Recent developments in yarn formation technology for producing innovative hybrid yarn structures from staple carbon and thermoplastic fibers for high-performance composites

Abstract

Technological developments in the processing of staple carbon fiber disclosed that producing hybrid yarn with improved homogeneity, uniformity, compactness and orientation can fully utilize the potential in high-performance composites. Therefore, developing hybrid yarn structures through yarn formation technology has become an emerging trend in the past few years. The present paper aims to highlight the recent development in the yarn formation technology for producing innovative yarn structures from staple carbon and thermoplastic fibers for high-performance fiber-reinforced plastics. For this purpose, pre-spinning, spinning and post-spinning operations of yarn formation technology are reviewed to technological aspects and processing of staple carbon fiber. Furthermore, recent developments in developing flyer, friction and wrap-spun hybrid yarn for high-performance composites are also presented in this paper. An attempt is carried out to develop the relationship between hybrid yarn structures and composite properties. The comparison of tensile properties of thermoplastic plastic composites shows that composite based on hybrid yarn structure possesses 300% and 700% higher tensile strength compared to nonwovens and injection molding composites.

Development of yarns from recycled carbon fiber based on friction spinning technology with specific properties for thermoset composites

“…The main processing zone consists of a main cylinder and three pairs of workers and strippers. 12 The sketch and the relevant parameters for the carding machine are illustrated in Figure 2 for a better overview. This semi-industrial scale long staple carding machine differs from conventional carding machines used for cotton or man-made fibers in that the arrangement of cylinder, worker and stipper ensures gentle processing of rCF.…”

“…1 So far, hybrid yarns from rCF and thermoplastic fiber (rCF content approx. 50% by weight) based on flyer, 3,4 wrap [5][6][7][8][9] and DREF friction [10][11][12] spinning machine have been reported.…”

“…10 Furthermore, due to the higher productivity (up to 250 m/min) and the potential for dust-free processing of rCF hybrid yarns into fabric structures (due to the use of a thermoplastic sheath covering the rCF in the core), friction spinning technology appears to be a viable industrial solution for the production of rCFbased hybrid yarns for thermoplastic composites. In previous studies, [10][11][12] hybrid yarns were developed from rCF and polyamide 6 fibers on the basis of friction spinning machines for thermoplastic composites. A satisfactory yarn quality was achieved with a core to sheath ratio of 80:20.…”

Tensile properties of thermoset composites based on yarn structures from recycled carbon fibre and low melting temperature Co-polyamide fibre

“…For this reason, hybrid yarn spinning is the most widely used method for processing rCF into a continuous yarn structure for the use in thermoplastic composites. To date, the development of hybrid yarns from staple rCF has been carried out using roving frame, 1,[3][4][5][6] wrap spinning [7][8][9][10] and friction spinning technologies. 11,12 However, spinning processes based on roving frame and wrap spinning technologies are limited by their low productivity due to the high yarn twist required to increase yarn strength for further processing.…”

Development of a micro-scale hybridized yarn structure from recycled carbon, aramid and polyamide 6 staple fibers for thermoplastic composites with improved impact strength

“…5 Therefore, the re-use of rCF in CFRPs for automotive parts is attracting interest from academia and industry. 6 Injection-molded parts and randomly oriented nonwovens used in the remanufacture of CFRPs are among the industrially established solutions for the production of semi-finished products from rCF. However, the strength of composites based on moldings and nonwovens made from rCF waste is low due to several factors: low fiber length efficiency due to low fiber orientation, damage during processing and low fiber content in composites.…”