Ready-to-Use Recycled Carbon Fibres Decorated with Magnetic Nanoparticles: Functionalization after Recycling Process Using Supercritical Fluid Chemistry

An innovative simultaneous process, using supercritical fluid (SCF) chemistry, was used to recycle uncured prepregs and to functionalize the recovered carbon fibres with Fe3O4 magnetic nanoparticles (MNPs), to produce a new type of secondary raw material suitable for composite applications. This specific functionalization allows the fibres to be heated by induction through a hysteresis loss mechanism characteristic for nanoparticle susceptor-embedded systems, for triggered healing properties and a potentially easy route for CF reclamation. Using SCF and hydrothermal conditions for recycling, functionalization of fibres can be performed in the same reactor, resulting in the creation of ready-to-use fibres and limiting the use organic solvent. After cutting the uncured prepreg to the desired length to fit in future applications, supercritical CO2 extraction is performed to partially remove some components of the uncured prepreg matrix (step 1). Then, the recycled carbon fibres (rCFs), still embedded inside the remaining organic matrix, are brought into contact with reactants for the functionalization step (step 2). Two possibilities were studied: the direct synthesis of MNPs coated with PAA in hydrothermal conditions, and the deposition of already synthesized MNPs assisted by supercritical CO2-acetone. No CF surface activation is needed thanks to the presence of functional groups due to the remaining matrix. After functionalization, ready-to-use material with homogeneous depositions of MNPs at the surface of rCF is produced, with a strong magnetic behaviour and without observed degradation of the fibres.

Automated summary

An innovative process using supercritical fluid chemistry was used to recycle uncured prepregs and functionalize the recovered carbon fibers with magnetic nanoparticles. This allows for the production of a new type of secondary raw material suitable for composite applications. The process also enables the fibers to be heated through induction for triggered healing properties and potential carbon fiber reclamation.