Method for manufacturing high-tensile continuous fiber spun yarn using recycled carbon fiber and high-tensile continuous fiber spun yarn

Abstract

An embodiment method for manufacturing a high-tensile continuous fiber spun yarn using a recycled carbon fiber (rCF) includes recovering a rCF raw material from a waste composite material product, the waste composite material product including carbon fiber reinforced plastic (CFRP), fabricating a rCF nonwoven fabric using the recovered rCF raw material, producing slitter yarns cut into a long length and a predetermined narrow width by placing the rCF nonwoven fabric into slitter equipment in a slitting process, fabricating the high-tensile continuous fiber spun yarn with a predetermined thickness by twisting at least one of the slitter yarns through twisting equipment in a twisting process, and producing a spun yarn product by winding the high-tensile continuous fiber spun yarn on a bobbin using a spinning machine.

What is claimed is: 
     
         1 . A method for manufacturing a high-tensile continuous fiber spun yarn using a recycled carbon fiber (rCF), the method comprising:
 recovering a rCF raw material from a waste composite material product, the waste composite material product comprising carbon fiber reinforced plastic (CFRP);   fabricating a rCF nonwoven fabric using the recovered rCF raw material;   producing slitter yarns cut into a long length and a predetermined narrow width by placing the rCF nonwoven fabric into slitter equipment in a slitting process;   fabricating the high-tensile continuous fiber spun yarn with a predetermined thickness by twisting at least one of the slitter yarns through twisting equipment in a twisting process; and   producing a spun yarn product by winding the high-tensile continuous fiber spun yarn on a bobbin using a spinning machine.   
     
     
         2 . The method of  claim 1 , wherein recovering the rCF raw material comprises:
 separating only a carbon fiber portion from a CFRP filament winding obtained by cutting the waste composite material product using a separator; and   recovering the rCF raw material in a form of short fibers by treating the separated carbon fiber along with a formic acid, a hydrogen peroxide, and a surfactant in a raw material recovery process.   
     
     
         3 . The method of  claim 2 , wherein recovering the rCF raw material further comprises:
 performing a pretreatment process comprising putting the separated carbon fiber into a pretreatment tank and subjecting the separated carbon fiber to a first chemical reaction with the formic acid, the hydrogen peroxide, and the surfactant to penetrate and expand;   performing a cleaning process comprising putting the pretreated carbon fiber into a cleaning container and cleaning the pretreated carbon fiber under constant normal pressure and low temperature conditions; and   performing a main treatment process comprising putting the cleaned carbon fiber into a main treatment tank and subjecting the cleaned carbon fiber to a second chemical reaction using the formic acid, the hydrogen peroxide, and the surfactant to recover the rCF raw material in the form of short fibers.   
     
     
         4 . The method of  claim 1 , wherein fabricating the rCF nonwoven fabric comprises:
 performing a disintegration process comprising putting the recovered rCF raw material into pulper equipment and mixing the recovered rCF raw material with water to disintegrate the recovered rCF raw material;   performing a beating process comprising putting the rCF raw material subjected to the disintegration process into refiner equipment and crushing the rCF raw material with physical force in the refiner equipment to spread crushed fibers of the rCF raw material in a unit of strand;   performing a web forming process comprising spraying the rCF raw material subjected to the beating process onto a wire having finely sized meshes to remove part of the water and form the rCF nonwoven fabric, wherein an input amount of the rCF raw material is adjusted to produce the rCF nonwoven fabric of predetermined thickness and basis weight;   performing a dewatering process comprising compressing the rCF nonwoven fabric subjected to the web forming process to remove moisture;   performing a drying process comprising removing remaining moisture from the rCF nonwoven fabric with dry air heated using a cylinder dryer device after the dewatering process; and   performing a winding process comprising winding the dried rCF nonwoven fabric onto a spool.   
     
     
         5 . The method of  claim 4 , further comprising fabricating a roll-shaped carbon fiber nonwoven fabric product through a rewinding process comprising rewinding the wound rCF nonwoven fabric through a plurality of rollers after the winding process. 
     
     
         6 . The method of  claim 4 , wherein in the disintegration process, as a disintegration condition, 97.5% of water and 2.5% of the rCF raw material are mixed. 
     
     
         7 . The method of  claim 4 , wherein in the web forming process, the rCF nonwoven fabric is subjected to the web forming process under conditions of a feed speed of 1.5 m/min and a raw material supply amount of 60 to 80 g per unit. 
     
     
         8 . The method of  claim 7 , wherein in the winding process, the dried rCF nonwoven fabric is continuously wound on the spool at a speed of 1.5 m/min. 
     
     
         9 . The method of  claim 4 , wherein in the web forming process, the rCF nonwoven fabric is subjected to the web forming process under conditions set to increase a bonding force between short fibers. 
     
     
         10 . The method of  claim 1 , wherein producing the slitter yarns comprises producing the slitter yarns by evenly cutting the rCF nonwoven fabric under slitting conditions of a set width of 10 mm and a winding speed of 70 to 100 m/min. 
     
     
         11 . The method of  claim 1 , wherein producing the high-tensile continuous fiber spun yarn comprises producing the high-tensile continuous fiber spun yarn having a thickness of 0.7 mm by twisting the slitter yarns into a predetermined pattern. 
     
     
         12 . A high-tensile continuous fiber spun yarn comprising:
 a recycled carbon fiber (rCF), wherein the high-tensile continuous fiber spun yarn is a product of manufacturing steps comprising:   recovering a rCF raw material from a waste composite material product, the waste composite material product comprising carbon fiber reinforced plastic (CFRP);   fabricating a rCF nonwoven fabric using the recovered rCF raw material;   producing slitter yarns cut into a long length and a predetermined narrow width by placing the rCF nonwoven fabric into slitter equipment in a slitting process;   fabricating the high-tensile continuous fiber spun yarn with a predetermined thickness by twisting at least one of the slitter yarns through a twisting process; and   producing a spun yarn product by winding the high-tensile continuous fiber spun yarn on a bobbin.   
     
     
         13 . The high-tensile continuous fiber spun yarn of  claim 12 , wherein recovering the rCF raw material comprises:
 separating only a carbon fiber portion from a CFRP filament winding obtained by cutting the waste composite material product using a separator; and   recovering the rCF raw material in a form of short fibers by treating the separated carbon fiber along with a formic acid, a hydrogen peroxide, and a surfactant in a raw material recovery process.   
     
     
         14 . The high-tensile continuous fiber spun yarn of  claim 13 , wherein recovering the rCF raw material further comprises:
 performing a pretreatment process comprising putting the separated carbon fiber into a pretreatment tank and subjecting the separated carbon fiber to a first chemical reaction with the formic acid, the hydrogen peroxide, and the surfactant to penetrate and expand;   performing a cleaning process comprising putting the pretreated carbon fiber into a cleaning container and cleaning the pretreated carbon fiber under constant normal pressure and low temperature conditions; and   performing a main treatment process comprising putting the cleaned carbon fiber into a main treatment tank and subjecting the cleaned carbon fiber to a second chemical reaction using the formic acid, the hydrogen peroxide, and the surfactant to recover the rCF raw material in the form of short fibers.   
     
     
         15 . The high-tensile continuous fiber spun yarn of  claim 12 , wherein fabricating the rCF nonwoven fabric comprises:
 performing a disintegration process comprising putting the recovered rCF raw material into pulper equipment and mixing the recovered rCF raw material with water to disintegrate the recovered rCF raw material;   performing a beating process comprising putting the rCF raw material subjected to the disintegration process into refiner equipment and crushing the rCF raw material with physical force in the refiner equipment to spread crushed fibers of the rCF raw material in a unit of strand;   performing a web forming process comprising spraying the rCF raw material subjected to the beating process onto a wire having finely sized meshes to remove part of the water and form the rCF nonwoven fabric, wherein an input amount of the rCF raw material is adjusted to produce the rCF nonwoven fabric of predetermined thickness and basis weight;   performing a dewatering process comprising compressing the rCF nonwoven fabric subjected to the web forming process to remove moisture;   performing a drying process comprising removing remaining moisture from the rCF nonwoven fabric with dry air heated using a cylinder dryer device after the dewatering process; and   performing a winding process comprising winding the dried rCF nonwoven fabric onto a spool.   
     
     
         16 . The high-tensile continuous fiber spun yarn of  claim 15 , further comprising fabricating a roll-shaped carbon fiber nonwoven fabric product through a rewinding process comprising rewinding the wound rCF nonwoven fabric through a plurality of rollers after the winding. 
     
     
         17 . The high-tensile continuous fiber spun yarn of  claim 15 , wherein in the disintegration process, as a disintegration condition, 97.5% of water and 2.5% of the rCF raw material are mixed. 
     
     
         18 . The high-tensile continuous fiber spun yarn of  claim 15 , wherein in the web forming process, the rCF nonwoven fabric is subjected to the web forming process under conditions of a feed speed of 1.5 m/min and a raw material supply amount of 60 to 80 g per unit. 
     
     
         19 . The high-tensile continuous fiber spun yarn of  claim 18 , wherein in the winding process, the dried rCF nonwoven fabric is continuously wound on the spool at a speed of 1.5 m/min. 
     
     
         20 . The high-tensile continuous fiber spun yarn of  claim 12 , wherein producing the slitter yarns comprises producing the slitter yarns by evenly cutting the rCF nonwoven fabric under slitting conditions of a set width of 10 mm and a winding speed of 70 to 100 m/min.