Method of recycling carbon fiber

Patent metadata

Field	Value
Publication number	US-12370724-B2
Application number	US-202217664547-A
Country	US
Kind code	B2
Filing date	May 23, 2022
Priority date	May 24, 2021
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

Provided is a method of recycling carbon fibers that allows obtaining continuous carbon fibers. The present embodiment is a method of recycling carbon fibers that includes preparing a carbon fiber reinforced plastic molded product including carbon fiber reinforced plastic containing carbon fibers and a resin and drawing the carbon fiber reinforced plastic while performing a heating treatment on the carbon fiber reinforced plastic molded product. A temperature of the heating treatment is equal to or above a glass-transition temperature of the resin and below a thermal decomposition start temperature, and the temperature is below a thermal degradation temperature of the carbon fibers.

First claim

What is claimed is:

1. A method of recycling carbon fibers,
the method of recycling comprising:
preparing a carbon fiber reinforced plastic molded product including a carbon fiber reinforced plastic containing carbon fibers and a resin; and
drawing the carbon fiber reinforced plastic while performing a heating treatment on the carbon fiber reinforced plastic molded product,
removing the resin in the carbon fiber reinforced plastic that is drawn and conveyed; and
winding the conveyed carbon fibers that are removed of the resin;
wherein the carbon fiber reinforced plastic is drawn in the upper stream, while the carbon fibers are wound in the downstream;
wherein a temperature of the heating treatment is equal to or above a glass-transition temperature of the resin and below a thermal decomposition start temperature, and the temperature is below a thermal degradation temperature of the carbon fibers;
wherein the removing the resin includes bringing a dissolution liquid that dissolves the resin in the carbon fiber reinforced plastic into contact with the carbon fiber reinforced plastic,
wherein in the removing the resin, the drawn carbon fiber reinforced plastic is immersed into the dissolution liquid and subsequently the dissolution liquid is injected from a nozzle connected to an injection device toward the carbon fiber reinforced plastic to remove the resin from the carbon fibers, and
wherein the method of recycling further comprises, after the removing the resin and before the winding the carbon fibers, applying a sizing agent to the carbon fibers obtained by removing the resin.

2. The method according to claim 1 ,
wherein the thermal decomposition start temperature of the resin is a temperature indicating a 5% weight loss in a weight change chart of a thermogravimetric analysis obtained by raising the temperature of the resin from 30° C. to 550° C. by 5° C./minute under a nitrogen atmosphere.

3. The method according to claim 1 ,
wherein the thermal decomposition start temperature of the resin is a temperature indicating a 5% weight loss in a weight change chart of a thermogravimetric analysis obtained by raising the temperature of the resin from 30° C. to 550° C. by 5° C./minute under an air atmosphere.

4. The method according to claim 1 ,
wherein the temperature of the heating treatment is below 400° C.

5. The method according to claim 1 ,
wherein the temperature of the heating treatment is equal to or below 360° C.

6. The method according to claim 1 ,
wherein the dissolution liquid contains at least one liquid selected from an acidic solution, an organic solvent, an aqueous hydrogen peroxide, or an ionic liquid.

7. The method according to claim 1 ,
wherein the dissolution liquid is an acidic solution.

8. The method according to claim 1 , further comprising
cutting the drawn carbon fiber reinforced plastic.

9. The method according to claim 1 ,
wherein the heating treatment is performed using superheated steam.

10. The method according to claim 1 ,
wherein the resin comprises a thermosetting resin or a thermoplastic resin.

11. The method according to claim 1 ,
wherein the resin comprises an epoxy resin.

Assignees

• Toyota Motor Co Ltd

Inventors

• Numata Yusuke
• Ishii Hiroyuki
• Kano Akira
• Hirayama Shinichiroh

Classifications

• B29B2017/0293

  Dissolving the materials in gases or liquids · CPC title

• Y02W30/66

  Disintegrating fibre-containing textile articles to obtain fibres for re-use · CPC title

• Y02W30/52

  Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly · CPC title

• Y02W30/20

  Waste processing or separation · CPC title

• B29B2017/0496

  Pyrolysing the materials · CPC title