Moldable Nonwoven Structural Components via Scrim Diffusion
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Solution Overview
Problem
The automotive, aircraft, and aerospace industries seek structural materials with a high strength-to-weight ratio that are environmentally friendly and do not contribute negatively to the environment at end of life, as traditional petroleum-based materials have a high weight-to-strength ratio and negative environmental impact.
Innovation Solution
A nonwoven material composed of natural fibers and modified polypropylene fibers with Maleic Anhydride grafted Polypropylene, combined with a scrim layer that is either on the surface or sandwiched between layers, is used to create a lightweight structural component with enhanced flexural strength by diffusing the scrim layer into the material, reducing weight while meeting or exceeding structural requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional petroleum-based materials are used for structural components, then structural strength is achieved, but weight-to-strength ratio is high and environmental impact is negative
Solution Approach 1:
The patent uses a composite material system consisting of natural fibers (cellulosic, flax, hemp, jute, or bamboo) combined with thermoplastic binder fibers to create a nonwoven fabric that achieves structural strength while reducing weight. This composite approach allows the material to meet structural requirements with lower density compared to traditional petroleum-based materials.
Solution Approach 2:
The patent modifies the properties of polypropylene fibers by grafting Maleic Anhydride onto them, creating grafted polypropylene fibers. This chemical modification changes the parameters of the binder fibers to improve bonding with natural fibers, thereby enhancing the overall strength of the lightweight nonwoven structure.
2Strength
If traditional petroleum-based materials are used for structural components, then structural requirements are met, but environmental friendliness deteriorates
Solution Approach 1:
The patent modifies the properties of polypropylene fibers by grafting Maleic Anhydride onto them, creating grafted polypropylene fibers. This chemical modification changes the parameters of the binder fibers to improve bonding with natural fibers, thereby enhancing the overall strength of the lightweight nonwoven structure.
Solution Approach 2:
The patent modifies the properties of polypropylene fibers by grafting Maleic Anhydride onto them, creating grafted polypropylene fibers. This chemical modification changes the parameters of the binder fibers to improve bonding with natural fibers, thereby enhancing the overall strength of the lightweight nonwoven structure.
3Strength
If scrim layer is added to enhance flexural strength, then flexural strength increases, but material complexity increases
Solution Approach 1:
The patent combines the scrim layer with the nonwoven fabric layers to form a single integrated molded structural component. This merging of layers during the molding process achieves the desired flexural strength while simplifying the overall structure compared to assembling separate components.
Solution Approach 2:
The patent uses a composite material system consisting of natural fibers (cellulosic, flax, hemp, jute, or bamboo) combined with thermoplastic binder fibers to create a nonwoven fabric that achieves structural strength while reducing weight. This composite approach allows the material to meet structural requirements with lower density compared to traditional petroleum-based materials.
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 nonwoven material achieves significant weight reduction while exceeding structural requirements, such as flexural strength, and provides a sustainable alternative to traditional materials by utilizing renewable natural fibers and a bonding process that enhances material strength and durability.
Implementation Method 1
a scrim layer is at least partially melted and diffused into the nonwoven web
Implementation Method 2
a scrim layer is at least partially melted and diffused into the nonwoven web
Implementation Method 3
modified polypropylene fibers with Maleic Anhydride grafted Polypropylene
Data Source
Figure 1~3
AI summary
A nonwoven, moldable material and method of construction thereof is provided. The nonwoven material includes at least one nonwoven mat (14, 114) formed from blended and bonded natural cellulosic fibers and Polypropylene containing Maleic Anhydride grafted Polypropylene fibers. A scrim layer (16, 116) is at least partially melted and diffused into the nonwoven mat to form an alloy region (18, 118) containing material of both the nonwoven mat and the scrim layer, which provides the nonwoven, moldable material having a density between about 300-1200gsm with a flexural strength across machine direction of about 76N.