Integrated Electrochemical Reactions for Reclaiming and Modifying Carbon Fiber from Composite Wastes

The growing demand for carbon fiber coupled with the high cost and energy input required to manufacture virgin carbon fiber provide substantial economic and environmental motivation for reclaiming carbon fiber from carbon fiber reinforced composites. However, the harsh treatment typically required for extracting carbon fiber from chemically cross-linked thermosetting resins greatly diminishes the mechanical properties of the recovered carbon fiber, preventing them from meeting performance metrics necessary for many industrial applications. This program will develop advanced recycling approaches that recover high-value carbon fiber at commercially competitive prices. This strategy employs a two-phase approach in which initial mechanical processing to isolate carbon fiber reinforced composites from aircraft waste is coupled with a cutting-edge electrochemical strategy for carbon fiber recovery. Electrochemical degradation of the resin occurs under mild conditions, allowing carbon fibers with high mechanical properties to be extracted. The small technology footprint will give manufacturers the ability to recycle carbon fiber reinforced composites scrap internally and reabsorb recovered fibers into secondary applications.  This program will focus on validating that electrochemically recovered carbon fiber can substitute virgin carbon fiber in composite manufacturing and develop the foundation necessary for this technology to be rapidly scaled and transitioned to aircraft manufacturers and end-of-life processors.