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An innovative recycling process for thermoset composite laminates is proposed by thermo-mechanical disassembly and further compression molding of hybrid thermoformable composite plates. Due to the thermo-mechanical process, single cured plies are extracted from the waste laminate. Subsequently re-lamination is performed by interposing thermoplastic films between the reclaimed composite plies. Final consolidation is carried out by compression molding. In order to show the feasibility of the novel recycling technology, carbon fiber reinforced composite plates by autoclave molding were thermo-mechanically disassembled in a manual roll bending machine after heating in oven. Reclaimed cured plies were laminated by alternating thermoplastic interlayers made of low density polyethylene. The hybrid laminate was consolidated at the temperature of 220C and the holding pressure of 38.5 bar. Results from bending tests on virgin and recycled plates showed the very good agglomeration of the hybrid samples and the optimal preservation of performances of initial cured plies of the virgin material into the recycled plate.

Recycling of Carbon Fiber Laminates by Thermo-mechanical Disassembly and Hybrid Panel Compression Molding