# US 12,759,207 B2 · Low permeation structures from recycled composite material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,207 B2 - Document ID: US12759207B2 - Status: Granted - Kind: B2 - Application number: 18/348,512 - Filed: 2023-07-07 - Published: 2025-01-09 - Granted: 2026-10-13 - Earliest claimed: 2023-07-07 - Assignees: FMC Technologies, Inc. - Applicants: FMC Technologies, Inc. - Inventors: Gabriel Silva; Anh Tuan Do - Web page: https://patentgrep.com/patent/US12759207B2 ## CPC - B29C 48/022: {characterised by the choice of material} - B29B 17/0412: {to large particles, e.g. beads, granules, flakes, slices} - B29C 48/09: Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B33Y 80/00: Products made by additive manufacturing - F16L 9/121: {with three layers} - F16L 9/133: the walls consisting of two layers - B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material - B29K 2105/26: Scrap {or recycled material} - B29K 2307/04: Carbon - B29L 2023/22: {Tubes or pipes, i.e. rigid (bent tubes not for use as pipe couplings B29L2023/004)} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Systems, methods, and devices for providing a low permeability pressure containing structure from high performance recycled composite material, such as polymer carbon fiber composite. One or more recycled scrap composite parts are mechanically processed to form a plurality of fragments based on protected carbon fiber, which are then formed into the pressure containing structure. The distribution of the plurality of fragments and fibers included therein generate a tortuous effect that decreases the permeability of the pressure containing structure, such that the pressure containing structure is suitable for transporting and storing gases and other fluids that may corrode traditional steel pressure structures. ## Claims ### Claim 1 A method of producing a pressure containing structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material having a plurality of fibers therein; mechanically processing the one or more recycled parts into a plurality of fragments with a random fiber distribution such that the plurality of fibers within each fragment of the plurality of fragments is arranged in a varied orientation; and forming, via a forming process, the plurality of fragments into the pressure containing structure thereby producing the pressure containing structure, wherein the random fiber distribution of the plurality of fragments generates a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure. ### Claim 2 (depends on 1) The method of claim 1, wherein the carbon fiber composite material comprises carbon fiber polyether ether ketone, and wherein an initial matrix of the carbon fiber composite material protects a plurality of short fibers disposed therein. ### Claim 3 (depends on 1) The method of claim 1, wherein the forming process comprises an extrusion process using an extruder device. ### Claim 4 (depends on 1) The method of claim 1, wherein the forming process comprises an additive manufacturing process using a 3D printer, the method further comprising: processing the plurality of fragments into a powder form comprising a plurality of granules with an average particle diameter of about 10 micrometers to about 100 micrometers; and providing the plurality of granules to the 3D printer. ### Claim 5 (depends on 1) The method of claim 1, further comprising: selecting a fragment size for the plurality of fragments based on a pressure level associated with the pressure containing structure. ### Claim 6 (depends on 1) The method of claim 1, wherein the forming process comprises an injection molding process using an injection mold. ### Claim 7 (depends on 1) The method of claim 1, further comprising: forming a first layer of the pressure containing structure using a first portion of the plurality of fragments oriented in a first direction; and forming a second layer of the pressure containing structure using a second portion of the plurality of fragments oriented in a second direction distinct from the first direction. ### Claim 8 A method of producing a pressure containing structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts to form a plurality of fragments; forming the pressure containing structure by fusing the plurality of fragments into the pressure containing structure, wherein the plurality of fragments are selectively oriented to generate a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure; forming a first layer of the pressure containing structure using a first portion of the plurality of fragments selectively oriented in a first selected direction; and forming a second layer of the pressure containing structure using a second portion of the plurality of fragments selectively oriented in a second selected direction distinct from the first selected direction. ### Claim 9 (depends on 8) The method of claim 8, wherein the plurality of fragments are fused into the pressure containing structure via an extrusion process using an extrusion device. ### Claim 10 (depends on 8) The method of claim 8, further comprising: forming a third layer of the pressure containing structure using a third portion of the plurality of fragments selectively oriented in a third selected direction distinct from the second selected direction. ### Claim 11 (depends on 8) The method of claim 8, wherein mechanically processing the one or more recycled parts comprises feeding the one or more recycled parts into a cutting device configured to cut the one or more recycled parts along an axis parallel to a fiber direction of a plurality of fibers of the carbon fiber composite material to thereby form the plurality of fragments while preserving the plurality of fibers. ### Claim 12 (depends on 8) The method of claim 8, further comprising: adding additional carbon fiber material to the plurality of fragments. ### Claim 13 (depends on 12) The method of claim 12, further comprising: adding an additional polymer material to the plurality of fragments prior to forming the pressure containing structure. ### Claim 14 (depends on 8) The method of claim 8, wherein the first portion of the plurality of fragments comprises a first plurality of fibers is oriented in the first selected direction and the second portion of the plurality of fragments comprises a second plurality of fibers oriented in the second selected direction. ### Claim 15 A pressure containing pipe comprising: a carbon fiber polyether ether ketone (PEEK) material configured to provide a low permeability pressure seal for containing a fluid inside the pressure containing pipe; and a plurality of fused mechanically recycled fragments comprising the carbon fiber PEEK material, wherein the carbon fiber PEEK material has a random fiber distribution that generates a tortuous effect to thereby reduce a permeability of the pressure containing pipe. ### Claim 16 (depends on 15) The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized gaseous hydrogen fluid disposed therein, and wherein the carbon fiber PEEK material prevents corrosion of the pressure containing pipe. ### Claim 17 (depends on 16) The pressure containing pipe of claim 16, wherein the carbon fiber PEEK material comprises a concentration of between 20% to 50% carbon fiber by volume. ### Claim 18 (depends on 15) The pressure containing pipe of claim 15, further comprising: a first layer of the carbon fiber PEEK material including one or more first fibers oriented in a first direction; and a second layer of carbon fiber PEEK material including one or more second fibers oriented in a second direction distinct from the first direction. ### Claim 19 (depends on 15) The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized hydrogen fluid. ### Claim 20 (depends on 15) The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized carbon dioxide fluid.