Composite and structure, methods for manufacturing the same and uses thereof
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Solution Overview
Problem
Existing methods for manufacturing microfibrillated cellulose (MFC) reinforced composites face challenges in achieving high volume fractions of cellulose microfibrils within the polymer matrix, which is energy-intensive and difficult to achieve.
Innovation Solution
The use of MFC monofilaments, yarns, or nonwoven fabrics permeated with a hydrophobic resin to create composite structures that enhance stress transfer and provide improved mechanical properties such as stiffness, strength, and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high volume fraction of cellulose microfibrils is achieved through conventional methods, then composite stiffness and strength are improved, but energy consumption increases significantly
Solution Approach 1:
The patent changes the physical state and surface properties of cellulose microfibrils through chemical treatment and coating processes. By modifying parameters such as surface hydrophobicity, fibril diameter distribution, and surface chemistry, the treatment enables better resin infiltration and interfacial bonding without requiring excessive energy input for fibril separation and alignment.
Solution Approach 2:
The invention creates a multi-component composite structure consisting of cellulose microfibrils, hydrophobic resin coating, and polymer matrix. This hierarchical composite approach enhances the overall strength and stiffness by optimizing the interaction between components, allowing lower volume fractions of treated microfibrils to achieve the same mechanical properties that would require higher fractions of untreated fibrils.
2Strength
If conventional MFC reinforcement methods are used, then composite mechanical properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary treatment to the cellulose microfibrils before they are incorporated into the composite structure. The hydrophobic resin coating and surface modification are performed in advance, creating pre-treated microfibril products that can be directly integrated into composite manufacturing processes without requiring complex in-situ treatment equipment or multi-step processing sequences.
3Stability of the object's composition
If high volume fraction of MFC is achieved, then composite stiffness is improved, but manufacturing difficulty increases
Solution Approach 1:
By modifying the surface parameters of cellulose microfibrils through hydrophobic treatment, the patent reduces inter-fibril friction and improves resin wetting. This enables easier processing and consolidation of high-volume-fraction microfibril composites during manufacturing, reducing the complexity associated with achieving high stiffness through high fibril content.
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 approach allows for the efficient production of MFC reinforced composites with enhanced mechanical properties, reduced energy consumption, and environmental sustainability, making them suitable for various applications including sports equipment and construction materials.
Implementation Method 1
a fabric made up of yarn comprising microfibrillated cellulose (MFC) fibers, the fabric being permeated by a hydrophobic resin encapsulating at least one of two opposing surfaces of the fabric
Implementation Method 2
permeated by a hydrophobic resin encapsulating at least one of two opposing surfaces of the fabric
Data Source
AI summary
Described herein is a composite structure that includes microfibrillated cellulose (MFC) monofilament permeated by a hydrophobic resin. Also described herein are a structure and methods of manufacturing the composite material and structure and the uses thereof.