In-line carbon fiber intermediates: lower-cost process for composite semi-finished products
Methods that reduce the cost of producing carbon fiber composites by processing raw carbon fibers in-line into intermediates such as tapes, rods and pellets. The process incorporates thermoplastic or thermosetting materials to produce CFRP semi-finished products with carbon fiber weight fractions between 30-70%.
The problem
Carbon fiber composites are remarkable materials which provide high strength-to-weight ratio, stiffness, environmental resistance, and design flexibility. These composites are produced by integrating carbon fiber intermediates with polymer matrices and manipulated to form the desired product. The singular factor slowing wider adoption is the higher cost of fit for purpose carbon fiber intermediates.
The solution
Researchers at the University of Tennessee have developed methods to reduce the costs producing carbon fiber composites. The solution features the in-line processing of raw carbon fibers into a range of intermediates for semi-finished products such as tapes, rods, pellets, etc. This process also includes the incorporation with thermoplastic or thermosetting materials to produce CFRP semi-finished products that contain carbon fiber weight fractions between 30-70%. These solutions are detailed in two patents:
- Thermoplastic impregnation of large tow textile grade carbon fiber - US20250091254A1. Intermediates of 3k - 50k filaments
- Process to manufacture carbon fiber intermediate products in-line with carbon fiber production - US11441001B1. Intermediates of 100k - 600k filaments
Benefits
- Reduces total product costs by 35% with in-line process
- Easily implemented into existing manufacturing lines
- Applicable to tape placement, pulltrusion, injection molding, and compression molding.
Patent status
US20250091254A1 & US11441001B1
About University of Tennessee, Knoxville
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