Abstract

A method produces a flat semi-finished product from a fiber composite material that contains individual carbon fibers, carbon fiber bundles, or a mixture thereof in a defined anisotropic fiber orientation and a thermoplastic matrix material. The anisotropy of the carbon fibers is created in a carding process using the high orientability of admixed non-carbon textile fibers, at least some of the non-carbon textile fibers being thermoplastic, and the carbon fibers having been isolated from waste or used parts. The flat fibrous web which is produced by a carding process and which has a specific orientation of the carbon fibers in the longitudinal direction is compressed into a sheet material under the effect of heat. This enables the use of carbon fibers, for example from production waste, as reinforcing fibers, whereby a less expensive raw material is provided and the carbon fibers are contained in the waste materials are recycled.

IPC Classes  ?

• D01G 15/00 - Carding machines or accessoriesCard clothingBurr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements
• D04H 3/002 - Inorganic yarns or filaments
• D04H 3/004 - Glass yarns or filaments
• D04H 3/015 - Natural yarns or filaments
• D04H 3/02 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
• D04H 3/12 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
• B29K 101/12 - Thermoplastic materials
• B29K 707/04 - Carbon

Abstract

The invention relates to a fiber-based carrier structure made of fractions of industrially produced reinforcing fibrous materials, which comprises endless fibers in a tangled arrangement as a first reinforcing fiber component and which comprises endless fiber bundles as a second reinforcing fiber component, wherein the fiber-based carrier structure also has a pore system. According to the invention, endless individual fibers and endless fiber bundles are used as a mixture preferably in an isotropic tangled arrangement to produce a fiber-based carrier structure, the pore system of which is an open-cell pore system and is openly accessible from outside. Said fiber-based carrier structure enables the absorption of liquids and/or solid particles by the selection of a defined mixture ratio of endless fiber bundles and endless individual fibers, wherein the capacity to be impregnated with and the capacity to absorb liquid and/or solid powdery materials can be set by means of the mixture ratio.

IPC Classes  ?

• D04H 1/4242 - Carbon fibres
• B29C 70/12 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of short length, e.g. in the form of a mat
• D04H 1/4274 - RagsFabric scraps
• D04H 1/4282 - Addition polymers

Abstract

A nonwoven material is composed of a nonwoven batt of a plurality of bundles formed of carbon fibers. At least some of the bundles have a curved progression that includes a curved vertex area of a first curvature between the bundle ends and at least one bundle end area of a second curvature extending from said one bundle end to the vertex. The first curvature is greater than the second curvature, in particular it is greater by at least 50%.

IPC Classes  ?

• D04H 11/00 - Non-woven pile fabrics
• D01G 15/00 - Carding machines or accessoriesCard clothingBurr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
• D04H 1/4391 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
• B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
• D04H 1/06 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated man-made fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
• D04H 1/4242 - Carbon fibres
• D04H 1/4274 - RagsFabric scraps
• D04H 1/4374 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
• D04H 1/46 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
• D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
• D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
• D04H 3/045 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles for net manufacturing
• D04H 5/02 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
• D01G 1/04 - Severing continuous filaments or long fibres, e.g. stapling to form staple fibres not delivered in strand form by cutting
• D01G 7/00 - Breaking or opening fibre bales
• D01G 13/00 - Mixing, e.g. blending, fibresMixing non-fibrous materials with fibres
• B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
• B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
• B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements

Abstract

A flat textile structure comprising a reinforcing grid and at least one pile layer which is situated in a flat manner on at least one surface of the reinforcing grid, characterized in that the flat textile structure has a weight per unit area of from 40 to 140 g/m2, the pile layer consists predominantly of carbon fibres, the carbon fibres in the flat textile structure have a proportion of the weight per unit area of from 60 to 97%, the reinforcing grid has a proportionate weight per unit area of from 2.5 to 12.5 g/m2 and the flat textile structure is strengthened.

IPC Classes  ?

• D04H 1/46 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
• D04H 5/02 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
• D04H 5/04 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by applying or incorporating chemical or thermo-activatable bonding agents in solid or liquid form
• D04H 5/06 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
• D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
• D04H 1/485 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
• D04H 1/488 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
• D04H 1/4242 - Carbon fibres
• D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
• D04H 1/4374 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
• D04H 1/4274 - RagsFabric scraps
• D04H 1/06 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated man-made fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements

Abstract

The invention relates to a pile layer, comprising a plurality of bundles, which are partially opened up into individual fibers and which comprise carbon fibers, and comprising foreign substances, and wherein the carbon fibers have at least a mass fraction of 70% of the total mass of the pile layer, and the foreign substances no more than 30%, but not less than 2%, wherein the foreign substances are obtained from a recycling process.

IPC Classes  ?

• D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
• D04H 1/4274 - RagsFabric scraps
• D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
• D04H 1/4242 - Carbon fibres
• D04H 1/06 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated man-made fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements

Abstract

The nonwoven material is composed of a pile layer which has a plurality of bundles comprising carbon fibers, wherein at least some of the bundles have a curved course that comprises a curved vertex area of a first curvature between the bundle ends and at least one bundle end area of a second curvature, located at the bundle ends, wherein the first curvature is greater than the second curvature in particular by at least 50%.

IPC Classes  ?

• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements
• D04H 1/06 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated man-made fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
• D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
• D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
• D04H 1/4274 - RagsFabric scraps
• D04H 1/4242 - Carbon fibres

Abstract

The invention relates to a method for producing pellets from fiber composite materials suitable for further processing in a plastics finishing method, said pellets containing individual carbon fibers, carbon fiber bundles, or a mixture thereof and at least one thermoplastic matrix material. The method is characterized in that carbon fibers, carbon fiber bundles, or a mixture thereof are isolated from waste or used parts that contain carbon fiber, laid flat together with the thermoplastic matrix material, compressed into a sheet material under the effect of heat, and subsequently cooled and comminuted into pellets, platelets, or chips. The method according to the invention enables the use of carbon fibers, for example from textile production waste, adhered or cured production waste, from processed CFRP waste components or the like, as reinforcing fibers, whereby an inexpensive raw material is provided and the carbon fibers that are contained in said waste materials are recycled for a useful application. The final carbon fibers, carbon fiber bundles, or mixture thereof are brought into a pourable and readily meterable form and can be used as raw materials for extrusion or injection molding for example.

IPC Classes  ?

• B29B 9/04 - Making granules by dividing preformed material in the form of plates or sheets
• B29B 9/14 - Making granules characterised by structure or composition fibre-reinforced

Abstract

The present invention relates to a method for producing a flat semi-finished product from fiber composite material that contains individual carbon fibers, carbon fiber bundles, or a mixture thereof in a defined anisotropic fiber orientation and at least one thermoplastic matrix material. The method is characterized in that the anisotropy of the carbon fibers is created in a carding process using the high orientability of admixed non-carbon textile fibers, at least some of the non-carbon textile fibers being thermoplastic, and the carbon fibers having been isolated from waste or used parts containing carbon fiber. The flat fibrous web which is produced by means of the carding process and which has a specific orientation of the carbon fibers in the longitudinal direction is compressed into a sheet material in at least one subsequent step under the effect of heat. The method according to the invention enables the use of carbon fibers, for example from textile production waste, adhered or cured production waste, from processed CFRP waste components or the like, as reinforcing fibers, whereby a less expensive raw material is provided and the carbon fibers, carbon fiber bundles, or mixture thereof that are contained in said waste materials are recycled for a useful application.

IPC Classes  ?

• B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements