Description:
Background
Thermoset carbon fiber–reinforced polymer (CFRP) composites are popular for their exceptional specific modulus and strength, leading to a projected global demand of approximately 285,000 tons annually. A recycling method recovers the embedded carbon fibers, and post-processing recovers valuable resin monomers.
Technology Description
USC researchers have developed an electrochemical method for recycling CFRP composites by generating methyl radicals under controlled conditions, which selectively degrade the polymer matrix. Unlike conventional chloride-based electrochemical methods that require chlorine-derived oxidants, radical-mediated depolymerization pathways are used. The process rapidly liberates carbon fibers from the polymer matrix, allowing recovery of recycled fibers with minimal surface or structural damage. Completing the loop, valuable monomers are recovered from the reinforcing polymer, and recovered sheets are remanufactured.
Benefits
•Recovery of carbon fibers suitable for reuse
•Quicker matrix degradation compared to preexisting methods
•Less energy intensive than thermal or catalyst-heavy oxidative processes
•Process optimization and control
Stage of Development
•Bench-scale demonstration
Applications
•Aerospace composites end-of-life recycling
•Automotive lightweight materials recovery
•Reclamation of production scrap
Publications
Green Chem., 2025, 27, 2184-2188. DOI: 10.1039/d4gc05299d
Green Chem., 2023, 25, 7058-7061. DOI: 10.1039/d3gc01765f