Intumescent Composite Layers for Non-Damaging Material Disassembly
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Solution Overview
Problem
Current methods for disassembling multi-material composites are inefficient, leading to incomplete resource recovery, property degradation, and environmental harm, as they often involve aggressive chemicals, high temperatures, or mechanical processes that compromise material integrity.
Innovation Solution
Incorporating an intumescent composition between composite substrates, comprising a mixture of carbon source, acid source, and expanding agent, which swells and separates the substrates at a controlled temperature below their degradation point, allowing for non-damaging disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If chemical processes are used to recover materials from composites, then material recovery is achieved, but highly aggressive chemicals and process conditions are required
Solution Approach 1:
The patent introduces an intumescent coating as an intermediary layer between composite substrates. This coating contains carbon source, acid source, and expanding agent that work together to facilitate separation. The coating acts as a mediator that enables material recovery without requiring aggressive chemicals, as it decomposes at controlled temperatures to create separation between substrates.
Solution Approach 2:
The invention changes the temperature parameter from the high temperatures and aggressive chemical conditions of traditional methods to a controlled thermal decomposition range of the intumescent coating (typically 100-300°C). This parameter change allows for milder processing conditions while achieving effective separation and material recovery.
2Loss of substance
If thermal treatment is used to degrade the matrix, then fiber recovery is possible, but high temperatures compromise fiber continuity and cause property degradation
Solution Approach 1:
The patent segments the composite structure by introducing an intumescent coating layer between substrates. When heated, this coating decomposes and creates separation, allowing fibers to be recovered without exposing them to the high temperatures that would degrade their properties. The segmentation isolates the thermal degradation process to the coating layer only.
Solution Approach 2:
The intumescent coating serves as a thermal intermediary that protects the fiber substrates from direct exposure to high temperatures. The coating decomposes at lower temperatures (100-300°C) before the fibers would be damaged, acting as a protective barrier that enables fiber recovery while maintaining fiber continuity and properties.
3Loss of substance
If mechanical grinding is used to process composites, then material separation is achieved, but fiber continuity is compromised
Solution Approach 1:
The patent replaces the mechanical grinding system with a thermal decomposition system. Instead of using mechanical forces that would chop and damage fibers, the invention uses controlled thermal decomposition of the intumescent coating to separate substrates. This substitution of the separation mechanism preserves fiber continuity while achieving effective material separation.
4Use of energy by moving object
If incineration is used for energy recovery, then energy is recovered, but the composite is destroyed and high value materials are converted to greenhouse gases
Solution Approach 1:
The patent converts the potentially harmful thermal decomposition process into a beneficial separation mechanism. Instead of complete incineration that destroys materials and produces greenhouse gases, the intumescent coating is designed to decompose at controlled temperatures into non-toxic volatile compounds that facilitate separation. This transforms a harmful process into a beneficial one that enables material recovery while minimizing environmental impact.
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
Enables efficient separation of composite materials into mono-material constituents with minimal damage, facilitating recycling and reuse while reducing environmental impact.
Implementation Method 1
the intumescent composition is active at an intumescent predetermined temperature of from 120° C. to 450° C., the intumescent temperature being less than the degradation temperature of the at least two substrates
Implementation Method 2
When thermally activated, however, it will undergo significant swelling thanks to the liberation of non-toxic volatile compounds, resulting in chemical debonding and mechanical fracture of the substrates
Data Source
AI summary
A composite material comprising at least two substrates onto which a layer of an intumescent composition is set therebetween, the composition comprising a mixture of following individual constituents: from 5 weight % to 70 wt % of at least one carbon source, from 0 weight % to 50 wt % of at least one acid source, and from 5 weight % to 50 wt % of least one expanding agent, the total being 100 wt %, wherein the intumescent composition is active at an intumescent predetermined temperature of from 120° C. to 450° C., the intumescent temperature being less than the degradation temperature of the at least two substrates. Also a use of the intumescent composition for disassembling, at an intumescent predetermined temperature of from 120° C. to 450° C., a composite material comprising at least two substrates onto which a layer of the intumescent composition is set therebetween.