Fiber polymer composite
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Solution Overview
Problem
Polymer fiber composites made from polyolefin thermoplastic matrix materials and polyolefin fibers based on the same polyolefin face issues such as fibers losing orientation and properties due to thermal stress during embedding, as they are often exposed to temperatures close to their melting point.
Innovation Solution
Incorporating at least 5% by weight of amorphous poly-alpha-olefins in the matrix material to increase the difference between the melting temperatures of the fibers and the matrix, reducing thermal stress and maintaining fiber orientation, and using these composites in a process involving lower compacting temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin fibers are embedded in polyolefin matrix material at high temperatures, then the matrix material can properly embed the fibers, but the fibers lose orientation and properties due to thermal stress
Solution Approach 1:
The patent changes the temperature parameter by using a matrix material with lower melting point than the fibers, enabling embedding at temperatures that preserve fiber properties. Specifically, the matrix material melts at 115-145°C while the fibers maintain stability above this range, creating a temperature window for successful embedding without fiber degradation.
Solution Approach 2:
The patent creates a composite system where the matrix material and fibers have deliberately different thermal properties. The matrix comprises polyolefin with melting point 115-145°C while the fibers have melting point 160-180°C, ensuring the matrix softens and embeds the fibers at temperatures below the fiber degradation threshold.
2Ease of manufacture
If high compacting temperature is used to embed fibers in matrix material, then the matrix material flows and bonds properly, but the fibers are exposed to temperatures close to their melting point causing property loss
Solution Approach 1:
The patent fundamentally changes the temperature parameter range for compaction by selecting a matrix material with lower melting point (115-145°C) than conventional polyolefins. This allows compaction to occur at temperatures sufficient for matrix flow and bonding but below the threshold that causes fiber property degradation.
Solution Approach 2:
The matrix material acts as an intermediary that mediates between the compaction process and the fibers. By having the matrix melt and flow at lower temperatures, it provides the necessary bonding and embedding function without transmitting excessive thermal stress to the fibers.
3Ease of manufacture
If the matrix material melting point is close to the fiber melting point, then processing is simpler, but the fibers are exposed to harmful thermal stress during embedding
Solution Approach 1:
The patent deliberately changes the melting point parameter of the matrix material to create a deliberate gap between matrix and fiber melting temperatures. The matrix melts at 115-145°C while fibers melt at 160-180°C, creating a 15-45°C safety margin that eliminates thermal stress on fibers during processing.
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 amorphous poly-alpha-olefins in the matrix material allows for lower compacting temperatures, minimizing thermal stress on the fibers, preserving their original properties, and resulting in semi-finished products with improved mechanical properties and flexibility, such as higher perforation energy and similar haptic to untreated fibers.
Implementation Method 1
subjecting the ply to conditions of time, temperature and pressure sufficient to melt a proportion of the first layer, to melt the second layer entirely, and to melt a proportion of the third layer
Implementation Method 2
the fibers are partly melted or exposed to temperatures close to the glass transition or melting temperature when being embedded into the matrix
Implementation Method 3
subjecting the ply to conditions of time, temperature and pressure sufficient to melt a proportion of the first layer, to melt the second layer entirely, and to melt a proportion of the third layer; and to compact the ply
Data Source
AI summary
The present invention relates to fiber polymer composite comprising polypropylene fibers and a matrix material, the matrix material being in direct contact with at least some of the fibers, characterized in that the matrix material comprises 50% to 100% by weight based on the whole matrix material of an amorphous propylene-rich poly-alpha-olefin, to a process for producing the fiber polymer composite, and to the use of the fiber polymer composite.