Patent No. EP2536546 (titled "Method For Producing A Flat Semi-Finished Product From Fiber Composite Material") was filed by SGL Automotive Carbon Fibers on Feb 3, 2011. The application was issued on Oct 25, 2017.
A method for producing a flat fiber composite semi-finished product involves isolating finite carbon fibers, carbon fiber bundles, or a mixture thereof from waste or used parts. These are mixed with thermoplastic foreign fibers and processed via carding to produce a fibrous web. To overcome the processing difficulties of smooth, crimp-free carbon fibers and achieve high longitudinal alignment, thermoplastic foreign fibers are added during carding in a mixing ratio and/or with a geometry that enables a fiber anisotropy of at least 1:2. The resulting oriented fibrous web is subsequently compressed under heat to form a sheet material. The thermoplastic matrix material typically comprises 5% to 95% of the product, acting as a binder during thermal consolidation.

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