Composite Material Curing with Polyurethane Binder
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Solution Overview
Problem
Existing methods for manufacturing composite materials result in products with moderate mechanical properties, limiting their application in construction and other industries where higher strength is required, and often involve incineration or landfilling of recyclable materials.
Innovation Solution
A method involving a dry homogeneous mixture of fiber material and thermoset particles with a specific moisture content, combined with polyol and isocyanate to form a viscous compound, cured under pressure to create a composite material with improved mechanical properties, allowing for the recycling of non-thermoplastic and used fiber materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset particles are used as filler material with cross-linking by poly-isocyanate, then volume is obtained, but mechanical properties remain moderate
Solution Approach 1:
The invention uses a composite material system combining thermoset particles (2-15 mm), fiber material (2-40 mm length), polyol, and isocyanate. This multi-component composite approach enables improved mechanical properties through synergistic interactions between different materials, where fibers provide reinforcement and thermoset particles provide volume and structural stability.
Solution Approach 2:
The invention optimizes specific parameters including particle size (2-15 mm for thermoset, 2-40 mm for fibers), moisture content (equilibrium with air at dew point ≤25°C), and component ratios (fiber volume percent 10-80%). These parameter optimizations enable enhanced mechanical properties while maintaining manufacturing feasibility.
2Reliability
If dust and fibers are removed to achieve proper cross-linkage, then cross-linking quality improves, but material loss increases
Solution Approach 1:
The invention changes the approach by controlling moisture content within a specific range (equilibrium with air at dew point ≤25°C) rather than removing all moisture. This parameter optimization allows dust and fibers to remain in the mixture while still achieving effective cross-linking, thereby reducing material loss while maintaining cross-linking quality.
Solution Approach 2:
The invention applies local quality control by allowing different components (dust, fibers, thermoset particles) to remain in the mixture with specific localized functions. Instead of uniform removal, each component serves its purpose: fibers for reinforcement, dust for filler volume, and thermoset particles for structural matrix, all while maintaining cross-linking quality through controlled moisture content.
3Strength
If recycled materials are used, then environmental benefit and cost reduction are achieved, but mechanical properties decrease
Solution Approach 1:
The invention optimizes parameters for recycled materials including particle size (2-15 mm for thermoset particles), fiber length (2-40 mm), and moisture content (equilibrium with air at dew point ≤25°C). These parameter controls ensure that recycled materials meet specific quality thresholds, enabling enhanced mechanical properties while utilizing cost-effective recycled inputs.
Solution Approach 2:
The invention creates a composite system where recycled thermoset particles and fibers are combined with virgin polyol and isocyanate. This hybrid composite approach allows recycled materials to provide volume and basic structure while the virgin binding components ensure consistent cross-linking quality and mechanical performance, resolving the contradiction between using recycled materials and maintaining strength.
4Strength
If high pressure is applied during curing, then mechanical adhesion improves, but energy consumption increases
Solution Approach 1:
The invention optimizes the pressure parameter to a specific range (at least 50 bar) during curing. This optimized pressure level achieves sufficient mechanical adhesion between components while minimizing energy consumption compared to conventional high-pressure processes. The parameter optimization balances adhesion quality with energy efficiency.
Solution Approach 2:
The invention performs preliminary mixing and distribution of polyol and isocyanate components before the curing stage. This preliminary action ensures uniform distribution of reactants throughout the mixture, so that when pressure is applied during curing, the energy is used more efficiently for adhesion rather than for mixing, thereby reducing overall energy consumption while maintaining strong mechanical bonds.
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 produces composite materials with enhanced flexural strength, comparable to cast iron, suitable for various applications, reducing waste, and offering cost savings, impact resistance, and a non-rusting, anti-slip surface.
Implementation Method 1
adding at least one polyol and at least one isocyanate to the dry homogenous mixture for forming a viscous compound mixture
Implementation Method 2
By compressing this viscous homogeneous mixture before the reaction of the polyol and isocyanate takes place, the polyol and the isocyanate will be pressed in the pores of the particles
Implementation Method 3
forming a shaped object by curing the viscous homogeneous mixture in a mould at a temperature of 15-60°C under a pressure of at least 50 bar
Implementation Method 4
whereby the dry homogeneous mixture has a moisture content which is in equilibrium with air having a dew point of at most 25°C
Data Source
AI summary
The invention relates to a method for manufacturing a shaped object (20) from a composite material which comprises thermoset particles as filler material, fibers as reinforcement material and polyurethane as binder. The method comprises the steps of: a) providing a dry mixture of fiber material and thermoset particles with a predefined moisture content; b) the addition and uniform distribution of polyol and isocyanate to the dry mixture; c) curing the mixture (13) in a mould (28) at 15 - 60 0C under a pressure of at least 50 bar. The invention also relates to a shaped object (20) produced with this method.