Cross-Linked Lignocellulosic Pre-Preg Mat for Moisture Stability
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Solution Overview
Problem
Existing pre-preg materials derived from non-renewable sources face challenges in moisture resistance, dimensional stability, and recyclability, limiting their use in applications requiring durability and ease of recycling, especially when exposed to humid environments or liquids.
Innovation Solution
A process for producing a functional pre-preg mat from ligno-cellulosic fibers, treated with a cross-linking formulation containing carboxylic acid and polyol, which is then formed into a continuous mat and dried to a low moisture content, allowing for enhanced strength and stability while remaining recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ligno-cellulosic fibers are used as renewable material, then environmental sustainability is improved, but moisture resistance and dimensional stability deteriorate
Solution Approach 1:
The patent applies parameter changes by treating ligno-cellulosic fibers with a cross-linking formulation containing carboxylic acid and polyol, which chemically modifies the fiber structure to reduce hydrophilicity and improve dimensional stability while maintaining renewable material benefits
Solution Approach 2:
The patent creates a composite material system by combining ligno-cellulosic fibers with cross-linking agents (carboxylic acid and polyol), forming a hybrid structure that exhibits both renewable material properties and enhanced moisture resistance
2Reliability
If ligno-cellulosic fibers are used as renewable material, then environmental sustainability is improved, but strength deteriorates
Solution Approach 1:
The cross-linking formulation chemically modifies the ligno-cellulosic fiber structure, changing the physical and chemical parameters to enhance mechanical strength while preserving the renewable nature of the material
Solution Approach 2:
By forming a composite between ligno-cellulosic fibers and cross-linking agents, the patent creates a material with synergistic properties that combine renewable sustainability with improved mechanical performance
3Object-affected harmful factors
If cross-linking formulation is applied to ligno-cellulosic fibers, then moisture resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The cross-linking formulation is applied in advance during the mat formation process, before final product manufacturing, which simplifies subsequent production steps while achieving the desired moisture resistance
Solution Approach 2:
The cross-linking formulation acts as an intermediary substance that facilitates the bonding between ligno-cellulosic fibers and provides moisture resistance, simplifying the overall manufacturing process by combining multiple functions in one treatment
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 process results in a bio-based, recyclable pre-preg mat with improved moisture resistance and strength, suitable for thermoforming, capable of replacing non-renewable composites and facilitating high recovery rates of waste materials.
Implementation Method 1
treated with a cross-linking formulation containing carboxylic acid and polyol
Implementation Method 2
dried to a low moisture content
Data Source
AI summary
A process for the manufacture of a functional pre-preg mat of ligno-cellulosic material is disclosed. In said process, pulp fibres are mixed with at least one functional solution including a cross-linking formulation. The cross-linking formulation has been prepared by dissolving at least one cross-linking agent in a water or alcohol based solvent at a temperature below 120° C. Pulp fibres treated with the at least one functional solution are then formed into an continuous mat. The mat of pre-preg ligno-cellulosic pulp fibres formed in the previous step is transferred to a drying step during which the temperature within the ligno-cellulosic mat is kept below 120° C. A functional pre-preg mat of ligno-cellulosic material suitable for use as raw material in a thermoforming process is also disclosed.