Fiber Reinforced Composite Materials Dimensional Stability

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Solution Overview

Problem

Wood composites, such as OSB and MDF, suffer from inferior dimensional stability compared to solid wood, leading to issues like warping and increased vulnerability to environmental factors, which are not adequately addressed by increasing material size or using solid wood due to cost and weight concerns.

Innovation Solution

Combining cellulosic materials with fibrous mats bonded by a formaldehyde-free binder composition, including non-woven glass fiber mats and a 'B'-stage curable binder made from a carbohydrate and amino-amide, to enhance dimensional and mechanical stability without increasing cost, weight, or bulk.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If larger pieces of material are used to improve dimensional stability, then dimensional stability is improved, but cost, volume, and weight increase

Engineering Contradiction:
Improvedimensional stabilityVSAvoidweight
Core Design Contradiction:
Stability of the object's compositionVSWeight of stationary object

Solution Approach 1:

The patent applies composite materials by combining cellulosic materials with fibrous mats (such as glass fibers, metal fibers, or natural fibers) to create a hybrid structure. This composite approach provides the dimensional stability of larger pieces while maintaining the lightweight properties of smaller components, as the fibrous reinforcement network distributes stresses and prevents warping without requiring increased material volume or weight.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by strategically placing fibrous mats at specific locations within the composite structure where reinforcement is most needed. The fibrous reinforcement is distributed throughout the cellulosic matrix in a targeted manner, providing enhanced dimensional stability at critical areas without uniformly increasing the weight or volume of the entire component.

Inventive Principle:
Principle #3Local quality

2Stability of the object's composition

If larger pieces of material are used to improve dimensional stability, then dimensional stability is improved, but cost increases

Engineering Contradiction:
Improvedimensional stabilityVSAvoidcost
Core Design Contradiction:
Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent uses composite materials to achieve dimensional stability through the synergistic combination of cellulosic materials and fibrous reinforcements. This approach is more cost-effective than using larger pieces of solid material because it allows the use of smaller, less expensive components that are reinforced with a relatively small amount of fibrous material, rather than requiring large volumes of expensive solid stock.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by modifying the structural and compositional parameters of the material system. By changing from a homogeneous solid material to a composite structure with fibrous reinforcement, the patent achieves improved dimensional stability while reducing the quantity and cost of cellulosic material required, as the fibrous network provides structural support that allows for optimized material usage.

Inventive Principle:
Principle #35Parameter changes

3Stability of the object's composition

If solid wood is used to improve dimensional stability, then dimensional stability is improved, but cost and weight increase

Engineering Contradiction:
Improvedimensional stabilityVSAvoidweight
Core Design Contradiction:
Stability of the object's compositionVSWeight of stationary object

Solution Approach 1:

The patent creates a composite material system that combines cellulosic materials with fibrous mats to replicate and enhance the dimensional stability of solid wood. The fibrous reinforcement network (comprising glass, metal, or natural fibers) embedded in the cellulosic matrix provides structural rigidity and warping resistance comparable to solid wood, but with significantly reduced weight due to the lower density of the composite structure compared to solid timber.

Inventive Principle:
Principle #40Composite materials

4Weight of stationary object

If wood composites are used instead of solid wood, then cost and weight are reduced, but dimensional stability deteriorates

Engineering Contradiction:
ImproveweightVSAvoiddimensional stability
Core Design Contradiction:
Weight of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent enhances conventional wood composites by incorporating fibrous mats (glass, metal, or natural fibers) into the cellulosic matrix. This creates a multi-phase composite structure where the fibrous reinforcement network compensates for the inherent dimensional instability of wood composites. The fibrous elements act as a structural scaffold that restricts cellulosic fiber movement and prevents warping, thereby improving dimensional stability while preserving the weight and cost advantages of composite construction.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by strategically positioning fibrous reinforcement within the wood composite structure. The fibrous mats are distributed throughout the composite at locations where dimensional control is most critical, providing targeted reinforcement that stabilizes the composite without requiring uniform increases in material density or weight throughout the entire component.

Inventive Principle:
Principle #3Local quality

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 composite materials exhibit improved dimensional stability, strength, and reduced weight, with properties comparable or superior to solid wood at a lower cost, while reducing warping and vulnerability to environmental factors.

Implementation Method 1

The fibrous mat may include fibers in a cured binder made from a binder composition that includes a carbohydrate and an amino-amide

Methodology Applied
Scientific EffectChemical bonding: Chemical Bonding

Data Source

PatentEP2509787B1Fiber reinforced composite materials and methods for their manufacture
Publication Date: 2015.05.06 JOHNS MANVILLE CORP

AI summary

Composite materials that have at least one substrate layer, and at least one fibrous mat are described. The fibrous mat may include fibers in a cured binder made from a binder composition that includes a carbohydrate and an amino-amide. The amino-amide may be formed from a reaction of an amine and an acid anhydride. In addition, methods of making a composite material are described. The methods may include the steps of providing a first substrate layer and contacting the first substrate layer with a fibrous mat comprising fibers in a partially cured, "B"-stage binder made from a binder composition that includes a carbohydrate and an amino-amide. The amino-amide may be formed from a reaction of an amine and an acid anhydride. The fibrous mat in contact with the first substrate layer may be cured to make a fully-cured binder composite.