Coupling Agent Addition to Lignin-Free Fiber Raw Stock
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Solution Overview
Problem
Existing processes for manufacturing composite materials face challenges in achieving sufficient adhesion between lignin-free fibers and plastics, particularly at high process temperatures, and in providing strong mechanical properties for composite materials.
Innovation Solution
A preliminary treatment process involving a hot-cold mixing device is used to add a coupling agent to raw stock, ensuring a high temperature and long dwell time for reaction between the coupling agent and raw stock, enhancing adhesion between fiber-based and polymer-based substances, and utilizing maleic anhydride modified polyolefins or silane-based coupling agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high process temperature (above 180°C) is used to ensure sufficient adhesion between coupling agent and raw stock, then adhesion is improved, but providing such temperature without a separate heating stage becomes problematic
Solution Approach 1:
The coupling agent is added to the raw stock mixture before the extrusion process, allowing the mixture to be heated to high temperature (above 180°C) during the extrusion heating stage. This preliminary addition enables the coupling agent to react with the raw stock components before forming the final composite structure, eliminating the need for a separate heating stage while ensuring sufficient adhesion.
2Ease of manufacture
If a coupling agent is added at the extrusion stage, then the process is simpler, but adhesion between lignin-free fiber and plastic remains insufficient
Solution Approach 1:
The coupling agent is incorporated into the raw stock mixture before extrusion, allowing extended contact time and reaction between the coupling agent and both the lignin-free fiber and plastic components. This preliminary incorporation ensures thorough mixing and chemical bonding throughout the mixture, resulting in superior adhesion between fiber and plastic while maintaining process simplicity.
Solution Approach 2:
The coupling agent remains continuously distributed throughout the raw stock mixture during the extrusion process, maintaining constant contact with both fiber and plastic components. This continuous presence ensures uninterrupted chemical bonding and mechanical interlocking, achieving superior adhesion without requiring separate processing stages.
3Strength
If the coupling agent is added to raw stock at a preliminary treatment stage, then adhesion is improved, but the process requires a hot-cold mixing device with heating stage
Solution Approach 1:
The hot-cold mixing device performs multiple functions: it mixes the coupling agent with the raw stock mixture, heats the mixture to high temperature (above 180°C) to enable chemical bonding, and prepares the mixture for subsequent extrusion. By combining mixing, heating, and preparation functions in a single device, the system achieves superior adhesion without requiring separate dedicated equipment for each function.
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
This process achieves excellent adhesion and improved mechanical properties for composite materials, with enhanced bonding between lignin-free wood fibers and plastics, resulting in a homogeneous and strong composite product.
Implementation Method 1
MAPE or MAPP reacts with wood fibers, forming a covalent bond between the carbonyl group of the anhydride and the hydroxyl group of the fiber
Implementation Method 2
raw stock that contains lignin-free material and a coupling agent are fed to the hot-cold mixing device to form the raw stock mixture
Data Source
AI summary
The invention relates to a process for manufacturing composite material which contains fiber based and polymer based material, wherein the manufacture includes a preliminary treatment process to form a raw stock mixture. According to the invention, the preliminary treatment process includes a hot-cold mixing device which comprises at least a heating stage, and that raw stock, which contains lignin-free material, and a coupling agent are fed to the mixing device to form the raw stock mixture, and adhesion between fiber based and polymer based substances of the raw stock is ameliorated by the coupling agent.