Nanofibrillated Cellulose Thermoplastic Composite Formability
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Solution Overview
Problem
Current composite materials reinforced with glass fibers lack the ability to be formed into various shapes due to their thermosetting nature and require long-term drying and compression, limiting their application and flexibility.
Innovation Solution
A multi-layered composite material is developed by thermocompressing layers of nanofibrillated cellulose and thermoplastic matrix polymers, where the nanofibrillated cellulose is inserted between hot-melt bonded polymer layers, allowing for improved adhesion and increased tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber-reinforced composite materials are used, then high strength is achieved, but the material cannot be formed into various shapes due to thermosetting nature
Solution Approach 1:
The patent changes the chemical state of the matrix polymer from thermosetting to thermoplastic. This parameter change allows the material to transition from a permanently set state to a re-moldable state above melting temperature, enabling various shaping operations while maintaining high strength through nanofibrillated cellulose reinforcement
Solution Approach 2:
The patent creates a composite material system combining nanofibrillated cellulose (NFC) with thermoplastic matrix polymer. This composite structure provides both the high strength from NFC reinforcement and the formability from thermoplastic matrix, resolving the contradiction between strength and adaptability
2Object-generated harmful factors
If 100% cellulose nanofiber composite material is used, then environmental friendliness is achieved, but long-term drying and compression are required
Solution Approach 1:
The patent changes the matrix material from pure cellulose to thermoplastic polymer matrix. This parameter change eliminates the need for long-term drying and compression processes, reducing processing time from days to hours while maintaining environmental friendliness through biodegradable thermoplastic matrices
Solution Approach 2:
The patent utilizes the phase transition properties of thermoplastic polymers. The material can be processed in the molten state and then solidified, eliminating the need for prolonged drying and compression that pure cellulose composites require, thus reducing processing time while maintaining structural integrity
3Strength
If 100% cellulose nanofiber composite material is used, then high strength is achieved, but the material has no thermoplasticity
Solution Approach 1:
The patent creates a composite where nanofibrillated cellulose provides reinforcement and strength, while the thermoplastic matrix polymer provides thermoplasticity. This composite structure allows the material to be molded and re-molded above the matrix melting temperature while maintaining high strength through NFC reinforcement
Solution Approach 2:
The patent segments the functional roles between two components: NFC provides structural reinforcement and strength, while the thermoplastic matrix provides processability and thermoplasticity. This functional segmentation allows both high strength and thermoplasticity to coexist in the composite material
4Strength
If thermocompressing is applied to bond polymer layers, then adhesion between layers is improved, but processing complexity increases
Solution Approach 1:
The patent utilizes the melting and solidification phase transition of thermoplastic polymers during thermocompressing. The heat and pressure cause the matrix to melt and bond layers together, then cooling solidifies the bond. This phase transition mechanism provides strong interlayer adhesion through a relatively simple thermal processing step
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 resulting composite material exhibits enhanced tensile strength, flexural modulus, and fracture properties, making it suitable for replacing glass fiber-reinforced materials in various industrial applications with improved processability and environmental sustainability.
Implementation Method 1
a first thermoplastic matrix polymer and a second thermoplastic matrix polymer which are hot-melt bonded
Data Source
AI summary
The present invention relates to a multi-layered composite material manufactured by thermocompressing a multi-layered sheet, comprising: a first sheet layer formed from a solution containing nanofibrillated cellulose and a first thermoplastic matrix polymer; and a second sheet layer formed from a solution containing a second thermoplastic matrix polymer. The multi-layered composite material of the present invention has the high strength and high elastic modulus.