An Integrative Chemical Recycling Approach for Catalytic Oxidation of Epoxy Resin and in situ Separation of Degraded Products

Although many approaches have been proposed to recycling waste epoxy resin (EP), the separation of mixed degraded products remains a challenge due to their similar structures. To address this, we present a catalytic oxidation strategy that enables mild degradation of EP and in situ separation of degraded products through supramolecular interactions. The oxidative degradation relies on FeIV=O radicals with strong oxidizing properties, which are generated from the electron transfer of FeCl2 with reaction reagents. As the FeIV=O radicals attacked the C-N bonds of EP, EP was broken into fragments rich in active functional groups. Meanwhile, the FeIV=O radicals were reduced to iron ions that can coordinate with the carboxyl groups on the fragments. As a result, the degraded products with different carboxyl content can be effortlessly separated into liquid and solid phase by coordinating with the catalyst. The success of this work lays the foundation for high-value application of degraded products and provides new design ideas for recycling waste plastics with complex compositions.

Mechanical Recycling of Carbon Fiber-Reinforced Polymer in a Circular Economy

This review thoroughly investigates the mechanical recycling of carbon fiber-reinforced polymer composites (CFRPCs), a critical area for sustainable material management. With CFRPC widely used in high-performance areas like aerospace, transportation, and energy, developing effective recycling methods is essential for tackling environmental and economic issues. Mechanical recycling stands out for its low energy consumption and minimal environmental impact. This paper reviews current mechanical recycling techniques, highlighting their benefits in terms of energy efficiency and material recovery, but also points out their challenges, such as the degradation of mechanical properties due to fiber damage and difficulties in achieving strong interfacial adhesion in recycled composites. A novel part of this review is the use of finite element analysis (FEA) to predict the behavior of recycled CFRPCs, showing the potential of recycled fibers to preserve structural integrity and performance. This review also emphasizes the need for more research to develop standardized mechanical recycling protocols for CFRPCs that enhance material properties, optimize recycling processes, and assess environmental impacts thoroughly. By combining experimental and numerical studies, this review identifies knowledge gaps and suggests future research directions. It aims to advance the development of sustainable, efficient, and economically viable CFRPC recycling methods. The insights from this review could significantly benefit the circular economy by reducing waste and enabling the reuse of valuable carbon fibers in new composite materials.

Bio-based hyperbranched epoxy resins: synthesis and recycling

Epoxy resins (EPs), accounting for about 70% of the thermosetting resin market, have been recognized as the most widely used thermosetting resins in the world. Nowadays, 90% of the world's EPs are obtained from the bisphenol A (BPA)-based epoxide prepolymer. However, certain limitations severely impede further applications of this advanced material, such as limited fossil-based resources, skyrocketing oil prices, nondegradability, and a "seesaw" between toughness and strength. In recent years, more and more research has been devoted to the preparation of novel epoxy materials to overcome the compromise between toughness and strength and solve plastic waste problems. Among them, the development of bio-based hyperbranched epoxy resins (HERs) is unique and attractive. Bio-based HERs synthesized from bio-derived monomers can be used as a matrix resin or a toughener resulting in partially or fully bio-based epoxy thermosets. The introduction of a hyperbranched structure can balance the strength and toughness of epoxy thermosets. Here, we especially focused on the recent progress in the development of bio-based HERs, including the monomer design, synthesis approaches, mechanical properties, degradation, and recycling strategies. In addition, we advance the challenges and perspectives to engineering application of bio-based HERs in the future. Overall, this review presents an up-to-date overview of bio-based HERs and guidance for emerging research on the sustainable development of EPs in versatile high-tech fields.

Improvement of lateral property of unidirectional-strengthened CFRP laminates using recycled carbon fiber

The unidirectional carbon fiber reinforced polymer (UD-CFRP) lacks the modulus of elasticity and strength in the lateral direction. This study investigates whether matrix resin with CFRP waste, recycled carbon fiber (rCF), can improve the lateral properties of CFRP. In total, twelve CFRP strips specimen were prefabricated of unidirectional carbon fiber (CF) sheet by hand lay-up (HLU) method and were tested by tensile test and X-ray computed tomography (X-ray CT). Factors such as fiber direction and void distribution significantly affecting its mechanical properties are assessed by X-ray CT inspection. It can be seen that rCF is mixed in a random direction at the position filled with matrix resin without rCF. However, a similar frequency of unimpregnation and voids can be observed in both specimens. Test results showed that experimental values of CFRP laminates with rCF-mixed matrix resin increased compared to the CFRP laminates without rCF. The percentage increase in the lateral tensile strength and modulus of elasticity of the rCFRP compared to the control specimen without rCF is 27.36% and 10.62%, respectively. This study proved that rCF can increase the lateral properties of unidirectional CFRP and shows the effective use of rCF for strengthening material in construction applications.

Investigation on the Mechanical Recycling of Carbon Fiber-Reinforced Polymers by Peripheral Down-Milling

Carbon fiber-reinforced plastics (CFRPs) are composite materials that play a significant role in the growth of many industrial fields where high performance and lightness of the structures are required. At the same time, the management at the end of their life has required the development of more and more sustainable and efficient recycling solutions. Considering this, the present research work aims to investigate a mechanical recycling method and the cutting strategies able to machine CFRP components in their entirety, using a common milling machine in a job shop scheme, making a shorter supply chain, and leading to economic and environmental benefits. In detail, laminates obtained by unidirectional carbon fiber prepregs were worked through the peripheral down-milling process, by varying the spindle speed and the feed rate. The recording of the cutting forces enabled the evaluation of features such as the cutting power and the specific cutting energy. Moreover, the chips from the milling process were classified as a function of their dimensions. Finally, specimens made of chips and epoxy resin were characterized under bending conditions, to evaluate the effectiveness of using the chips from CFRP peripheral milling as the polymer's reinforcement and, in addition, to appreciate the goodness of this recycling strategy.

Multifunctional Characteristics of Carbon Fibers Modified with Imidazolium Ionic Liquids

A multifunctional designing approach is of great importance for advanced composite applications. This study assessed the use of ionic liquids (ILs) to modify the surface of carbon fiber (CF) and impart multifunctional characteristics to it. For that, ethanolic solutions of different ILs, 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-butyl-3-methylimidazolium chloride and 1-(2-hydroxyethyl)-3-methylimidazolium chloride, at different concentrations, were used to treat the CF. Fourier-transform infrared spectroscopy confirmed the presence of IL on the CF surface. The contact angle for 1% w/v IL-treated CF and DGEBA epoxy decreased by up to 35%, corresponding to an increase in surface energy of fiber, accompanied by an increase of 91% in interfacial shear strength. These enhancements were achieved with the hydroxy-functionalized IL, showing the tunability of CF properties through the N-imidazolium substituent. An increase in crystallite size along the basal plane was also found due to the ordering of the graphitic structure on the surface. Moreover, there was a decrease in electrical resistivity of 77%. In all, the imidazolium ILs were considered a promising approach to induce multifunctional characteristics, namely enhanced interfacial strength and electrical conductivity, to unsized CF, which can also be beneficial for recycled fibers without deteriorating their inherent surface properties.

Progress in Chemical Recycling of Carbon Fiber Reinforced Epoxy Composites

Carbon fiber reinforced polymer (CFRP) composites are indispensable in a variety of applications, because of their high specific strength. CFRPs are generally constructed by carbon fibers as reinforcements and crosslinked polymers as binders. Due to the irreversible nature of the crosslinked polymers, CFRPs are neither repairable nor recyclable. Once the material is damaged or out of service, landfill or incineration are the typical ways to deal with the waste. These methods are taking no advantages from the residue value of the waste and adds burdens to the environment. To extend the service life and reduce the waste and cost, it is desirable to develop effective recycling technology to reserve the residue value of carbon fiber and polymer matrix. In the past decade, chemical recycling by cleaving the covalent bonds in a solvent has been considered as an ideal path for the recycling of CFRP wastes and deserves more investigations and attentions, because it has the potential to recover both valuable CFs and polymer matrix. In this review, the discussion is focused on the recent progress on the chemical recycling of CFRP. The primary matrix resin of CFRP discussed in this review is epoxy resin which is the most widely used polymer matrix in industry. In addition, the challenges and outlook are also provided. This article is protected by copyright. All rights reserved.