Fiber-containing particles with dual-tapered shape
AssigneeVartega Inc.
InventorsJordan Gray Harris, Kylie Marie Van Aken, Sean Paul Kline, Andrew Timothy Maxey, Sean Louis Hankins
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Abstract
Recycled carbon fibers are processed by rotational tumbling in a mixture with binder material to prepare fiber-containing particles having a dual-tapered shape and general alignment of fibers with a longitudinal direction of the particles. Bulk products including such fiber-containing particles are compounded with polymer and pelletized to prepare fiber-reinforced composite pellets, which are useful for applications such as injection molding to prepare molded products of carbon fiber-reinforced composite material with recycled carbon fibers.
Claims33
A bulk product comprising a plurality of fiber-containing particles, the plurality of fiber-containing particles comprising:
- from 90 weight percent to 99.5 weight percent reinforcing fibers;
- from 0.5 weight percent to 10 weight percent binder, holding the reinforcing fibers in a particle structure;
- each said fiber-containing particle comprising:
- a particle length dimension, being a maximum separation distance in a longitudinal direction between first and second longitudinal ends of the particle;
- a maximum particle width dimension transverse to the longitudinal direction at a longitudinal location between the first and second longitudinal ends;
- an aspect ratio equal to the particle length dimension divided by the maximum particle width dimension;
- and
- a dual-tapered shape comprising a first tapered portion tapering in the longitudinal direction away from the longitudinal location toward the first longitudinal end and a second tapered portion tapering in the longitudinal direction away from the longitudinal location toward the second longitudinal end;
- and
- the plurality of fiber-containing particles further comprising:
- a weight average particle length dimension of the fiber-containing particles is in a range of from 3 millimeters to 40 millimeters, wherein the weight average particle length dimension is an average on a weight basis of the particle length dimensions of the fiber-containing particles;
- and
- a weight average aspect ratio of the fiber-containing particles of at least 1.5, wherein the weight average aspect ratio is an average on a weight basis of the aspect ratios of the fiber-containing particles;
- and
- wherein the particle length dimensions of at least 2 weight percent of the fiber-containing particles are outside of a range of from 0.8 times the weight average particle length dimension to 1.2 times the weight average particle length dimension.
Dependencies are inferred from the claim text.