We use “raw carbon fiber” and waste and cut fibers from the carbon fiber processing industry (in other words, recycled carbon fiber) to produce nonwovens. The use of carbon fiber has proven many times over the past few years, and its unique properties have revolutionized entire industries, generating new dynamics. These fibers are attractive not only for their special appearance but also for their functional properties. Therefore, they can be used to solve different problems and requirements in various technologies, such as lightweight construction, corrosion resistance and material sustainability. So today, we will discuss non-woven carbon fiber through the post.
What is non-woven fabric?
Nonwovens are broadly defined as sheets or webs that are mechanically, thermally or chemically bonded by intertwining fibers or filaments. It can also pass through perforated membranes. In addition, they are porous flat sheets made directly from individual fibers or from molten plastic or plastic films. Because nonwovens are not made by weaving or knitting, there is no need to convert fibers into yarns.
Advantages of carbon fiber nonwovens
- Compared with “original carbon fiber” textiles, the cost advantage of carbon fiber non-woven fabrics can reach 70%.
- Compared with glass fiber reinforced components, the weight of the final product with the same performance can be reduced by up to 60%.
- Similarly, compared with aluminum parts, the weight of the final product can be reduced by 70% under the same performance.
- As the raw material of carbon fiber non-woven fabrics, the fibers are provided by the carbon fiber processing industry and are used as scraps for the production of fabrics and non-crimp fabrics. In addition, fibers with “end-of-life” content can also be used in nonwovens production.
About carbon fiber nonwovens, a production waste
Innovation in nonwovens is now as fast as demand is growing, and almost every industry has unlimited possibilities to adapt to nonwovens. Of course, carbon fiber nonwovens also occupy a certain market.
This guide focuses on a series of case studies including the development of carbon fiber nonwovens from production waste by Runcorn, UK-based Sigmatex. Up to 30 percent of carbon fiber ends up as waste in the manufacturing supply chain, explains Peter Sestic, Chief Textile Engineer at Sigmatex.
Waste reduction is a major issue in the composites industry and Sigmatex has a strong incentive to minimize its environmental footprint. Therefore, the company developed a technology to recycle carbon fiber waste and convert it into non-woven fabrics. Nonwovens are made from virgin/slurry fibers to maximize resin compatibility in composite stacks as an economical way to add stiffness and bulk.
The fibers are typically 30-70 mm in length and are randomly oriented. Notably, the recycling route reduces Sigmatex’s landfill contribution by up to 90% (approximately 150 tons per year).
How we send waste back to the recycling bin
The fibers used as raw materials for carbon fiber non-woven fabrics are provided by the carbon fiber processing industry. These may be leftovers from fabric and spread production, or fibers from “end-of-life” components. In addition to pure carbon fibers, blends with other fiber types (such as thermoplastic fibers) can also be processed according to customer requirements.