Multilayer Composite Surface Layer for Thermoformable Recycling
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Solution Overview
Problem
Thermoset polymer matrices in composite materials are rigid and difficult to recycle, and their crosslinked surfaces make it challenging to achieve a decorative finish while maintaining thermoformability and recyclability in fiber-reinforced composite parts.
Innovation Solution
A multilayer composition featuring a thermoplastic surface layer and a substrate layer with a polymeric thermoplastic (meth)acrylic matrix and fibrous reinforcement, where the fibrous material has a high aspect ratio or two-dimensional structure, allowing for thermoforming and recycling without additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoset polymer matrix is used in composite materials, then mechanical performance and rigidity are improved, but recyclability and thermoformability deteriorate
Solution Approach 1:
The composite material is divided into two separate layers: a substrate layer made of thermoset polymer matrix providing mechanical strength, and a surface layer made of thermoplastic polymer providing recyclability and thermoformability. This segmentation allows each layer to independently fulfill its specific function without compromising the other.
Solution Approach 2:
The invention uses a composite structure combining thermoset polymer matrix in the substrate layer with thermoplastic polymer in the surface layer. This composite approach leverages the advantages of both material types: the rigidity and strength of thermosets and the recyclability and formability of thermoplastics.
2Shape
If a gel coat or paint layer is applied to hide the fibrous surface, then surface aesthetics are improved, but recyclability and thermoformability deteriorate due to crosslinking
Solution Approach 1:
The surface layer uses thermoplastic polymer instead of crosslinked thermoset or paint coatings. This parameter change in material selection maintains the decorative surface finish while preserving thermoformability and recyclability, as thermoplastics can be melted and reformed without chemical crosslinking.
Solution Approach 2:
The surface layer acts as a sacrificial aesthetic layer that can be easily replaced or recycled independently from the structural substrate layer. This allows the expensive and complex substrate to be preserved while the surface layer is managed separately for aesthetic purposes.
3Stability of the object's composition
If additional adhesives are used to bond layers, then adhesion between layers is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bonding function is merged into the surface layer material itself through primer treatment, eliminating the need for separate adhesive applications. The primer is applied directly to the substrate and forms an integrated bonding interface between the substrate and surface layer.
Solution Approach 2:
The surface layer system provides its own bonding capability through the primer treatment, making the system self-sufficient without requiring additional adhesive components. The thermoplastic surface layer bonds directly to the primed substrate through diffusion and mechanical interlocking.
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 solution provides a decorative surface that hides the fibrous aspect, ensures adhesion between layers, allows for shape transformation, and facilitates recycling by using commercially available components in a cost-effective and scalable manufacturing process.
Implementation Method 1
the surface layer comprising a thermoplastic polymer A... allows for shape transformation
Implementation Method 2
polymerising the liquid (meth)acrylic syrup impregnating said fibrous substrate
Data Source
AI summary
The present invention relates to a multilayer composition comprising a surface layer comprising a thermoplastic polymer A and a substrate layer comprising a polymeric composite material based thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement. The multilayer composition is suitable for mechanical or structured parts or articles with a decorative surface aspect The present invention concerns also a manufacturing process for multilayer mechanical or structured parts or articles and three-dimensional mechanical or structured parts.