Basalt Fibre Structural Shell for Recyclable Composite Recovery
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Solution Overview
Problem
Existing fibre-reinforced resin composites used in marine vessels and wind turbine blades are difficult to recycle due to the strong bond between glass/carbon fibres and thermoset plastics, leading to single-use materials that often end up in landfills, with limited options for recovery or recycling.
Innovation Solution
A structural shell made with basalt fibres reinforced by a thermoplastic polymer material that can be thermally cracked at 200-600°C, allowing separation and recovery of both fibres and resin without significant deterioration in properties, enabling recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass or carbon fibres are used to reinforce thermoset plastics, then the composite achieves high strength and lightweight properties, but the fibres cannot be recovered and reused at end of life
Solution Approach 1:
The patent changes the chemical parameter of the resin from thermoset to thermoplastic. Thermoplastic resins can be melted and reprocessed, enabling fibre recovery. The basalt fibres are reinforced with thermoplastic resin that can be heated to melt and separate from the fibres, allowing the fibres to be recovered and reused while maintaining composite strength during service.
Solution Approach 2:
The patent uses a composite material system consisting of basalt fibres and thermoplastic resin. This composite provides both the desired mechanical strength and the recyclability needed. The specific combination of basalt fibres with thermoplastic resin creates a material that can be easily separated at end of life through heating, enabling fibre recovery without significant property deterioration.
2Strength
If fibres are made porous to absorb resin for strong bonding, then bond strength increases, but material separation at end of life becomes impossible
Solution Approach 1:
The patent changes the thermal parameter of the resin system. By using thermoplastic resin instead of thermoset resin, the material transitions from a permanently crosslinked state to a reversible state that can be melted and reprocessed. This parameter change enables both strong bonding during service and easy separation at end of life through heating.
Solution Approach 2:
The patent converts the typically harmful effect of strong bonding into a beneficial feature. The strong bond between basalt fibres and thermoplastic resin provides excellent mechanical properties during service, while the same strong bonding can be reversed through heating, enabling complete material separation and fibre recovery at end of life.
3Strength
If thermoset plastics are used to reinforce basalt fibres, then the composite becomes rigid and strong, but the resin cannot be recovered for reuse
Solution Approach 1:
The patent changes the fundamental parameter of resin reversibility. By selecting thermoplastic resin over thermoset resin, the system gains the ability to reverse the bonding process through heating. The thermoplastic resin maintains rigidity and strength during service but can be melted and recovered for reuse, eliminating the loss of substance problem associated with thermoset systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The structural shell maintains high flexural strength and can be fully recycled, with fibres and resin recovered for reuse, reducing waste and environmental impact.
Implementation Method 1
a polymer material, wherein the polymer material is capable of at least partially thermally cracking at a temperature of from 200 to 600°C
Data Source
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AI summary
The present invention provides a structural shell comprising a basalt fibre- reinforced material, wherein the basalt fibre-reinforced material comprises a polymer material, the polymer material being capable of at least partially thermally cracking at a temperature of from 200 to 600°C.