Liquid composition comprising a wax compound, its process of polymerization, use and material or composition obtained following polymerization of composition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for impregnating fibrous substrates with thermoplastic polymers face challenges such as high viscosity, evaporation of monomers, and environmental issues, leading to incomplete impregnation and mechanical defects in composite materials.
Innovation Solution
A liquid composition comprising (meth)acrylic monomer, (meth)acrylic polymer, and a wax compound is used, which maintains a dynamic viscosity between 10 mPa*s and 10,000 mPa*s, reducing monomer evaporation to less than 20 wt% and enabling efficient impregnation and polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the chain length or molecular mass of thermoplastic polymer is reduced to achieve low viscosity and sufficient fluidity for impregnation, then the fluidity is improved, but the mechanical properties such as deformation modulus deteriorate
Solution Approach 1:
The patent changes the physical state of the polymer from solid to liquid by using oligomers with controlled molecular weight (500-5000 g/mol) and adjusting the ratio of monomer to oligomer (90:10 to 50:50 by weight). This parameter adjustment allows the composition to have low viscosity at processing temperature while maintaining adequate mechanical properties after curing
Solution Approach 2:
The patent creates a composite liquid composition combining monomer and oligomer in specific ratios, where the oligomer provides viscosity control and the monomer ensures complete polymerization. This composite approach allows optimization of both processing fluidity and final mechanical properties
2Ease of operation
If the temperature is increased to reduce viscosity and improve fluidity for impregnation, then the fluidity is improved, but thermoinduced degradation occurs leading to decreasing molecular weight
Solution Approach 1:
The patent changes the approach from temperature-based viscosity reduction to composition-based viscosity control. By selecting oligomers with specific molecular weights (500-5000 g/mol) and using them in controlled ratios with monomer, the composition achieves low viscosity at room temperature without requiring high processing temperatures that would cause degradation
Solution Approach 2:
The oligomer acts as an intermediary substance that provides the necessary fluidity without requiring thermal energy. It serves as a molecular weight bridge between low molecular weight monomers and high molecular weight polymers, enabling low-viscosity processing while maintaining thermal stability
3Ease of operation
If organic solvent is used to dissolve thermoplastic polymer for impregnation, then the fluidity is improved, but environmental issues arise due to large quantities of solvent requiring evaporation
Solution Approach 1:
The patent extracts and eliminates the harmful organic solvent component from the system. Instead of using solvent-based solutions, it employs a solvent-free composition of monomer and oligomer where the oligomer itself provides the necessary fluidity, completely removing the environmental burden of solvent evaporation
Solution Approach 2:
The oligomer serves as a temporary fluidity provider that is consumed during polymerization. It is not a persistent environmental contaminant like organic solvents, but rather a reactive component that becomes part of the final polymer matrix, eliminating long-term environmental issues
4Ease of operation
If monomer is used for impregnation and polymerized after impregnation, then the fluidity is improved, but monomer evaporation occurs leading to incomplete wetting and mechanical defects
Solution Approach 1:
The patent performs preliminary action by adding oligomer to the monomer before impregnation. This pre-formulation step creates a stabilized liquid composition where the oligomer suppresses monomer evaporation during the impregnation process, ensuring complete wetting before polymerization occurs
Solution Approach 2:
The oligomer acts as an intermediary that reduces monomer volatility during handling. It forms a liquid mixture with the monomer that has lower vapor pressure than pure monomer, preventing evaporation losses while maintaining the reactivity needed for complete polymerization
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 composition achieves reduced evaporation and improved impregnation, resulting in high conversion and mechanical integrity of composite parts with minimal defects.
Implementation Method 1
a liquid composition comprising a monomer, a (meth)acrylic polymer and a wax compound... yields to a liquid composition having reduced evaporation of the (meth)acrylic monomer
Implementation Method 2
The wetting or correct impregnation of the fibers by the thermoplastic polymer can only be achieved, if the thermoplastic resin is sufficiently fluid
Implementation Method 3
Once polymerized, the thermoplastic polymeric syrup constitutes the matrix of the composite material
Data Source
AI summary
A liquid composition including a monomer, a (meth)acrylic polymer and a wax compound. The liquid composition can be used as a syrup and especially as a syrup for impregnation of fibres or fibrous material. Also, a thermoplastic material obtained after polymerization of the liquid composition. Also, a process for manufacturing such a liquid composition. Also, a process for impregnating a fibrous substrate of long or continuous fibres with such a liquid composition. Also, a fibrous substrate impregnated with such a liquid composition which is useful for manufacturing composite parts. Also, a process for manufacturing mechanical parts or structural elements made of composite material and mechanical parts or structural elements made of composite material obtained via a process using such a liquid composition.