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In this study, recycled carbon fibers (rCFs) recovered from waste carbon composites were used to manufacture wet-laid nonwoven fabrics. The aim was to improve dispersibility by investigating the changes in the dispersibility of carbon fibers (CFs) based on the content of the dispersant carboxymethyl cellulose (CMC) and the binder polyvinyl alcohol (PVA), and the length and basis weight of the CFs. In addition, the chemical property changes and oxygen functional group mechanisms based on the content of the CMC dispersant and PVA binder were investigated. The nonwoven fabrics made with desized CFs exhibited significantly improved dispersibility. For nonwoven fabrics produced with a fixed binder PVA content of 10%, optimal dispersibility was achieved at a dispersant CMC concentration of 0.4%. When the dispersant CMC concentration was fixed at 0.4% and the binder PVA content at 10%, the best dispersibility was observed at a CF length of 3 mm, while the maximum tensile strength was achieved at a fiber length of 6 mm. Dispersibility remained almost consistent across different basis weights. As the dispersant CMC concentration increased from 0.2% to 0.6%, the oxygen functional groups, such as carbonyl group (C=O), lactone group (O=C-O), and natrium hydroxide (NaOH), also increased. However, hydroxyl group (C-O) decreased. Moreover, the contact angle decreased, while the surface free energy increased. On the other hand, when the dispersant CMC concentration was fixed at 0.4%, the optimal binder PVA content was found to be 3%. As the binder PVA content increased from 0% to 10%, the formation of hydrogen bonds between the CMC dispersant and the PVA binder led to an increase in C=O and O=C-O bonds, while C-O and NaOH decreased. As the amount of oxygen increased, the contact angle decreased and the surface free energy increased. [ABSTRACT FROM AUTHOR]

Upcycling recycled carbon fibers recovered from waste carbon composites can reduce the price of carbon fibers while improving disposal-related environmental problems. This study assessed and characterized recycled carbon fibers subjected to sizing treatment using N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (APS) chemically coordinated with polyamide 6 (PA6) and polypropylene (PP) resins. Sizing treatment with 1 wt.% APS for 10 s yielded O=C-O on the surface of the carbon fiber, and the -SiOH in the APS underwent a dehydration–condensation reaction that converted O=C-O (lactone groups) into bonds of C-O (hydroxyl groups) and C=O (carbonyl groups). The effects of C-O and C=O on the interfacial bonding force increased to a maximum, resulting in an oxygen-to-carbon ratio (O/C) of 0.26. The polar/surface energy ratio showed the highest value of 32.29% at 10 s, and the interfacial bonding force showed the maximum value of 32 MPa at 10 s, which is about 15% better than that of commercial carbon fiber (PA6-based condition). In 10 s resizing treatments with 0.5 wt.% 3-methacryloxypropyltrimethoxysilane (MPS), C-O, C=O, and O=C-O underwent a dehydration–condensation reaction with -SiOH, which broke the bonds between carbon and oxygen and introduced a methacrylate group (H2C=C(CH3)CO2H), resulting in a significant increase in C-O and C=O, with an O/C of 0.51. The polar/surface free energy ratio was about 38% at 10 s, with the interfacial bonding force increasing to 27% compared to commercial carbon fiber (PP-based conditions). MPS exhibited a superior interfacial shear strength improvement, two times higher than that of APS, with excellent coordination with PP resin and commercial carbon fiber, although the interfacial bonding strength of the PP resin was significantly lower. [ABSTRACT FROM AUTHOR]