Bio-based Composite Sheet Bending via Perforated Pressing
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Solution Overview
Problem
The environmental impact of fossil-based plastics and fiber-reinforced polymers is high due to manufacturing and disposal challenges, and there is a need for improved methods to produce environmentally friendly, complex-shaped composite articles.
Innovation Solution
A method involving the use of sheets comprising cellulosic fibers and a composite agent, where the sheets are perforated to form recesses and then pressed in a tool to bend and shape the composite article, allowing for the creation of complex shapes with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fossil-based plastics and fiber-reinforced polymers are used to achieve high strength-to-weight ratio and rigidity, then mechanical performance is improved, but environmental impact increases due to manufacturing and disposal challenges
Solution Approach 1:
The patent changes the material parameters by replacing fossil-based polymers with bio-based polymers and natural fibers in the composite material composition, thereby reducing environmental impact while maintaining mechanical performance through controlled material substitution
Solution Approach 2:
The patent employs composite materials consisting of bio-based polymers combined with natural fibers (such as flax, hemp, or other renewable fibers) to achieve the desired mechanical properties while reducing environmental harm compared to traditional FRP composites
2Object-generated harmful factors
If bio-based polymers and natural fibers are used to reduce environmental impact, then environmental friendliness is improved, but supply volume and quality consistency are insufficient
Solution Approach 1:
The patent applies local quality by using different fiber types and bio-based polymer combinations in specific regions or layers of the composite material, allowing optimization for both environmental performance and supply availability in different application areas
3Adaptability or versatility
If complex-shaped composite articles are manufactured to meet diverse application requirements, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct stages: preparing the bio-based composite material, molding the complex shape, and applying finishing treatments, thereby reducing overall process complexity while maintaining adaptability to various article shapes
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
This method enables the production of composite articles with high moisture resistance, improved mechanical properties, and reduced environmental impact, suitable for various applications such as sport appliances, furniture, and vehicle parts.
Implementation Method 1
pressing the at least one sheet in a pressing tool such that bending of the at least one sheet occurs at the location of the one or more recesses
Data Source
AI summary
The present disclosure provides a method for manufacturing a composite article.