The recycling of thermoset materials into thermoplastic composites

However, interest in CFRTPs has grown rapidly across multiple industries including automotive, aerospace, and sporting goods, because of intrinsic advantages over thermoset counterparts: Despite these advantages, extensive use of thermoplastic matrices has been restricted by the high melt viscosities and melting temperatures. To ensure proper impregnation of fiber beds and void removal, high-performance CFRTP parts must therefore be processed at high pressure and temperature.

The recycling of thermoset materials into thermoplastic composites

Barbara Sadowy October 15, Prodrive Composites has developed a process for manufacturing recyclable composite components that can satisfy future end-of-life requirements without any compromise in the performance of the original parts. Called P2T Primary to Tertiarythe process not only simplifies recycling, but endows a composite material with the potential to fulfil three or more useful lifetimes.

P2T composites do not require heat or pressure during manufacture, which means there is no need for an autoclave, reducing costs and enabling the scaling up of production without major investment. The basis of the process is the use of a reactive thermoplastic resin instead of the more usual thermosetting type; a plastic monomer is reacted with a catalyst in the presence of the fibres to produce a cured laminate.

The recycling of thermoset materials into thermoplastic composites

Prodrive believes it is the first to develop this technique, which emerged through a development programme with an automotive OEM customer who required a high-performance structural material with lower environmental impact than conventional composites.

The main barrier to recycling has been the type of resin used; thermosetting resins predominate but these cannot be readily recycled. Thermosetting resins were highly convenient materials to support this supply chain but, as tighter end-of-life regulations are introduced, better alternatives are required.

Composites produced by the P2T process can be recycled multiple times. The highest mechanical properties are obtained during first use of the virgin fibres, enabling highly loaded structural items such as suspension wishbones to be manufactured.

When the secondary part reaches the end of its life, it can be chopped and remoulded into block material with properties suitable for 3-D solid components. This tertiary part can itself be recycled several times until, finally, just the re-melted resin is recovered and the fibres are milled to supply other, lower grade parts.Wide parent rolls of prepreg material are precision slit into slit tapes in widths ranging from 1/8 to 1+ inch.

The tapes are then spooled for use by AFP and ATL fabrication processes.

Although the dominant composite market is the polymer–matrix composites (in particular the thermoset type), other types of composite materials deserve also certain attention when recycling is considered. Thermosetting plastics such as polyurethane and epoxy resins, by contrast, cannot be remelted; these are usually ground or shredded for use as fillers or insulating materials. So-called biodegradable plastics include starches that degrade upon exposure to sunlight (photodegradation), but a . THERMOPLASTIC COMPOSITES B. S. Panigrahy1, A. Rana2, P. Chang3, However problem of recycling and limited petroleum Plastics can be broadly classified in two groups, thermoplastic and thermoset. A thermoplastic is a material that can be processed or molded on application of .

Thermoplastic and thermoset resins have similar performance characteristics, and both can be combined with carbon, glass or other fibers to form prepreg systems.

Page 2 Figure 1 – A Programmed Epoxy Thermoset Conversion into its Thermoplastic Counterpart []. Past work with this material has examined how the cleavage functions in the presence of fibers and the effect on the post-recycled fiber performance [1].

Automotive | Composites UK

TenCate Advanced Composites’ Global Director Product and Market Strategy, Dr John Darlington, is presenting a white paper on the compound benefits of a hybrid composite, spanning thermoset and thermoplastic technologies, for aerospace applications during the Aerospace Conference Programme on day 2 of the event.

Recycling of thermosetting polymers: Their blends and composites Epoxy resins possess high resistance to chemicals and corrosion. Also, possess moderate toughness, flexibility and excellent mechanical and electrical behavior.

It is also used as outstanding adhesives for different substrates.

The recycling of thermoset materials into thermoplastic composites

Total composite recycling is achieved using a specific chemical recycling process, whereby the fibers and thermoset can be separated, recovered, and reused. Key to Connora’s technology is the transformation of the thermoset into its thermoplastic counterpart.

Although the dominant composite market is the polymer–matrix composites (in particular the thermoset type), other types of composite materials deserve also certain attention when recycling is considered.

Recycling | ThermoPlastic composites Research Center