Infinity | High-performance tapes made from recycled carbon fibers for lightweight construction

At the start, there is an innovative type of pyrolysis which, in addition to the use of high-quality rCF, for the first time also enables material recycling of the pyrolysis oil produced.

After separation of fibers and matrix, the fibers obtained by the process are prepared in a modified textile carding process and further processed into highly oriented rCF tapes in an additional downstream process.

Value chain considered in the Infinity project: fiber recovery by pyrolysis, tape processing, fiberplacement and functionalization.

By using different fiber placement technologies, these highly oriented rCF tapes can be deposited according to the load path to find application in demanding areas such as aerospace. In addition, due to its discontinuous fiber structure, very high draping capability up to deep drawability / flowability can be achieved with the rCF tape, and there is the possibility of realizing tight lay-up ratios (steering), which - according to the current state of the art - are not possible with unidirectional materials.

In the direct injection molding process, the rCF tapes are also functionalized using recycled carbon fibers as a reinforcing phase. In addition, the component receives further functionalization through physical foaming.

Thus, this material represents the highest possible recycling result for CFRP components at the fiber level and is far superior to the current recycling methods, such as hazardous waste incineration or recycling as classic rC nonwovens.

In the »Infinity« project, the fiber-friendly recycling process is demonstrated using a thermoplastic structural component from the aerospace sector, which can also be used to show material substitution.

By drawing up a life cycle assessment, the potential CO2 savings in fiber separation, the manufacture of the component, and its functionalization are also demonstrated.  

Of course, the process is not limited to the aerospace sector but is explicitly transferred to all lightweight construction sectors (automotive, wind power, and sports).