Composite building materials and methods of manufacture

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Solution Overview

Problem

The high cost and environmental impact of producing plastic composites using virgin thermoplastic materials, combined with the significant waste generated from carpet waste disposal, necessitate the development of a cost-effective and sustainable alternative that incorporates recycled materials while maintaining performance characteristics.

Innovation Solution

A composite building material is created using layers of polymeric fibers and a binding agent, with top and bottom layers of resin-impregnated paper, incorporating recycled carpet waste, which improves stiffness, moisture resistance, and thermal stability, and reduces manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If virgin thermoplastic materials are used to produce plastic composites, then the mechanical strength and structural integrity are improved, but the manufacturing cost increases and environmental impact worsens

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the material parameters by substituting virgin thermoplastic materials with recycled carpet waste fibers combined with a binding agent. This parameter change maintains adequate mechanical strength while significantly reducing manufacturing cost and environmental impact, resolving the contradiction between strength and manufacturing cost

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining recycled carpet waste fibers with a binding agent to form plastic composite boards. This composite approach allows the use of lower-cost recycled materials while achieving the necessary structural integrity through the synergistic combination of fiber reinforcement and binding matrix

Inventive Principle:

Principle #40Composite materials

2Reliability

If resin-impregnated paper layers are added to the composite structure, then moisture resistance and dimensional stability are improved, but the device complexity increases

Engineering Contradiction:

Improvemoisture resistanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the composite board into distinct functional layers: core layers made from recycled carpet waste and binding agent, and outer layers made from resin-impregnated paper. This segmentation allows each layer to perform its specific function (structural core vs. protective moisture barrier), improving moisture resistance without excessive complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different material qualities to different locations within the composite structure. The resin-impregnated paper layers are specifically placed at the outer surfaces where moisture exposure is greatest, providing localized moisture protection where it is most needed, while the inner core layers maintain structural integrity

Inventive Principle:

Principle #3Local quality

3Strength

If long polymeric fibers are used in the core layer, then mechanical strength is improved, but manufacturing uniformity becomes difficult

Engineering Contradiction:

Improvemechanical strengthVSAvoidthickness uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent employs a dynamic manufacturing process using a continuous conveyor system with heated rollers that progressively form and cure the composite layers. This dynamic process allows long fibers to be distributed and consolidated uniformly during movement, achieving both mechanical strength from long fibers and thickness uniformity through controlled processing

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements a continuous manufacturing process where the composite board is continuously formed, heated, and cured on a moving conveyor belt. This continuous action ensures consistent fiber distribution and uniform thickness throughout production, resolving the contradiction between using long fibers for strength and maintaining manufacturing precision

Inventive Principle:

Principle #20Continuity of useful action

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 use of resin-impregnated paper significantly enhances the mechanical and thermal properties of the composite, reducing moisture absorption and dimensional changes, while the incorporation of recycled carpet waste lowers production costs and environmental impact, achieving performance equivalent to virgin plastic composites.

Implementation Method 1

use of top and/or bottom layers of resin-impregnated paper can significantly improve various performance characteristics of the composite building materials including, for example, greater stiffness, greater resistance to mechanical damage, less moisture absorption

Methodology Applied

Scientific EffectAbsorption (physical): Absorption (physical)

Implementation Method 2

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11572646B2Composite building materials and methods of manufacture

Publication Date: 2023.02.07 RISE BUILDING PRODUCTS LLC

AI summary

An example composite building material includes one or more layers of polymeric fibers, binding agent, and optional fillers, and at least one surface layer of resin-impregnated paper disposed above and/or below the one or more layers. The one or more layers can include a core layer with longer polymeric fibers and top and bottom layers with shorter polymeric fibers. A method of manufacturing the composite building material includes forming the one or more layers, applying the at least one surface layer above and/or below the one or more layers, and heating and pressing the combined layers.