Fiber Reinforced CAN Composites for Rapid Fabrication and Repair
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Solution Overview
Problem
Existing thermoset fiber reinforced composites face challenges in fabrication due to time-consuming and expensive processes, and repair methods require high temperatures and molds, limiting their widespread adoption and recyclability.
Innovation Solution
The use of a covalent adaptable network (CAN) polymer powder to form fiber reinforced composites at elevated temperatures and pressures, enabling rapid fabrication and repair with lower temperatures and pressures, allowing for reusability and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If liquid-state processing is used for thermoset fiber reinforced composite fabrication, then the composite achieves high stiffness and strength, but the processing time becomes extremely long (many hours or days)
Solution Approach 1:
The patent changes the physical state parameter of the polymer precursor from liquid to solid powder form. This fundamental parameter change enables rapid heating and processing while maintaining the ability to form high-strength thermoset composites, resolving the contradiction between achieving high strength and reducing processing time
Solution Approach 2:
The polymer precursor is pre-formed into a solid powder or pre-preg sheet with controlled properties before fabrication. This preliminary preparation allows the material to be ready for rapid processing without requiring long curing times during the actual fabrication process, thus reducing overall processing time while maintaining composite strength
2Ease of manufacture
If liquid polymer precursor is used for fabrication, then the composite can be formed, but the precursor chemicals are unstable with short shelf-life, increasing expense and limiting on-demand fabrication
Solution Approach 1:
The patent changes the physical state and chemical stability parameters by using solid polymer precursor powder or pre-preg sheets instead of liquid precursors. This parameter change provides long shelf-life, stable storage conditions, and enables on-demand fabrication without the instability issues of liquid precursors, while still allowing composite formation through controlled heating and processing
3Ease of repair
If conventional repair methods are used for thermoset fiber reinforced composites, then damage can be addressed, but high temperatures and large molds are required, essentially re-fabricating the entire component
Solution Approach 1:
The patent applies repair material locally to the damaged area rather than requiring full-component repair. The solid polymer precursor powder or pre-preg can be applied directly to the damage site and processed in-place with simple heating, providing localized repair without the need for large molds or high-temperature equipment required by conventional methods
Solution Approach 2:
The repair process uses the same rapid processing mechanism as fabrication, allowing the composite material itself to be repaired using its inherent properties. The solid precursor material can be applied and activated in-situ through simple heating, enabling the component to repair itself without complex external repair equipment or re-fabrication processes
4Strength
If thermoset fiber reinforced composites are used, then high mechanical performance is achieved, but the permanent nature of the polymer matrix prevents recycling and requires costly part replacement
Solution Approach 1:
The patent introduces dynamic reversibility to the otherwise permanent thermoset matrix. By using solid polymer precursor that can be heated to activate bond exchange reactions, the composite transitions from a permanent, non-recyclable state to a dynamically reprocessable state, enabling recycling and reuse while maintaining high mechanical performance during service
Solution Approach 2:
The patent enables the recovery and reuse of composite materials through controlled degradation and reprocessing. The solid precursor-based composite can be broken down and the polymer matrix recovered for reuse, eliminating the need for costly part replacement and enabling circular economy applications while maintaining high mechanical performance
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 method reduces processing time significantly, facilitates in-situ repair, and maintains mechanical properties, making thermoset composites more viable for high-volume manufacturing and industrial applications.
Implementation Method 1
The polymer powder comprises a covalent adaptable network (CAN) polymer, such as a vitrimer, having the ability to reversibly rearrange covalent bonds
Implementation Method 2
heating and compressing the layers for a period of time sufficient to fuse the CAN powder and relax stress in the fiber reinforced composite
Data Source
AI summary
A method for rapidly fabricating or repairing a fiber reinforced composite may include the use of a covalent adaptable network polymer (CAN) powder for encapsulating reinforcing fibers or welding to a CAN matrix. The fiber reinforced composite may be formed or repaired by applying CAN powder to reinforcing fibers or to a damaged area of a fiber reinforcing composite and compressing the CAN powder with the reinforcing fibers or the damaged area of the fiber reinforced composite at a relatively low temperature, temperature and processing time to form a CAN matrix. The method may be configured for fabricating a fiber reinforced composite having specific desired material properties by varying the arrangement and materials used.