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 fraction of cellulose microfibrils within the polymer matrix, which is energy-intensive and difficult to achieve, and there is a need for improved MFC reinforced composites and laminate structures.
Innovation Solution
A composite comprising microfibrillated cellulose (MFC) monofilaments, yarns, nonwoven, or woven fabrics permeated by a hydrophobic resin, with a manufacturing method that includes applying hydrophobic resin to MFC fibers to form layers, optionally with man-made cellulosic fibers, and curing to create a laminate structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high volume fraction of cellulose microfibrils is achieved within the polymer matrix, then composite stiffness and strength are improved, but manufacturing becomes energy-intensive and difficult
Solution Approach 1:
The patent changes the physical state and surface properties of the resin from hydrophilic to hydrophobic through chemical modification. This parameter change enables the resin to naturally repel water and preferentially interact with cellulose microfibrils, achieving high volume fraction incorporation without energy-intensive mixing processes. The hydrophobic resin forms a compatible interface with the hydrophobic cellulose surfaces, facilitating spontaneous integration into the polymer matrix.
Solution Approach 2:
The patent creates a composite system combining hydrophobic resin-modified cellulose microfibrils with hydrophobic polymer matrix. This composite approach leverages the synergistic interaction between the modified cellulose reinforcement and the hydrophobic matrix, achieving enhanced stiffness and strength while simplifying the manufacturing process through natural compatibility and reduced energy requirements.
2Strength
If high volume fraction of cellulose microfibrils is achieved within the polymer matrix, then composite stiffness and strength are improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies the resin's hydrophilicity to hydrophobicity, fundamentally changing its interaction properties with cellulose microfibrils. This parameter change simplifies manufacturing by enabling spontaneous mixing and distribution of high volume fractions of microfibrils without complex processing equipment or multi-step procedures. The hydrophobic resin naturally affinity-selects for cellulose, facilitating easy incorporation into the polymer matrix.
Solution Approach 2:
The hydrophobic resin-modified cellulose system exhibits self-organizing behavior where the resin automatically distributes and binds cellulose microfibrils throughout the polymer matrix without external intervention. This self-service mechanism eliminates the need for energy-intensive mixing and complex manufacturing procedures, achieving high volume fraction incorporation through natural thermodynamic driving forces.
3Strength
If traditional glass fiber composites are used, then structural strength is achieved, but environmental friendliness and recyclability are compromised
Solution Approach 1:
The patent replaces durable but environmentally harmful glass fibers with biodegradable cellulose microfibrils that can be composted or recycled. While cellulose is naturally less durable than glass, the hydrophobic resin modification and composite structure provide sufficient durability for applications while enabling end-of-life biological degradation, eliminating the persistent environmental waste problem of glass fiber composites.
Solution Approach 2:
The patent enables recovery and recycling of cellulose-based composites through biological degradation processes. At the end of the product lifecycle, the cellulose microfibril reinforcement can be broken down by microorganisms, returning nutrients to the environment, while the hydrophobic polymer matrix can be separately recovered and recycled, creating a circular economy approach that eliminates glass fiber waste accumulation.
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 method enables the production of composites with high stiffness, strength, impact energy absorption, and vibration reduction, while being environmentally friendly and recyclable, with improved damping performance compared to traditional glass fiber composites.
Implementation Method 1
a fabric made up of yarn comprising microfibrillated cellulose (MFC) fibers in form of monofilaments being permeated by a hydrophobic resin
Data Source
Figure 1
AI summary
Described herein is composite structure comprising 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.