ACCE 2011 1

Sustainability with Automotive CFCs:Reclaimed Carbon Fibre - cPBT Thermoplastic Composite

Yogi Mensch Jim Mihalich Jackie Rehkopf

MIT, LLC. Cyclics Corp. Plasan Carbon Composites

ACCE 2011 2

Motivation for this R&D

What We Did

How It Turned Out

Next Steps

OUTLINE

ACCE 2011 3

Manufacturing WasteManufacturing Waste Material CostsMaterial Costs

MOTIVATION

Carbon Fibre Composites

For

Mainstream Automotive

Carbon Fibre Composites

For

Mainstream Automotive

Life Cycle Life Cycle

ACCE 2011 4

MOTIVATION

Reduce WasteReduce Waste Reduce Energy CostsReduce Energy Costs

SustainabilitySustainability

Carbon Fibres from Reclamation

Requires 96% less energy than the

manufacture of virgin carbon fiber.

Reclaimed Carbon Fibre Retains 85% to 95% of its Original Performance

Reclaimed Carbon Fibre Can Be Used in Either Thermoset or Thermoplastic Matrices

CFRP Reclamation Technologies

• Reduce manufacturing scrap

• Reduce end-of-life waste

ACCE 2011 5

Thermoplastic Matrix

Advantages:

Typically More Options for CFRP Manufacturing Process

Typically Higher Toughness Than Thermosets

Typically Easier to Recycle

MOTIVATION

ACCE 2011 6

MIT-LLC Reclamation Technologies

+

Cyclic Polybutylterphthalate (cPBT)

Reclaimed Carbon Fibre Composite (rCFC)

for Potential Automotive Applications

Approach

ACCE 2011 7

Polymer and Processing Attributes:

Emits No VOCs During Processing

Very Low Initial Melt Viscosity 40 cps

Rapid Impregnation of Fibrous or Particulate Reinforcements

High Fibre Volumes Can Be Achieved

Crystallization and Polymerization Controlled by Temp & Catalyst

No Measurable Exotherm

Typically Low Pressure Molding

Demolding Part Does Require Tool Cooling

Cyclic Polybutylene terephthalate(cPBT)

ACCE 2011 8

End-Product Attributes:

Emits minimal VOCs during in-service

Can Achieve High Molecular Weight

High Stiffness and Strength

Excellent Dimensional Stability

Good Thermal Stability (continuous use temp ~ 100C; HDT ~ 200C)

Weldable and Thermoformable

Easily Recycled

Cyclic Polybutylene terephthalate(cPBT)

ACCE 2011 9

MIT – Closed-Loop System

ACCE 2011 10

Manual Process

Prep Mold

rCF layup with CBT resin

Determine # of layers and thickness for part/plaque

Determine Desired Fibre Volume

Distribute Resin Evenly Between Fibre Layers

rCF with cPBT

ACCE 2011 11

Manual Process cont’d:

Dry Layup in Vacuum Oven @ < 2torr, 90C for 4 h or more

or in Dessicant Oven at 110C overnight

Compression Mold

200C Press and Mold

Close Press Slowly to Melt Resin, Gradually Apply Pressure to

Wet-out Layup

Hold Pressure at 200 psi and Cure for 1 hour

Turn Off Press and Allow to Cool < 120C Under Pressure

Demould and Cool to Room Temp

rCF with cPBT

ACCE 2011 12

Finished Panel of rCF/ cPBT

ACCE 2011 13

test palque control number

unit 082411-03 082411-03 082411-02 082511-01

Material composition

fiber mat - composition wgt %

reclaimed carbon fiber T800 25mm per cent 49% 49% 49% 49%

reclaimed carbon fiber T800 12mm per cent 49% 49% 49% 49%

binder material per cent 2% 2% 2% 2%

Plaque composition

carbon mat net weight in plaque grams 90.37 90.37 86.36 96.12

cPBT net weight in plaque grams 119.32 119.32 120.72 118.72

total plaque wgt grams 209.69 209.69 207.08 214.84

carbon mat net weight % % 43.1% 43.1% 41.7% 44.7%

cPBT net weight % % 56.9% 56.9% 58.3% 55.3%

FvF % % 35.8% 35.8% 34.5% 37.3%

plaque thickness mm 1.55 1.55 1.57 1.57

density g/cm3

1.49 1.49 1.45 1.50

Test regiment

specimen use - test type flexural flexural tensile tensile

orientation (machine or cross machine) md / cmd md cmd md cmd

test method ASTM D790 ASTM D790 ASTM D3039 ASTM D3039

Flexural Properties MEAN of 5 specimens

Flex Str psi 44,594 34,535

Flex Mod psi 4,510,178 2,349,746

Tensile Properties MEAN of 5 specimens

Tensile Str psi 46,536 24,252

Modulus of Elasticity psi 50,231,279 2,991,017

rCF/cPBT TEST PLAQUE SUMMARY

ACCE 2011 14

Flexural Properties of PlasticsTest Date 25-Aug-11

Plaque Control Number 082411-03 Orientation MD

Report Number 377

width thickness max load flex str flex strain bend stiffflex

modulus

test no specimen id (inches) (inches) (lbf) (psi) (lbs/inch) (psi)

1992 md 1 0.517 0.062 41.70 39,357 0.0078 1,288 5,104,171

1993 md 2 0.516 0.063 50.80 47,223 0.0110 1,101 4,262,576

1994 md 3 0.52 0.062 46.70 43,828 0.0087 1,266 4,992,459

1995 md 4 0.52 0.061 45.90 44,586 0.0105 1,011 4,186,386

1996 md 5 0.517 0.062 50.90 47,977 0.0112 1,157 4,005,300

mean 0.518 0.062 47.20 44,594 0.0098 1,164.6 4,510,178

median 0.517 0.062 46.70 44,586 0.0105 1,157.0 4,262,576

std dev 0.002 0.001 3.84 3,405 0.0015 115.3 501,616

maximum 0.520 0.063 50.90 47,977 0.0112 1,288.0 5,104,171

minimum 0.516 0.061 41.70 39,357 0.0078 1,011.0 4,005,300

range 0.004 0.002 9.20 8,620 0.0034 277.0 1,098,871

Load Cell S/N (TVI108030) Crosshead Speed (inches/minute) or Rate 0.067

rCF/cPBT Flexural Properties MD

ACCE 2011 15confidential

Flexural Properties

rCF/cPBT Flexural Properties MD

ACCE 2011 16

Flexural Properties of PlasticsTest Date 25-Aug-11

Plaque Control Number 082411-03 Orientation CMD

Report Number 378

width thickness max load flex str flex strain bend stiffflex

modulus

test no specimen id (inches) (inches) (lbf) (psi) (lbs/inch) (psi)

1992 cmd 1 0.514 0.061 37.9 37,204 0.0164 609 2,547,464

1993 cmd 2 0.516 0.06 42.5 42,126 0.0205 570 2,435,086

1994 cmd 3 0.511 0.061 32.6 32,116 0.0182 522 2,199,083

1995 cmd 4 0.513 0.062 29.5 28,043 0.0156 508 2,029,089

1996 cmd 5 0.513 0.06 32.7 33,185 0.0142 576 2,538,006

mean 0.513 0.061 35.0 34,535 0.0170 557.0 2,349,746

median 0.513 0.061 32.7 33,185 0.0164 570.0 2,435,086

std dev 0.002 0.001 5.1 5,352 0.0024 41.4 227,672

maximum 0.516 0.062 42.5 42,126 0.0205 609.0 2,547,464

minimum 0.511 0.060 29.5 28,043 0.0142 508.0 2,029,089

range 0.005 0.002 13.0 14,083 0.0063 101.0 518,375

Load Cell S/N (TVI108030) Crosshead Speed (inches/minute) or Rate 0.067

rCF/cPBT Flexural Properties CMD

ACCE 2011 17

Flexural Properties

rCF/cPBT Flexural Properties CMD

ACCE 2011 18

Tensile Properties of PlasticsTest Date 29-Aug-11

Plaque Control Number 082411-02 Orientation MD

Report Number 386

yield yield str. tensile tensile str.modulus of

elasticity

test no specimen id (lbs) (psi) (lbs) (lbs) (psi)

2023 md 1 10.28 240.67 1,969.96 46,134.93 46,901,000

2024 md 2 12.55 293.82 1,625.42 36,066.08 53,499,860

2025 md 3 10.46 251.48 1,955.12 46,998.12 49,012,201

2026 md 4 9.84 235.36 1,772.61 42,406.93 51,528,014

2027 md 5 9.58 219.34 2,013.48 46,075.01 50,215,318

mean 10.54 248.13 1867.32 43,536.21 50,231,279

median 10.28 240.67 1955.12 46,075.01 50,215,318

std dev 1.18 28.05 163.62 4,534.91 2,497,114

maximum 12.55 293.82 2013.48 46,998.12 53,499,860

minimum 9.58 219.34 1625.42 36,066.08 46,901,000

range 2.97 74.48 388.06 10,932.04 6,598,860

Load Cell S/N (TVI108030) Crosshead Speed (inches/minute) or Rate 0.2

rCF/cPBT Tensile Properties MD

ACCE 2011 19

Tensile Properties

rCF/cPBT Tensile Properties MD

ACCE 2011 20

Tensile Properties of PlasticsTest Date 29-Aug-11

Plaque Control Number 082411-02 Orientation CMD

Report Number 389

yield yield str. tensile tensile str.modulus of

elasticity

test no specimen id (lbs) (psi) (lbs) (lbs) (psi)

2033 cmd 1 7.47 175.38 1,076.76 25,276.15 2,972,692

2034 cmd 2 2.02 47.89 1,018.27 24,186.97 2,881,688

2035 cmd 3 5.6 130.56 1,107.61 25,818.34 3,010,247

2036 cmd 4 3.62 84.47 1,006.62 23,464.41 3,195,003

2037 cmd 5 3.35 74.13 1,017.74 22,516.28 2,895,454

mean 4.41 102.49 1045.40 24,252.43 2,991,017

median 3.62 84.47 1018.27 24,186.97 2,972,692

std dev 2.14 50.52 44.32 1,336.00 125,898

maximum 7.47 175.38 1107.61 25,818.34 3,195,003

minimum 2.02 47.89 1006.62 22,516.28 2,881,688

range 5.45 127.49 100.99 3,302.06 313,315

Load Cell S/N (TVI108030) Crosshead Speed (inches/minute) or Rate 0.2

rCF/cPBT Tensile Properties CMD

ACCE 2011 21

Tensile Properties

rCF/cPBT Tensile Properties CMD

ACCE 2011 22

test palque control number

unit 082411-03 082411-03 082411-02 082511-01

Material composition

fiber mat - composition wgt %

reclaimed carbon fiber T800 25mm per cent 49% 49% 49% 49%

reclaimed carbon fiber T800 12mm per cent 49% 49% 49% 49%

binder material per cent 2% 2% 2% 2%

Plaque composition

carbon mat net weight in plaque grams 90.37 90.37 86.36 96.12

cPBT net weight in plaque grams 119.32 119.32 120.72 118.72

total plaque wgt grams 209.69 209.69 207.08 214.84

carbon mat net weight % % 43.1% 43.1% 41.7% 44.7%

cPBT net weight % % 56.9% 56.9% 58.3% 55.3%

FvF % % 35.8% 35.8% 34.5% 37.3%

plaque thickness mm 1.55 1.55 1.57 1.57

density g/cm3

1.49 1.49 1.45 1.50

Test regiment

specimen use - test type flexural flexural tensile tensile

orientation (machine or cross machine) md / cmd md cmd md cmd

test method ASTM D790 ASTM D790 ASTM D3039 ASTM D3039

Flexural Properties MEAN of 5 specimens

Flex Str psi 44,594 34,535

Flex Mod psi 4,510,178 2,349,746

Tensile Properties MEAN of 5 specimens

Tensile Str psi 46,536 24,252

Modulus of Elasticity psi 50,231,279 2,991,017

rCF/cPBT RESULTS SUMMARYtest palque control number

unit 082411-03 082411-03 082411-02 082511-01

Material composition

fiber mat - composition wgt %

reclaimed carbon fiber T800 25mm per cent 49% 49% 49% 49%

reclaimed carbon fiber T800 12mm per cent 49% 49% 49% 49%

binder material per cent 2% 2% 2% 2%

Plaque composition

carbon mat net weight in plaque grams 90.37 90.37 86.36 96.12

cPBT net weight in plaque grams 119.32 119.32 120.72 118.72

total plaque wgt grams 209.69 209.69 207.08 214.84

carbon mat net weight % % 43.1% 43.1% 41.7% 44.7%

cPBT net weight % % 56.9% 56.9% 58.3% 55.3%

FvF % % 35.8% 35.8% 34.5% 37.3%

plaque thickness mm 1.55 1.55 1.57 1.57

density g/cm3

1.49 1.49 1.45 1.50

Test regiment

specimen use - test type flexural flexural tensile tensile

orientation (machine or cross machine) md / cmd md cmd md cmd

test method ASTM D790 ASTM D790 ASTM D3039 ASTM D3039

Flexural Properties MEAN of 5 specimens

Flex Str psi 44,594 34,535

Flex Mod psi 4,510,178 2,349,746

Tensile Properties MEAN of 5 specimens

Tensile Str psi 46,536 24,252

Modulus of Elasticity psi 50,231,279 2,991,017

ACCE 2011 23

Reclaimed Scrap T800 Carbon Fibre

Formed a rCF mat of 25mm and 12 mm fibres

Manually Processed with cPBT to Produce 35% FVF

rCF/cPBT Composite

1st Attempt Achieved Mechanical Properties

Appropriate for Semi-Structural Applications

Overall Summary

ACCE 2011 24

Develop a manufacturing process for rCF/cPBT

Higher fibre volume

faster impregnation/consolidation

Select automotive application suited for anticipated

mechanical properties with ~50% FVF

Next Steps

ACCE 2011 25

Questions or Comments?

Reclaimed Carbon Fibre - cPBT Thermoplastic Composite

Yogi Mensch Jim Mihalich Jackie Rehkopf

MIT, LLC. Cyclics Corp. Plasan Carbon Composites