Fraunhofer ITWM Supports Development of New CFRP Fibers with Simulation Expertise

ProStAir: Reducing Pollutant Emissions with Recycled Fibers

Presseinformation / November 05, 2019

The heavier a motor vehicle, the higher its exhaust emissions. For years, the automotive industry has been trying to counteract this trend by increasing the use of lightweight components. As a rule, these consist of carbon fibre reinforced plastics (CFRP). The Fraunhofer Institute for Industrial Mathematics ITWM supports the development of novel CFRP fibers in the ProStAir project with its simulation expertise.

The CO2 balance of original carbon fibers (CF) is viewed critically due to the energy-intensive production process, which also makes the material expensive. More cost-effective are recycled carbon fibers (rCF), which are processed into nonwovens and used for CFRP components. However, their strength is lower than that of CFRP based on CF fabrics.

Investigation of Aerodynamic Random Nonwovens

In the new ProStAir project (process and structure modeling for novel airlay carbon fiber nonwovens and their isotropy behavior), Fraunhofer researchers are investigating the resilience of these materials. They belong to the group of aerodynamic random nonwovens; they are produced in so-called airlay systems.

© STFI/Wolfgang Schmidt
Virtual presentation of the simulated alignment of recycled carbon fibers in the nonwoven.

Here, the raw material, for example fiber mats made from renewable raw materials or recycled plastic fibers, is opened and the fibers are fed into the air stream by the roller. The air-fiber mixture then lands on a belt where it is compressed by suction. The aim of the nonwovens producers is to produce maximum voluminous nonwovens using as little raw material as possible.

The airlay process is extremely economical and particularly suitable for processing rCF. In addition, it offers the possibility of aligning the fibers in the surface and even in the room. So far, the complex machine settings have only been found empirically. These preliminary tests cost time, material and energy.

Airlay Modeling and Simulation

The aim of ProStAir is to model and simulate rCF nonwovens production using airlay and to develop software with which nonwovens manufacturers can control their machines more efficiently. So it is possible to save material and time. The task of Fraunhofer ITWM is explained by Johannes Schnebele, employee of the department Transport Processes: »We will use the software tools developed at the ITWM to predict the isotropy and strength of the nonwoven and show how these properties can be controlled by process parameters.«

Fraunhofer ITWM's project partner is the Saxon Textile Research Institute (Sächsisches Textilforschungsinstitut e.V.). (STFI) in Chemnitz, where the airlay plant is located for testing the production of nonwovens.

© Fraunhofer ITWM
Sketch of the airlay process.

Press Release

Fraunhofer ITWM Supports Development of New CFRP Fibers with Simulation Expertise

ProStAir: Reducing Pollutant Emissions with Recycled Fibers

Investigation of Aerodynamic Random Nonwovens

Further Information

Airlay Modeling and Simulation

Contact Press / Media

Ilka Blauth