Bio-Based Resin Layered Structures for Recyclable Aircraft Components

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Solution Overview

Problem

Traditional airplane structures made from phenolic resin materials, derived from fossil fuels, generate waste upon degradation and cannot be recycled, leading to significant landfill contributions.

Innovation Solution

A layered material assembly is formed by coupling fabric components with a bio-based resin product, such as polyfurfuryl alcohol (PFA), which is exposed to curing conditions to bond the layers together, creating structures suitable for aircraft applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If fossil-fuel based phenolic resin materials are used to manufacture airplane structures, then lightweight and inexpensive products are achieved, but significant waste is generated when structures degrade and cannot be recycled

Engineering Contradiction:

Improvewaste generationVSAvoidmanufacturing cost and simplicity

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameter of the resin material from fossil-fuel based phenolic resin to bio-based resin (such as lignin-based or furan-based resins). This parameter change enables the material to be recyclable and biodegradable, directly addressing the waste generation issue while maintaining manufacturing process compatibility and cost-effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structures combining bio-based resin with reinforcing fibers (such as natural fibers like hemp, flax, or recylced carbon fiber). This composite approach maintains the structural performance and lightweight characteristics required for aircraft applications while enabling recyclability and reduced waste through the use of sustainable material components

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If traditional phenolic resin materials are used, then structural performance and lightweight characteristics are maintained, but the materials are not bio-based and contribute to landfill waste

Engineering Contradiction:

Improvestructural integrityVSAvoidenvironmental harm from non-bio-based materials

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The patent modifies the material composition parameter by substituting phenolic resin with bio-based resin alternatives such as lignin-based resins or furan-based resins. This chemical parameter change enables the material to be bio-based and environmentally friendly while maintaining cross-linking mechanisms and structural integrity required for aircraft structures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the previously harmful aspect of non-biodegradable phenolic resin into a benefit by using bio-based resins that are biodegradable and recyclable. The structural performance is maintained through careful selection of bio-based resin formulations and composite structures, turning the environmental disadvantage into an environmental advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 bio-based resin structures provide a sustainable alternative that can be recycled and reduce waste, maintaining structural integrity and performance comparable to traditional materials.

Implementation Method 1

exposing the layered material assembly to one or more curing conditions to cure the layer components together

Methodology Applied

Scientific EffectCuring:

Implementation Method 2

The bio-based resin product may be dispersed throughout the first fabric, such that the first fabric may be impregnated with the bio-based resin product

Methodology Applied

Scientific EffectImpregnation: Absorption (physical)

Data Source

PatentUS20250312995A1Systems and methods for forming a structure including a bio-based resin product

Publication Date: 2025.10.09 THE BOEING CO

AI summary

A method of forming a structure includes positioning a first layer component onto a portion of a top surface of a second layer component and positioning a third layer component onto a portion of a bottom surface of the second layer component to form a layered material assembly. The first layer component and the third layer component are configured to be manufactured of a first fabric and a bio-based resin product, and the second layer component is configured to be manufactured of a second material and the bio-based resin product. The method includes exposing the layered material assembly to one or more curing conditions to create a cured material assembly, and forming the cured material assembly into the structure configured to be disposed onboard an aircraft system.