Composite Textile Material Manufacturing Machinery
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Solution Overview
Problem
Existing composite materials for thermoforming lack efficiency in manufacturing processes, often resulting in weak mechanical properties, high hydrocarbon content, and environmental concerns due to non-recyclable and toxic components, particularly in the use of wood and fiberglass.
Innovation Solution
A composite material composed of 40-50% polypropylene fibers and 50-60% long natural fibers like hemp, jute, or sisal, processed using a modular machinery system that includes chopping, weighing, mixing, interlacing, and rolling to create a strong, recyclable, and low-hydrocarbon-content material suitable for thermoforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wood is used in furniture manufacturing, then functional and esthetic properties are improved, but environmental harm increases due to excessive tree cutting
Solution Approach 1:
The patent applies composite materials by combining natural fibers (hemp, jute, sisal) with thermoplastic polymers (polypropylene, polyethylene) to create a composite textile material that replaces wood. This composite structure provides both functional strength and environmental benefits, as the natural fibers maintain mechanical properties while being recyclable and sustainable.
2Productivity
If composite materials are made for thermoforming, then productivity is improved, but mechanical strength decreases
Solution Approach 1:
The patent applies parameter changes by optimizing the fiber length (5-100 mm), fiber diameter (70-80 denier), and composition ratios (40-50% polypropylene, 50-60% natural fibers) to achieve both good thermoforming properties and mechanical strength. The specific parameter ranges are tuned to balance processability and structural integrity.
Solution Approach 2:
The composite structure of thermoplastic-bound natural fibers provides both thermoformability and mechanical strength, resolving the contradiction between ease of manufacturing and structural integrity.
3Ease of manufacture
If aqueous foam mix method is used, then manufacturing ease is improved, but harmful factors increase due to incomplete drainage and fiberglass content
Solution Approach 1:
The patent changes the manufacturing approach by using a dry mixing process instead of aqueous foam, eliminating water drainage issues and avoiding fiberglass content. The fibers are mixed in dry state, formed into web, and then thermally bonded, removing the harmful factors associated with wet processing.
Solution Approach 2:
The patent uses 100% recyclable natural fibers without fiberglass, making the material environmentally friendly and suitable for circular economy applications, eliminating the need for burning disposal.
4Ease of manufacture
If short hemp fibers are used in thermoplastic, then manufacturing simplicity is improved, but mechanical strength decreases
Solution Approach 1:
The patent optimizes the fiber length parameter to 5-100 mm, which is longer than traditional short fibers but still suitable for automated processing. This parameter optimization maintains manufacturing simplicity while significantly improving mechanical strength compared to very short fibers.
Solution Approach 2:
The composite structure with optimized fiber length provides both ease of processing and improved mechanical properties, resolving the contradiction between manufacturing simplicity and strength.
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 solution provides a low-cost, 100% recyclable material with improved mechanical properties, reduced hydrocarbon content, and environmental benefits, such as reduced water and energy consumption, and lower workforce needs, suitable for various applications like automotive and furniture industries.
Implementation Method 1
chopping, weighing, mixing, interlacing, and rolling to create a strong, recyclable, and low-hydrocarbon-content material
Implementation Method 2
mixing, interlacing, and rolling to create a strong, recyclable, and low-hydrocarbon-content material
Implementation Method 3
chopping, weighing, mixing, interlacing, and rolling to create a strong, recyclable, and low-hydrocarbon-content material
Implementation Method 4
chopping, weighing, mixing, interlacing, and rolling to create a strong, recyclable, and low-hydrocarbon-content material
Implementation Method 5
A composite material composed of 40-50% polypropylene fibers and 50-60% long natural fibers like hemp, jute, or sisal
Data Source
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AI summary
The invention refers to a composite material developed for manufacturing thermoformed products with applications in furniture making, automotive industry, etc., a method and machinery for the manufacturing of the material in unwoven form. The composite material for thermoforming is made of a thermoplastic fibrous component consisting of 4-60 mm long and 7-16 DEN fine polypropylene fibers representing 40% to 50% of the total material weight and a plant fiber component which can be hemp, jute, sisal, coconut, etc., or a mix of natural fibers which is 70-80 DEN fine and 5 to 100 mm in length and represents 60% to 50% of the total material weight. The process for manufacturing the claimed composite material consists in taking and proportioning the components, followed by their mixing and coarse defibering and then a fine mixing in a four-chamber module which also opens the natural fibers to 70...80 DEN fine, followed by the consolidation of the fibers and, finally, the rolling of the resulting fabric in a roll. The machinery for the manufacturing of the claimed composite material has a modular structure, comprising two modules (1 and 2) for feeding the components, two modules (3 and 4) for weighing and proportioning the components, a primary mixing and coarse defibering module (5), a module (7) for the fine mixing and fibre opening, an interlacing module (8) and a module (9) for pulling and rolling the final fabric.