Year: 2024
Type: article
Abstract: Carbon fiber reinforced polymers (CFRPs, or composites) are increasingly replacing traditional manufacturing materials used in the automobile, aerospace, and energy sectors. With this shift, it is vital to develop end-of-life processes for CFRPs that retain the value of both the carbon fibers and the polymer matrix. Here we demonstrate a strategy to upcycle pre- and postconsumer polystyrene-containing CFRPs, cross-linked with unsaturated polyesters or vinyl esters, to benzoic acid. The thermoset matrix is upgraded via biocatalysis utilizing an engineered strain of the filamentous fungus Aspergillus nidulans, which gives access to valuable secondary metabolites in high yields, exemplified here by (2 Z,4 Z,6 E )-octa-2,4,6-trienoic acid. Reactions are engineered to preserve the carbon fibers with much of their sizing so that the isolated carbon fiber plies are manufactured into new composite coupons that exhibit mechanical properties comparable to those of virgin manufacturing substrates. In sum, this represents the first system to reclaim a high value from both the fiber fabric and polymer matrix of a CFRP.
DOI: 10.1021/jacs.4c10838
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: green
Funders: National Science Foundation, University of Southern California, University of Kansas, National Institutes of Health, National Oceanic and Atmospheric Administration, Wrigley Institute for Environmental Studies, University of Southern California, National Institute of Allergy and Infectious Diseases, National Center for Research Resources, Division of Civil, Mechanical and Manufacturing Innovation, Division of Chemistry, Division of Biological Infrastructure
Awards: Collaborative Research: Acquisition of a 400 MHz NMR at the University of Southern California, G1548999368, G1638050999, G2278757305, G3111046024, G3306068231, G3634295717, G4040018596, MRI: Acquisition of a 600 Mhz NMR Spectrometer at the University of Southern California, G496533347, G5366184946, BRITE Pivot: Remanufacturing Post-Consumer Carbon Fiber Composite Materials, MRI: Acquisition of an X-ray Diffractometer at the University of Southern California, Acquisition of a 500 MHz NMR Spectrometer for the University of Southern Calif, G7908808146, FMSG: Eco: Teambuilding, Training, Manufacturing Efficiency and Recycling for Sustainable Polymer Composites
OpenAlex ID: W4403716981