CCIC develops closed-loop continuous RCF remanufacturing process
CCIC has launched a pilot line for producing ContRGF fabrics, using recycled carbon fibers for automotive and other applications. A hybrid automotive hood was demonstrated with this material.
The Yangtze River Delta Carbon Fiber and Composite Material Innovation Center (CCIC, Changzhou, China) has developed a closed-loop recycling process for carbon fiber composites. This process reclaims full-length carbon fibers and reusable polyols from thermoset composites, demonstrated through a hybrid automotive hood featuring a virgin carbon outer skin and ContRGF core.
CCIC's recycling pathway is based on two proprietary technologies aimed at reintegrating materials into high-value supply chains. The first technology involves a mild catalytic degradation process tailored for epoxy-based continuous carbon fiber structures, such as pultruded wind turbine spar caps. This process preserves the original length of the fibers while decomposing the epoxy matrix into reusable polyols, ensuring complete recovery of both fiber and resin.
The second technology is a continuous remanufacturing process for long reclaimed carbon fibers. These fibers are aligned, joined, and restructured into continuous unidirectional carbon fiber fabrics, trademarked as ContRGF. This recycled material offers a low carbon footprint, reduced manufacturing costs, and high cost-effectiveness.
ContRGF fabrics are compatible with existing composite manufacturing methods, including hand layup, compression molding, vacuum forming, and resin transfer molding (RTM) without significant modifications. Target applications include automotive, rail transit, marine, consumer appliances, sports goods, and aircraft interior components.
CCIC has established a lab-scale catalytic degradation facility with customized processing chambers for recycling composite waste of various shapes and sizes. Additionally, a pilot rCF weaving line is operational, producing small batches of ContRGF fabrics and prepregs.
The team has fabricated a hybrid composite automotive hood demonstrator. According to Prof. Xiaosu Yi, CEO of CCIC, the design uses virgin carbon fiber fabric for the outer skin to ensure a Class A surface finish, while the inner core predominantly consists of ContRGF. This design balances surface quality, mechanical performance, and cost with a virgin-to-recycled fiber ratio of approximately 1:2-1:3.
Beyond the hood, CCIC has developed various automotive components and aircraft nonstructural composite prototypes. Dr. Ziqian Lui, director of industrial cooperation at CCIC, states that the company will continue to advance the technology readiness level and collaborate with partners globally to explore new market opportunities for recycled carbon fiber composites.
Source: Carbon Fiber Feed