CAN Fiber Composites for Rapid Low-Temperature Repair
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Solution Overview
Problem
Existing thermoset fiber reinforced composites face challenges in fabrication and repair due to time-consuming processes, high costs, and environmental issues, limiting their widespread adoption, especially in high-volume production and industrial sectors.
Innovation Solution
The use of a covalent adaptable network (CAN) polymer powder to form fiber reinforced composites through compression at elevated temperatures and pressures, enabling rapid fabrication and repair without the need for liquid-state processing or high temperatures, allowing for localized and recyclable composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid-state processing is used to fabricate thermoset fiber reinforced composites, then the composite structure is formed, but the processing time is extremely long (hours to days)
Solution Approach 1:
The patent changes the physical state parameter of the polymer from liquid to solid powder form. This fundamental parameter change enables a completely different processing mechanism - direct compression and heating of powder to form green bodies, followed by curing - which reduces processing time from hours/days to minutes while maintaining composite quality
Solution Approach 2:
The patent utilizes phase transitions of the polymer powder through controlled heating. The powder transitions from solid state through melting and curing to form the final composite structure. This phase transition approach eliminates the long liquid-state impregnation and curing processes, achieving rapid fabrication
2Reliability
If thermoset fiber reinforced composites are damaged, then the part must be replaced, but this results in high costs and loss of operation time
Solution Approach 1:
The patent introduces dynamic reversibility to the traditionally static thermoset composite system. By incorporating reversible crosslinking chemistry, the composite can transition between rigid service state and repairable state, allowing damage repair through simple heating and recompression without replacement
Solution Approach 2:
The patent enables recovery and reuse of damaged composite parts. Instead of discarding damaged components, the reversible chemistry allows the material to be reprocessed and restored to full functionality, extending component life and reducing waste
3Strength
If conventional thermoset composites are used, then high stiffness and strength are achieved, but the fabrication process is time-consuming and expensive
Solution Approach 1:
The patent performs preliminary actions by pre-forming the composite structure in a green body state through simple compression of powder and fibers. This preliminary structuring eliminates the need for time-consuming liquid impregnation and allows rapid subsequent curing, significantly improving fabrication efficiency while maintaining mechanical properties
4Ease of manufacture
If liquid polymer precursor is used for fabrication, then fiber impregnation is achieved, but the precursor chemicals are unstable and have short shelf-life
Solution Approach 1:
The patent changes the physical state parameter of the polymer from liquid to solid powder form. This fundamental parameter change enables a completely different processing mechanism - direct compression and heating of powder to form green bodies, followed by curing - which reduces processing time from hours/days to minutes while maintaining composite quality
Solution Approach 2:
The patent replaces the unstable liquid precursor (which has short shelf-life and requires careful handling) with a stable solid powder form. The powder can be stored indefinitely without degradation, eliminating the need for refrigeration and special handling, and can be processed on-demand
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 significantly reduces processing time, simplifies fabrication and repair processes, maintains mechanical properties, and enables recyclability, making thermoset fiber reinforced composites more viable for industrial applications.
Implementation Method 1
compressing the CAN powder and the reinforcing fibers at an elevated temperature and an elevated pressure to form a fiber reinforced composite material
Implementation Method 2
compressing the CAN powder and the reinforcing fibers at an elevated temperature and an elevated pressure
Implementation Method 3
the CAN matrix material undergoes a bond exchange reaction upon heating to a transformation temperature
Implementation Method 4
contacting the damaged surface of the fiber reinforced composite with a heated element
Data Source
AI summary
A method for rapidly fabricating or repairing a fiber reinforced composite may include the use of a covalent adaptable network polymer (CAN) powder for encapsulating reinforcing fibers or welding to a CAN matrix. The fiber reinforced composite may be formed or repaired by applying CAN powder to reinforcing fibers or to a damaged area of a fiber reinforcing composite and compressing the CAN powder with the reinforcing fibers or the damaged area of the fiber reinforced composite at a relatively low temperature, temperature and processing time to form a CAN matrix. The method may be configured for fabricating a fiber reinforced composite having specific desired material properties by varying the arrangement and materials used.