Lignin-Reinforced Resin Composite for Bio-Based Material Ratio
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Solution Overview
Problem
There is a need for more sustainable and bio-based resin matrices in fiber mat reinforced resin composites to reduce the use of petroleum-based resins, while maintaining properties suitable for various applications.
Innovation Solution
A fiber mat reinforced resin composite is produced using a resin matrix comprising thermoset resin crosslinked with lignin, where natural fibers with an average length of 150 µm - 9 mm are embedded, and lignin replaces part of the thermoset resin, enhancing the bio-based material ratio and composite properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lignin is used to replace part of the thermoset resin, then the bio-based material ratio is increased, but the mechanical strength may be compromised
Solution Approach 1:
The patent optimizes the particle size of lignin (2-200 μm) and its replacement ratio (5-60 wt%) to achieve the desired balance between bio-based content and mechanical strength. By controlling these parameters, the composite maintains adequate tensile strength while incorporating significant amounts of bio-based lignin material.
Solution Approach 2:
The invention creates a composite resin matrix system combining thermoset resin, lignin, and natural fibers. This multi-component composite approach allows the lignin to contribute to the bio-based content while the thermoset resin and fiber reinforcement maintain the structural strength requirements.
2Ease of operation
If natural fibers with average length of 150 μm - 9 mm are used, then the flexibility and formability are improved, but the manufacturing precision may be affected
Solution Approach 1:
The patent specifies a particular fiber length range (150 μm - 9 mm) that balances flexibility with manufacturability. This parameter optimization ensures the fibers are long enough to provide reinforcement but short enough to be handled and processed effectively in industrial settings.
3Reliability
If lignin with average particle size of 2 - 200 μm is used, then the compatibility with natural fibers is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent defines a specific particle size range for lignin (2-200 μm) that optimizes compatibility with natural fibers while considering industrial processing capabilities. This parameter specification ensures proper dispersion and bonding without requiring excessively complex manufacturing equipment or processes.
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 use of lignin increases the bio-based material ratio in the composite, improves flexibility and formability, maintains tensile strength, and allows for industrial-scale production, making it suitable for diverse applications while being environmentally friendly and cost-effective.
Implementation Method 1
the resin matrix comprises thermoset resin and lignin crosslinked with a curing agent
Implementation Method 2
Lignin is penetrated between the fibers of the at least one mat of fibers
Data Source
Figure 1
AI summary
The present invention related to a fiber mat reinforced resin composite comprising a reinforcing constituent of fibers in the form of at least one mat embedded within a resin matrix. The invention further relates to a method for the production of a fiber mat reinforced resin composite.