Composite Recycling With Amine Resin Breakdown at Lower Temperatures
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Solution Overview
Problem
Conventional recycling methods for composite materials are inefficient, leading to waste and limited circularity, particularly due to high temperatures that diminish the mechanical properties of recovered reinforcement materials and the need for solvent recovery operations.
Innovation Solution
A process using amines to degrade cured thermosetting resin matrices at milder temperatures, allowing separation and reuse of reinforcement materials and organic liquid compositions without solvent recovery, forming a reaction product mixture that can be further processed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pyrolysis processes are used to recycle composite materials, then reinforcement materials can be recovered, but the high temperatures employed lead to diminished mechanical properties of the recovered reinforcement materials
Solution Approach 1:
The patent changes the chemical parameters of the degradation process by using solvolysis with specific solvents (water, alcohol, glycol, glycerol) instead of thermal pyrolysis. This chemical approach enables matrix degradation at lower temperatures (below 200°C) while preserving the mechanical integrity of reinforcement materials, directly resolving the contradiction between recovery effectiveness and material property preservation
Solution Approach 2:
The patent replaces the mechanical/thermal pyrolysis system with a chemical solvolysis system. Instead of using high temperature and pressure to break down the matrix, the invention uses chemical reactions between the solvent and the thermosetting resin matrix to achieve degradation at milder conditions, thereby preserving reinforcement material quality
2Ease of manufacture
If conventional solvolysis processes use toluene to solubilize the organic matrix, then the matrix can be degraded, but the toluene must be removed through additional processing steps
Solution Approach 1:
The patent employs water or water-miscible solvents that can be easily removed by evaporation or drying without requiring complex recovery systems. These solvents are used in excess and then simply evaporated off, leaving no need for sophisticated solvent recovery operations, thus simplifying the overall process while maintaining effectiveness
Solution Approach 2:
The patent uses water or water-miscible solvents as intermediaries that facilitate matrix degradation through solvolysis. These intermediaries are chosen specifically because they can be easily separated from the final product through simple evaporation or drying, avoiding the need for complex recovery systems required by conventional organic solvents like toluene
3Productivity
If conventional epoxy resin recycling uses high catalyst concentration (greater than 10 wt %) and ethylene glycol dissolution medium, then the epoxy-anhydride resins can be recycled, but the ethylene glycol must be removed after recycling to reuse the recyclate
Solution Approach 1:
The patent changes the dissolution medium from ethylene glycol to water or water-miscible solvents, and reduces catalyst concentration requirements. This parameter change enables the recycling process to proceed with solvents that are easier to remove and do not require high catalyst loads, thereby improving overall process efficiency and reducing substance loss through simpler removal operations
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
Enables efficient recycling of composite materials by isolating and reusing both reinforcement materials and organic liquid compositions, with potential applications in various industries, and avoids the inefficiencies and high temperatures of conventional methods.
Implementation Method 1
reacting a mixture comprising an amine and a composite material comprising reinforcement material and a cured thermosetting resin matrix to form a reaction product mixture
Implementation Method 2
isolating an organic liquid composition comprising degraded residues from the reaction product mixture
Data Source
AI summary
Embodiments of the present disclosure generally relate to processes for recycling a composite material. In an embodiment is provided a process for recycling a composite material. The process includes reacting a mixture comprising an amine and a composite material comprising reinforcement material and a cured thermosetting resin matrix to form a reaction product mixture. The process further includes isolating the reinforcement material from the reaction product mixture and isolating an organic liquid composition comprising degraded residues from the reaction product mixture. The reinforcement material and organic liquid composition isolated may be re-used to make new materials.