CO2-Derived Composite Material Structures for Negative Embodied Carbon
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Solution Overview
Problem
Conventional carbon fibers are made from non-renewable mineral resources, leading to CO2 emissions and embodied carbon, which can be mitigated by forming carbon fiber composites from atmospheric CO2.
Innovation Solution
Electrochemically synthesizing carbon structures from CO2 to create carbon fiber composites with cellulosic and carbon waste fibers, combined with various resins and additives, using methods like melt processing and injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional carbon fibers are made from non-renewable mineral resources, then carbon fiber composites can be produced with high strength, but CO2 emissions increase and embodied carbon becomes positive
Solution Approach 1:
The patent converts CO2, a harmful greenhouse gas, into a beneficial resource for producing carbon fibers. By using CO2 as a carbon source in the polymerization process to create precursors like polyacrylonitrile, the invention transforms atmospheric CO2 into high-strength carbon fibers, simultaneously reducing emissions and producing structural materials with negative embodied carbon
Solution Approach 2:
The patent fundamentally changes the carbon source parameter from conventional petroleum-based feedstocks to atmospheric CO2. This parameter change involves using CO2 in electrochemical or catalytic processes to generate carbon-containing precursors, which are then processed into carbon fibers through standard manufacturing steps, thereby altering the embodied carbon signature while maintaining fiber performance
2Object-generated harmful factors
If carbon fibers are formed from atmospheric CO2, then negative embodied carbon is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent introduces intermediary substances and processes to bridge CO2 and carbon fiber production. CO2 is first converted into carbon-containing precursors such as polyacrylonitrile or other polymerizable compounds, which then serve as intermediates in the standard carbon fiber manufacturing sequence (spinning, stabilization, carbonization). This intermediary approach simplifies the overall process by using well-established fiber production techniques
Solution Approach 2:
The manufacturing process is segmented into distinct stages: (1) CO2 conversion to carbon-containing precursors through electrochemical or catalytic processes, (2) polymerization to form soluble polymers, (3) fiber spinning and stabilization, and (4) carbonization to produce final carbon fibers. This segmentation allows each step to be optimized independently and facilitates integration with existing manufacturing infrastructure
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
Produces carbon fiber composites with negative embodied carbon, maintaining strength and lightweight properties while reducing atmospheric CO2 emissions.
Implementation Method 1
electrochemically synthesized carbon structures derived from CO2
Data Source
AI summary
Composite materials and methods of manufacturing the same are described herein. The composite materials include electrochemically synthesized carbon structures manufactured using CO2 as a carbon source. The composite structures can further include cellulosic fibers and carbon waste fibers. The composite materials are manufactured using a method which provides negative embodied carbon in the composite material.