Patent Description:
Pre-impregnated composite fibers are expensive fibers because of the raw materials used and the process parameters involved in the manufacturing of the fibers. Generally, during the manufacturing of parts or objects from pre-impregnated composite fibers, a significant amount of cut-off waste is generated. The cut-off waste is typically disposed in landfills, thereby wasting a portion of the expensive fibers and contributing to environmental concerns associated with dumping waste in landfills.

In order to avoid such waste, the recycling of such fibers became a priority since the relatively expensive fibers, if recovered efficiently, could potentially be used in other industries, such as the automobile industry, sporting industries, shipping, and so on. Although some methods for recycling have been proposed, even the more efficient recycling processes tend to result in clumps of recycled fibers that are not particularly suitable for reuse in most of the industrial applications mentioned above due to their low bulk density. Accordingly, it may be desirable to define ways to process the fibers to increase their bulk density to the point where the recycled fibers can more easily and efficiently be incorporated into products.

<CIT> discloses a system and a method for recycling fibers that are pre-impregnated with a resin. The fibers are received in a container containing a solvent. Sound energy is provided into the container in order to facilitate removal of the resin from the fibers, and the disclosure focuses on the control of the frequency of the sound energy.

<CIT> discloses a method of recycling fiber-reinforced plastic. The plastic or resin material is burnt to remove it from the fibers. The carbon fibers are then kneaded into a thermoplastic resin.

<CIT> discloses reclaiming of carbon fibers from a composite part. The composite part and a solvent are centrifuged, for removing the solvent and at least a part of the resin.

<CIT> discloses the recycling of carpets, in particular of the face fibers thereon.

<CIT> discloses recycling of fiber-reinforced thermoplastic materials. The material to be recycled is first cut into pieces with a constant width, and these pieces are thereafter melted. The molten product containing fibers are then molded. The thermoplastic material is never separated from the fibers.

<CIT> discloses manufacture of fiber-containing compressed masses from pre-preg waste which is unhardened. The resin does not have to be removed from the fibers in this process. The waste is first cut into smaller pieces and is then mixed with a resin which is compatible with the resin in the waste. The mixture may be used for forming new structures.

<CIT> discloses recycling of waste from fiber-reinforced webbings, prepregs, etc. The waste is first ground to particles, which are then heated above the reaction temperature of the resin, such that its viscosity is reduced. The particles are then worked with shear forces such that the fibers are released, and the mixture of waste and fibers may be uniform. The mixture may then be formed into new products or cooled for future use.

<CIT> discloses recycling of carbon-fibre scrap, which is mixed with a plastic polymer and a resin. Hereby a pre-preg is obtained, which may be extruded.

<CIT> discloses a process for producing products from uncured prepreg and resin waste. The waste is treated with a solvent, comminuted, mixed and molded under pressure. Boards of building material may be formed thereof.

An example embodiment may provide a system for densification of recycled pre-preg fibers. The system may include a cutting device configured to receive the recycled pre-preg fibers having various lengths, and cut the recycled pre-preg fibers to produce cut fibers having a desired length, and a mixer configured to mix wetted, cut fibers to generate bound fibers having an increased bulk density relative to a bulk density of the cut fibers.

In an example embodiment, a method of densification of recycled pre-preg fibers is provided. The method may include receiving the recycled pre-preg fibers having various lengths, cutting the recycled pre-preg fibers to produce cut fibers having a desired length, wetting the cut fibers, and mixing the wetted, cut fibers to generate bound fibers having an increased bulk density relative to a bulk density of the cut fibers.

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Furthermore, as used herein, the term "or" is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other.

Some example embodiments disclosed herein may allow for the recovery of the expensive composite fibers, and the subsequent processing of such fibers in order to increase bulk density and enable easy mixing of such fibers to enable their subsequent use in follow-on manufacturing activities. Pre-impregnated composite fibers are composite material fibers that already have resins present in their structure. These pre-impregnated composite fibers are sometimes referred to as "pre-preg" fibers. The fibers themselves are usually woven or unidirectional fibers. Pre-preg fibers generally already contain some amount of matrix material or resin that is used to bind carbon fibers together for a particular use or application.

In order to recover pre-preg fibers for subsequent reuse, various systems or methods could be employed. In a typical situation, the pre-preg fibers may have resin that is only partially cured, in order to allow for easier handling. This material may be referred to as "B-Stage" material, and typically requires cold storage in order to prevent complete curing of the resin. B-Stage pre-preg is stored in cooled areas and then complete polymerization is performed by adding heat in a curing oven.

During the manufacturing process of parts made from pre-preg fibers, there tend to be large amounts of cut-off waste portions generated. These cut-off waste portions generally end up in landfills and represent a waste of expensive fiber materials. In order to reduce the amount of expensive fiber waste, more efficient methods of fiber recycling have been sought, which could perhaps recycle the fibers in these cut-off waste portions that would otherwise be discarded. According to one useful method of fiber recycling, sound energy is applied to these materials while the materials are disposed in a solvent bath. The sound energy separates the resins from the fibers in the presence of the solvent with greater efficiency. The fibers are then placed in a centrifuge to further facilitate separation, and also to recover excess solvent and some resin from the fibers. The fibers that result from this recycling process (i.e., out of the centrifuge) tend to be clumps of fibers having a low bulk density and a variety of different fiber lengths. Fibers of this type tend to mix very poorly with various thermoset and thermoplastic resins, and therefore are far less useful for consideration in manufacturing of other value added products.

Example embodiments may directly address this issue by increasing bulk density and creating greater consistency in the fiber lengths. Moreover, as will be seen below, the creation of consistency in fiber lengths can actually be helpful in facilitating the increase in bulk density. In this regard, to at least some degree, the method of densifying fibers that is described herein is enhanced by the fact that the fibers are more consistent in terms of their length when densification is commenced.

<FIG> illustrates a cycle of the stages of material associated with densifying fibers in accordance with an example embodiment. <FIG> illustrates a block diagram of various components or apparatuses that may be used at each respective stage. Referring now to <FIG> and <FIG>, the process of densification may begin with cut-off waste portions or pre-preg material <NUM>. The pre-preg material <NUM> may be placed in a solvent and subjected to sonication in a recycler <NUM> to remove resins from the fibers of the pre-preg material <NUM> and therefor produce fibers and solvent <NUM>. The pre-preg material <NUM> may include carbon fibers pre-impregnated with resin. The carbon fibers may take the form of a weave or may be unidirectional. The recycler <NUM> may receive the pre-preg material <NUM> along with enough solvent to completely cover the pre-preg material <NUM>. The solvent may be an organic solvent such as dimethylformamide, N,N-dimethylacetamide, acetone, toluene, acetonitrile, hexane, tetrahydrofuran, or the like. The solvent type and the amount of solvent loaded into the recycler <NUM> may be based on a number of factors, such as the type of resins contained in the composite fibers, the weight of composite fibers to be loaded into the recycler <NUM>, the approximate amount of resin contained within the composite fibers, etc. The solvent could be applied onto a loaded amount of pre-preg material <NUM>, or the pre-preg material <NUM> could be provided into a prepared bath of solvent. The ordering of the loading of materials is flexible in various different example recycling methods.

The carbon fibers of the pre-preg material <NUM> may be a variety of shapes and sizes and may contain several different resins. Thus, as stated above, the type of solvent provided into the recycler <NUM> may depend on the types of resins that are to be separated from the carbon fibers of the pre-preg material <NUM>. The recycler <NUM> may include an ultrasonicator or agitator that is used to apply one or more selected frequencies to the solvent and the pre-preg material <NUM> to cause sonication of the mixture. Sonication is the process of applying sound energy to agitate the solution contained within the recycler <NUM>. The sonication process initiates and improves the process of resin removal from the carbon fibers and, in some cases, may also make the resin available for biofuel production or other applications. In some embodiments, the sound waves propagate through a liquid medium (e.g., the solvent) resulting in alternating high pressure and low pressure cycles thereby creating very high local temperatures and shear forces to remove the resin from the carbon fibers. The agitator or ultrasonicator of the recycler <NUM> may include an energy source by which sound energy in a range from <NUM> to <NUM> may be applied to the fiber-solvent mixture. Typically, the sound energy may be applied for time periods ranging from one second to sixty minutes. In some example embodiments, the recycler <NUM> may employ unique sonication "strategies" or "techniques" based upon the relationship of time, given frequencies, and other environmental parameters (e.g., manual agitation, pressure, or temperature). As such, for example, the recycler <NUM> may be configured to execute algorithms that control the different aspects associated with the application of the sonication process to the fiber-solvent mixture. In this regard, for example, the recycler <NUM> may be configured to define specific frequencies to apply at corresponding different times or in different sequences and/or define a specific time interval, sequence, frequency, or the like for specific fibers, resins, or fiber/resin combinations to ensure that substantially all the resin is effectively removed from the carbon fibers thereby resulting in, responsive to removal of the resin, a collection of fibers and solvent <NUM>.

The fibers and solvent <NUM> may then be processed by a centrifuge <NUM> to produce recycled fibers <NUM> that are effectively dry and free of solvent. The recycled fibers <NUM> may come out of the centrifuge <NUM> in clumps that have a relatively low bulk density. Fibers having a low bulk density may not mix well with other thermoset and thermoplastic resins. Thus, as noted above, it may be desirable to increase bulk density. Accordingly, example embodiments may continue the processing of the recycled fibers <NUM> to produce fibers having a higher bulk density. At this point, it should also be noted that although a particular method of recycling was described above, any method of obtaining the recycled fibers <NUM> could be substituted in accordance with example embodiments. As such, example embodiments may begin with recycled fibers <NUM> (obtained by any means) and continue as described herein to increase the bulk density of the recycled fibers <NUM>.

As shown in <FIG> and <FIG>, an increase in bulk density (i.e., densification) of the recycled fibers <NUM> may be accomplished by initially cutting the recycled fibers <NUM> to consistent lengths. In this regard, the recycled fibers <NUM> may have widely varying lengths (e.g., from <NUM> inches to <NUM> inches). As will be seen below, densification of the recycled fibers <NUM> may be enabled, at least in part, by the elimination of this wide difference in lengths of the recycled fibers <NUM>. Accordingly, the recycled fibers <NUM> may be processed in a way that results in cut fibers <NUM> that have a more consistent length.

In some cases, the processing of the recycled fibers <NUM> to produce the cut fibers <NUM> may include a cutting device that may be configured to perform a chopping and/or screening process. Thus, for example, the cutting device may be embodied as a hammermill <NUM> that may be configured to chop the recycled fibers <NUM> to consistent lengths (e.g., a desired length). After processing by the hammermill <NUM>, a screen <NUM> may be employed to filter an output of the hammermill <NUM> to further ensure separation of fibers and selection of fibers having the desired length. In this regard, the screen <NUM> may be configure to pass only those fibers that are smaller than a selected length. As such, any fibers that remain longer than the selected length may be removed from the screen and added to the next group of recycled fibers <NUM> being added into the hammermill <NUM>. In this way, fibers that fail to meet the criteria for selection for continued processing are not wasted, but may have an opportunity, with a future batch of recycled fibers <NUM> that is being processed, to be passed on as cut fibers <NUM> that are processed for increasing bulk density.

The screen <NUM> may be a portion of the hammermill <NUM>, or a separate component. Moreover, in some cases, a fiber chopping device other than the hammermill <NUM> may be employed. In this regard, any device or combination of devices that can reduce the length of the fibers to a consistent length may be employed. In an example embodiment, an output of the hammermill <NUM> and/or screen <NUM> (i.e., the cut fibers <NUM>) may include separated material having between <NUM> to <NUM> filaments of carbon fiber that is cut to a length of between about <NUM> inches and <NUM> inches. In one example, a length of about <NUM> inches may be selected as the desired length.

The cut fibers <NUM> may therefore be relatively consistent in length (i.e., within a relatively small range of lengths), and be dry, prior to being fed into a mixer <NUM>, where densification occurs. This consistency in length may enhance densification, as will be explained in greater detail below. The mixer <NUM> may be a high intensity mixer or rotating tumbler that is configured to apply a mixing or tumbling motion to the cut fibers <NUM> therein. However, prior to being rotated or tumbled in the mixer <NUM>, the cut fibers <NUM> may be wetted (either in the mixer <NUM> or prior to entry into the mixer <NUM>). The wetting may be accomplished with water or another liquid (e.g., a binder or binding material) that may enhance binding of individual carbon fiber filaments of the cut fibers <NUM> to bind to each other.

In an example embodiment, moisture (e.g., water or the binder) may be added to the cut fibers <NUM> either within the mixer <NUM> or, as noted above, prior to insertion of the cut fibers <NUM> into the mixer <NUM>. In either case, the rotating or tumbling motion of the mixer <NUM> may cause the wetted, cut fibers to bounce off the interior of the mixer <NUM> rather than stick to or clump up on the interior of the mixer <NUM>. In some embodiments, the moisture may be sprayed into the mixer <NUM>, and the cut fibers <NUM> may be effectively wetted by rotation within the moisture inside the mixer <NUM>.

A ratio of water to fibers, or of binder to fibers may be selected by the operator depending upon the bulk density values that are desired for a particular application. In this regard, the thermoset or thermoplastic resin with which the fibers are ultimately to be mixed with may dictate the ratio of water to fibers or the ratio of binder to fibers. Moreover, the type of binder that is used (if any) may be selected based on the desired bulk density and/or the thermoset or thermoplastic resin with which the fibers are ultimately to be mixed for the specific products into which the fibers are planned for inclusion. As such, for example, the binder may be selected to the specific end use that is desired, and more particularly, may be selected to be compatible with the resin that is to be used in the specific end use that is desired.

In an example embodiment, tumbling of the wetted, cut fibers within the mixer <NUM> may result in formation of bound fibers <NUM>, which are substantially densified relative to the cut fibers <NUM> inserted into the mixer <NUM>. In this regard, the bound fibers <NUM> may form rice grain-type pellets that have a desired bulk density. The bound fibers <NUM> may be free flowing when mixed with resin. In other words, when the grains or pellets of the bound fibers <NUM> are mixed with pellets or grains of the resin, the mixture may be relatively easy to mix in desired ratios with relatively predictable and even ratios throughout the mixture. The corresponding composite material products formed in final treatment and curing may therefore be relatively consistent and high quality materials.

Densification is more efficient when preformed relative to the cut fibers <NUM>, due to the cut fibers <NUM> having similar lengths, and being wetted. Otherwise, the fibers may bind together to form webs of material that are less dense, and also not free flowing. However, fibers that are wetted and have similar lengths tend to bind together better in the mixer <NUM> to form desirable bound fibers <NUM> that are free flowing. In this regard, the bound fibers <NUM> tend to have lengths also similar to the lengths of the cut fibers <NUM> (e.g., from about <NUM> inches to about <NUM> inches) and generally do not grow in length by any appreciable amount. This is due to the specific phenomena that occurs to form the bound fibers <NUM>. <FIG> and <FIG> illustrate the phenomena in greater detail.

Of note, the particular phenomena relates to the cohesive forces of water molecules (or other liquids that may be used as the binder) when in the presence of other water molecules. For example, surface tension may be formed between water molecules that wet fibers so that a wetted fiber is less likely to adhere to a non-wetted material (e.g., the walls of the mixer <NUM>) than to another wetted fiber. However, the forces of adhesion that bind water molecules together may have to compete with the kinetic forces of the tumbling action created by the mixer <NUM>. The adhesion of water molecules to each other is maximum when there is maximum surface area presented over which water molecules can experience cohesion. Thus, the mixer <NUM> may rotate at a speed that is selected to achieve binding of adjacent wetted fibers only when the wetted fibers approach each other in such a way as to present maximum surface area for adhesion to each other. In other words, the wetting of the fibers and the speed of the tumbling are balanced to ensure that binding of fibers occurs when the wetted fibers have a parallel collision with each other where lengths of the fibers are also substantially aligned.

In this regard, as shown in <FIG>, which includes <FIG>, a first wetted, cut fiber <NUM> may encounter a second wetted, cut fiber <NUM> in any of number of random orientations during tumbling within the mixer <NUM>. <FIG> illustrates an interaction in which only the midsections of both the first wetted, cut fiber <NUM> and the second wetted, cut fiber <NUM> encounter each other during an interaction that occurs during tumbling within the mixer <NUM>. In this interaction, only a very small surface area of the first and second wetted, cut fibers <NUM> and <NUM> encounter each other and the cohesion of the water molecules wetting each fiber is not sufficient to overcome the kinetic energy imparted by the mixer <NUM> on the fibers, so they effectively bounce off each other and continue to rotate and tumble within the mixer <NUM>.

<FIG> illustrates an interaction in which an end portion of the first wetted, cut fiber <NUM> strikes a middle portion (or end portion) of the second wetted, cut fiber <NUM>. In this example also, only a very small surface area of the first and second wetted, cut fibers <NUM> and <NUM> encounter each other. Accordingly, the cohesion of the water molecules wetting each fiber is not sufficient to overcome the kinetic energy imparted by the mixer <NUM>. Again, the first and second wetted, cut fibers <NUM> and <NUM> effectively bounce off each other and continue to rotate and tumble within the mixer <NUM>.

In both <FIG>, the first and second wetted, cut fibers <NUM> and <NUM> approached each other such that their longitudinal directions of extension are at an angle relative to each other (i.e., they are not parallel to each other). These situations will generally result in a failure of the first and second wetted, cut fibers <NUM> and <NUM> to bind to each other. However, it is also possible for the first and second wetted ,cut fibers <NUM> and <NUM> to fail to bind to each other when parallel interactions occur.

<FIG> illustrates another possible interaction, this time the first and second wetted, cut fibers <NUM> and <NUM> approached each other with little to no angle therebetween. In other words, the first and second wetted, cut fibers <NUM> and <NUM> are substantially parallel to each other. However, their lengths are not aligned so that it is only end portions of the first and second wetted, cut fibers <NUM> and <NUM> that contact each other in the collision. In this collision as well, the kinetic energy of the first and second wetted, cut fibers <NUM> and <NUM> is greater than the forces of cohesion between the first and second wetted, cut fibers <NUM> and <NUM>. Thus, no binding occurs.

However, as shown in <FIG>, when the first and second wetted, cut fibers <NUM> and <NUM> approach each other with ends substantially aligned and parallel to each other, the forces of cohesion between the first and second wetted, cut fibers <NUM> and <NUM> (particularly between the water molecules on each respective fiber) are sufficient to overcome the kinetic energy of the first and second wetted, cut fibers <NUM> and <NUM> caused by the mixer <NUM>. In particular, since the respective ends of the first and second wetted, cut fibers <NUM> and <NUM> are proximate to each other when the collision occurs, and the first and second wetted, cut fibers <NUM> and <NUM> are also parallel to each other, the surface area over which the water molecules on each of the first and second wetted, cut fibers <NUM> and <NUM> experience cohesion toward each other is maximized. Thus, the first and second wetted, cut fibers <NUM> and <NUM> may bind to each other to form bound fibers <NUM>. The bound fibers <NUM> may then be available for continued interaction with other wetted fibers and/or bound fibers. However, the same general principles apply for collisions that occur subsequent to binding of one set of fibers until the numbers of bound fibers build up to form grains or pellets of bound fibers.

In this regard, <FIG> each illustrate collisions under similar circumstances to those shown in <FIG>, respectively, except that a third wetted, cut fiber <NUM> approaches the bound fibers <NUM> in the corresponding collision geometries explained in <FIG>. As can be seen in <FIG>, which is defined by <FIG>, collisions that occur between fibers at angles relative to each other generally do not result in binding. In this regard, the third wetted, cut fiber <NUM> does not bind with the bound fiber <NUM> of <FIG> due to the small surface area of contact between water molecules on the colliding objects. Moreover, collisions that are between parallel fibers that are not aligned linearly such that each of their respective ends are proximate to each other (as in <FIG> and <FIG>, where only a small amount of overlap occurs) also generally do not result in binding. However, when the third wetted, cut fiber <NUM> approaches the bound fibers <NUM> such that the third wetted, cut fiber <NUM> and the bound fibers <NUM> are generally parallel to each other and respective ends are generally aligned with each other (i.e., the fibers are aligned linearly with respective ends proximate to each other), the cohesion forces of the water molecules on the third wetted, cut fiber <NUM> and the bound fibers <NUM> are sufficient to overcome the kinetic energy of the fibers and binding occurs due to the large amount of surface area over which the cohesive forces act. Then, as shown in <FIG>, the third wetted, cut fiber <NUM> and the bound fibers <NUM> may bind together to form compound bound fiber <NUM>.

As can be appreciated from the description above, additional collisions that may occur between the compound bound fiber <NUM> and fibers that are linearly aligned therewith and parallel thereto may occur. These collisions may also result in further compound bindings to form the pellets or grains described above. Of note, because the bindings generally occur only when the contact surface area between fibers is maximized, the overall length of the pellets or grains may be relatively consistent with the lengths of the fibers (e.g., at a selected length from about <NUM> inches to <NUM> inches such as, for example, <NUM> inches). However, since slight misalignments of the ends of the fibers may still result in relatively large contact surface areas between fibers, binding may still occur between fibers that are not necessarily perfectly aligned. As such, some growth in the lengths of bound fibers and compound bound fibers may occur. In various example embodiments, the lengths of the grains or pellets that form from compounding of bound fibers may remain less than about <NUM>% to about <NUM>% longer than the range of lengths of the fibers.

It should also be appreciated that inside the mixer <NUM>, a multitude of collisions of fibers are likely to occur during tumbling. Moreover, of these many collisions, the vast majority will have alignments similar to those shown in <FIG>, <FIG>, and only relatively small numbers of collisions will have alignments similar to those shown in <FIG> and <FIG>. However, even in situations where alignments like those of <FIG> and <FIG> occur at the time of collision, it would be even more rare that the fibers are approaching each other by moving in equal and opposite directions. Instead, at the point of collision, one or each fiber may have some form of momentum that tends to represent a twisting action relative to the other fiber. As such, when collisions occur involving some form of twisting action, at least one of the fibers may tend to wrap around the other fiber to at least some degree. This form of binding, involving a twisting action at impact, may actually form even stronger bonds that a binding of fibers that approach each other from equal and opposite directions and are perfectly aligned. Through the tumbling process that occurs within the mixer <NUM>, many random collisions occur and result in the bindings described above, thereby increasing the bulk density of the contents of the mixer <NUM> through the bindings of the carbon fibers therein.

As mentioned above, a proper balance is sought between kinetic energy of the wetted, cut fibers in the mixer <NUM> and the forces of cohesion of the water molecules on the fibers so that binding only occurs when alignments such as those shown in <FIG> and <FIG> are present. This balance is potentially different for corresponding different fibers (e.g., in terms of length and/or material composition). The balance may also change for different degrees of wetness, and/or for different binders (other than or in addition to water). Accordingly, in some cases, the mixer <NUM> may have a variable speed, and the speed may be adjusted until bindings occur and generate the desired grain or pellet shape and size. In this regard, if operation of the mixer <NUM> generates webs of bound materials, or pellets or grains that have substantially longer lengths (i.e., greater than <NUM>% to <NUM>% longer) than the lengths of the cut fibers <NUM>, the speed of the mixer <NUM> may be increased. Conversely, if the numbers of bindings are too low and excessive mixing still fails to produce substantial increases in bulk density, the speed of the mixer <NUM> may be reduced. Eventually, and after a relatively short period of operation of the mixer <NUM>, the proper speed may be determined for a given set of ingredients and conditions. The resulting grains or pellets may then also be free flowing and well suited for mixing with selected thermoset or thermoplastic resins to produce composite materials for use in product manufacturing.

<FIG> illustrates a block diagram of a method of densification of recycled pre-impregnated fibers. As shown in <FIG>, the method may include receiving the recycled prepreg fibers having various lengths at operation <NUM> and cutting the recycled pre-preg fibers to produce cut fibers having a desired length at operation <NUM>. The method may further include wetting the cut fibers at operation <NUM> and mixing the wetted, cut fibers to generate bound fibers having an increased bulk density relative to a bulk density of the cut fibers at operation <NUM>.

In some embodiments, the method (and corresponding apparatus or system in or with which the method may be performed) may be configured to include additional, optional operations, and/or the operations described above may be modified or augmented. Some examples of modifications, optional operations and augmentations are described below. It should be appreciated that the modifications, optional operations and augmentations may each be added alone, or they may be added cumulatively in any desirable combination. In this regard, for example, wetting the cut fibers may include wetting the cut fibers in a high intensity mixer or before insertion into the high intensity mixer. In some cases, cutting the recycled prepreg fibers may include cutting the recycled pre-preg fibers in a hammermill. In an example embodiment, the method may further include passing the cut fibers through a screen configured to pass cut fibers having the desired length. In this regard, for example, the desired length may be a length selected in a range from about <NUM> inches to about <NUM> inches. In some cases, mixing the wetted, cut fibers may include mixing the wetted, cut fibers in a variable speed mixer. In an example embodiment, the bound fibers may form grains or pellets having a length less than <NUM>% longer than the desired length. In some embodiments, the method may further include an initial operation of removing resin from the recycled pre-preg fibers via sonication in a solvent bath prior to the cutting of the recycled pre-preg fibers. In some cases, the method may also further include removing the solvent from the recycled pre-preg fibers in a centrifuge prior to the cutting of the recycled pre-preg fibers.

Claim 1:
A system for densification of recycled pre-preg fibers, the system comprising:
a recycler (<NUM>) configured to remove resin from pre-preg material (<NUM>) via sonication to extract recycled pre-preg fibers (<NUM>) from the pre-preg material (<NUM>)
a cutting device (<NUM>) configured to receive the recycled pre-preg fibers (<NUM>) having various lengths and a first bulk density,
and cut the recycled pre-preg fibers (<NUM>) to produce cut fibers (<NUM>) having a desired length; and characterized in
a mixer (<NUM>) configured to mix wetted, cut fibers (<NUM>) to generate bound fibers (<NUM>) having a second bulk density that is increased relative to the first bulk density of the cut fibers.