Development of high‐strength carbon fiber/thermoplastic epoxy resin composites and it's recyclability

Abstract The realization of the recycling of epoxy resin composites has important practical significance for “carbon peak, carbon neutrality” and resource conservation, and recycling. In this study, high‐strength carbon fiber fabric reinforced thermoplastic epoxy (TPE) composites (CFF/TPE) were successfully fabricated by a laminated hot‐pressing process, and both CFF and TPE were efficiently recycled via an ultrasonication‐assisted solvent method. The CFF/TPE composites present mechanical properties (tensile strength: 705 MPa, flexural strength: 711 MPa) by optimizing the process parameters, which are comparable to those of carbon fiber reinforced thermosetting epoxy. Moreover, the tensile strength retention rates of recycled CFF and TPE are 92% and 89%, respectively. The recycled CFF can be completely reprocessed through the same hot‐pressing process, and the recycled CFF/TPE composite exhibited high efficiency reuse and excellent mechanical properties (high strength of reaching 94% of CFF/TPE). This approach provides a new strategy for the facile production of high‐performance carbon fiber reinforced epoxy composites with high efficiency recycling. Highlights Recyclable carbon fiber fabric reinforced thermoplastic epoxy composites (CFF/TPE) are fabricated by a laminated hot‐pressing process. The composite exhibits excellent mechanical properties, which is comparable to that of carbon fiber reinforced thermosetting epoxy. The carbon fiber fabric and thermoplastic epoxy can be efficiently recycled via a simple ultrasonication‐assisted solvent method, and resued.