Nano-particulate Placement in Composites via Depletable Foam

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Solution Overview

Problem

Current methods for incorporating nano-particulates into composites face challenges such as high resin viscosity and difficulty in selectively placing them, leading to poor out-of-plane performance and matrix failure in advanced composites.

Innovation Solution

The development of composite materials using a nano-particulate-depletable material, such as polystyrene foam, where nano-particulates are selectively placed within the composite by depleting the depletable material during the infusion process, allowing for improved dispersion and distribution of nano-particulates within the structural material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If nano-particulates are dispersed in liquid resins using sonication and shear techniques, then nano-particulates can be introduced into composites, but resin viscosity increases excessively making infusion difficult and fiber wetting inhibited

Engineering Contradiction:

Improvenano-particulate concentrationVSAvoidresin infusion difficulty

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent segments the composite structure into three distinct components: structural fibers, depletable foam carrier material, and nano-particulates. This segmentation allows each component to be optimized independently - the foam carrier enables high nano-particulate loading without directly increasing resin viscosity, as the particles are suspended in the foam rather than the resin.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The depletable foam acts as an intermediary carrier between the nano-particulates and the final composite structure. The foam suspends and distributes the nano-particulates during manufacturing, then depletes away to leave the particles in place. This intermediary approach avoids the viscosity problems of direct resin suspension while enabling controlled particle placement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If traditional microscale fiber reinforcement is used to strengthen matrix-rich regions, then reinforcement can be attempted, but these regions are difficult to reinforce due to their formation in gaps between interlaced fiber bundles

Engineering Contradiction:

Improvematrix-rich region strengthVSAvoidreinforcement difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by concentrating nano-particulates specifically in matrix-rich regions through the foam carrier placement strategy. The foam is positioned in areas needing reinforcement, and upon depletion, leaves nano-particulates precisely where matrix material is excessive and reinforcement is needed, rather than uniformly distributing reinforcement throughout the composite.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the scale parameter from microscale fiber reinforcement to nanoscale particulate reinforcement. This parameter change enables reinforcement of matrix-rich regions at a different scale level, where nano-particulates can be more effectively distributed and integrated into the matrix material compared to traditional microscale fibers.

Inventive Principle:

Principle #35Parameter changes

3Strength

If composites are designed to improve out-of-plane performance, then structural performance can be enhanced, but poor out-of-plane performance occurs due to matrix failure

Engineering Contradiction:

Improveout-of-plane strengthVSAvoidmatrix failure resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates a multiscale composite material system combining structural fibers, matrix resin, depletable foam carrier, and nano-particulates. This hierarchical composite structure addresses matrix failure by introducing nano-particulates that can bridge microcracks and reinforce the matrix phase, improving out-of-plane performance and reliability simultaneously.

Inventive Principle:

Principle #40Composite 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

This method enables cost-effective, selective placement of nano-particulates, enhancing the mechanical and electrical properties of composites, and potentially creating a network of current carriers, improving the structural integrity and performance of composites in applications like naval, automotive, and aerospace sectors.

Implementation Method 1

depleting the depletable material such that the nano-particulates are selectively placed on or within the structural material

Methodology Applied

Scientific EffectDepletion:

Implementation Method 2

dispersing the nano-particulates on or within a polystyrene foam during manufacture of the polystyrene foam

Methodology Applied

Scientific EffectDispersion:

Data Source

PatentUS8404162B2Composite materials and methods for selective placement of nano-particulates within composites

Publication Date: 2013.03.26 FLORIDA STATE UNIV RES FOUND INC

AI summary

Composite materials and methods for making composites are provided. The method includes providing a nano-particulate-depletable material that includes a plurality of nano-particulates on or within a depletable material; positioning the nano-particulate-depletable material on or within a structural material; and depleting the depletable material such that the nano-particulates are selectively placed on or within the structural material. Depletion may include infusion of a resin into the structural material. The depletable material may be a polymeric foam, and the nano-particulates may be carbon nanotubes.