Halogen-Free Flame-Retardant Composite Board Recycling
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Solution Overview
Problem
The challenge lies in effectively recycling and reusing waste fiber composite materials from production processes, particularly in making them halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite boards while maintaining mechanical strength and passing flammability standards, as traditional disposal methods are environmentally and economically unsustainable.
Innovation Solution
A manufacturing method involving the preparation of a recycled material with a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite, forming a core layer through extrusion, and hot pressing it with a reinforcement layer to create a composite board where the recycled fiber core penetrates and cross-links with the reinforcement layer, achieving mechanical strength and UL94-V0 flammability compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional landfill and incineration treatment methods are used for waste fiber composite materials, then disposal is simple, but environmental harm increases and landfill costs increase
Solution Approach 1:
The patent applies the discarding and recovering principle by collecting waste fiber composite materials from production processes and transforming them into reusable core layer materials through extrusion. The recycled fibers are processed into granules, mixed with virgin polymer, and extruded to form a core layer that can be hot-pressed into composite boards, thereby recovering valuable materials instead of discarding them through landfill or incineration.
2Productivity
If recycled fiber composite materials are used to manufacture new composite boards, then material recycling is achieved, but mechanical strength may be compromised
Solution Approach 1:
The patent applies the composite materials principle by creating a layered structure where a core layer made of recycled fiber composite materials is sandwiched between reinforcement layers made of virgin or high-performance fibers. This composite structure allows the recycled core to provide bulk material efficiency while the outer reinforcement layers restore and enhance the overall mechanical strength, achieving both recycling goals and structural performance requirements.
Solution Approach 2:
The patent applies the local quality principle by assigning different functional requirements to different parts of the composite board. The core layer made from recycled materials is positioned in the interior where it provides volume and basic structural support, while the reinforcement layers made from higher quality materials are positioned at the surfaces where they bear the primary mechanical loads. This localized material assignment optimizes both recycling utilization and mechanical performance.
3Reliability
If flame retardant additives are added to achieve flammability standards, then fire safety is improved, but halogen-containing additives may cause environmental and health issues
Solution Approach 1:
The patent applies the parameter changes principle by changing the chemical composition parameters of the flame retardant system. Instead of using traditional halogen-containing flame retardants, the invention employs halogen-free flame retardant additives that maintain the required fire safety performance (achieving UL94-V0 rating) while eliminating the harmful halogen elements that cause environmental pollution and health issues during combustion.
4Strength
If fiber length is increased to improve mechanical strength, then strength is improved, but processing difficulty and cost increase
Solution Approach 1:
The patent applies the local quality principle by using different fiber length specifications in different layers of the composite board. The core layer made from recycled materials uses shorter fiber granules that are easier to process and extrude, while the reinforcement layers use longer, higher-quality fibers that provide the necessary mechanical strength. This localized fiber length assignment optimizes both processing ease and final product 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 enables the recovery and recycling of fiber composite waste, enhancing mechanical strength and ensuring compliance with stringent flammability standards, thus addressing environmental and legislative pressures by producing a halogen-free flame-retardant composite board with improved mechanical properties and recyclability.
Implementation Method 1
adding a polymer base material to the recycled material to form a core layer material and extruding the core layer material with a low shear extruder
Implementation Method 2
extruding the core layer material with a low shear extruder
Implementation Method 3
hot pressing the core layer material by rollers to obtain a recycled fiber core layer
Implementation Method 4
stacking and hot pressing the recycled fiber core layer and the reinforcement layer to cause the halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite of the recycled fiber core layer penetrating into the pores of the reinforcement layer
Implementation Method 5
penetrating into the pores of the reinforcement layer to form a composite board in which dissimilar materials of recycled fiber core layer and the reinforcement layer are cross-linked with each other
Implementation Method 6
stacking and hot pressing the recycled fiber core layer and the reinforcement layer
Data Source
AI summary
A manufacturing method of a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite board, comprising steps of: preparing a recycled material containing a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite; adding a polymer base material to the recycled material to form a core layer material and extruding the core layer material with a low shear extruder; hot pressing the core layer material by rollers to obtain a recycled fiber core layer; preparing a reinforcement layer containing a fiber material or a fabric with pores; and stacking and hot pressing the recycled fiber core layer and the reinforcement layer.