Herb-Derived Thermoplastic Composites for Aerospace Recycling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The recycling of thermoset composites is difficult due to their irreversible chemical reaction, and existing composite materials heavily rely on petrochemicals, which are non-renewable and unsustainable, particularly for mission-critical aerospace applications.
Innovation Solution
Thermoset resins are produced from essential oils of herbs and plants, specifically through olefin metathesis to form diphenolic products, which can be polymerized into high heat-resistant materials, reducing petrochemical dependence and enabling the creation of lightweight, thermally resistant composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset composites are used for aerospace applications, then high strength-to-weight ratio and thermal resistance are achieved, but recycling becomes extremely difficult due to irreversible chemical crosslinking
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional thermoset chemistry to thermoplastic chemistry, fundamentally changing the material's response to heat and stress. This allows the composite to maintain high strength-to-weight ratio while enabling recycling through melting and remolding, directly resolving the contradiction between performance and recyclability
Solution Approach 2:
The patent uses composite materials by combining thermoplastic resin with reinforcing fibers to create a new class of recyclable composite materials. This composite approach maintains the structural integrity and strength-to-weight ratio needed for aerospace applications while introducing recyclability through the thermoplastic matrix that can be melted and reformed
2Temperature
If petrochemical-based thermoset resins are used, then high heat resistance and structural integrity are achieved, but reliance on non-renewable resources increases
Solution Approach 1:
The patent applies parameter changes by substituting the chemical composition basis from petrochemicals to plant-based essential oils while maintaining the critical parameter of heat resistance. This transformation preserves the functional performance needed for aerospace applications while fundamentally changing the resource base to renewable materials
Solution Approach 2:
The patent employs the principle of using renewable, biodegradable plant-based materials instead of persistent petrochemicals. The essential oil-derived thermoplastic resins provide the necessary performance characteristics while being sourced from renewable plant resources, reducing dependence on finite petroleum reserves
3Ease of operation
If thermoplastic resins are used instead of thermoset, then impact resistance increases and recyclability improves, but high-temperature performance may be compromised
Solution Approach 1:
The patent applies parameter changes by selecting and engineering specific thermoplastic polymers with high melting points and thermal stability. This allows the material to maintain thermoplastic recyclability and impact resistance while achieving the high-temperature performance required for aerospace applications through careful polymer selection and formulation
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 approach allows for the development of renewable, high-strength, lightweight composite materials suitable for aerospace applications, offering improved thermal resistance and reduced reliance on petroleum-based resources, facilitating recycling challenges and enhancing impact resistance.
Implementation Method 1
These products transform by the reaction known as olefin metathesis (Chemical Schematic 1) to give new products that are dimeric in structure having two equivalents of protected phenolic groups in the molecule.
Implementation Method 2
The diphenolic products from natural and renewable sources can then be inserted into the many known polymerization reactions (Chemical Schematic 2) to those skilled in the art including, but not limited to, polyesters, polycarbonates, polycyanurates, polyurethanes, polyetherimides, polyetheretherketones, and polysulfones.
Implementation Method 3
In a thermoset resin, the raw uncured resin molecules are crossed linked through a catalytic chemical reaction. Through this chemical reaction, most often exothermic, the resin creates extremely strong bonds to one another, and the resin changes state from a liquid to a solid.
Data Source
AI summary
A process, thermoset resin, and thermoplastic structures from renewable chemical feedstocks derived from the essential oils from herbs and other plants. The processes for making diphenol products including extracting isomers of 4-methoxyphenylpropene from plant sources, transforming isomers by olefin cross or self-cross olefin metathesis and at least one catalyst to produce dimeric structures having two equivalents of protected phenolic groups, and deprotecting methyl ethers to yield diphenolic products.