Parallelogram Fabric Patch Material for Composite Recycling
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Solution Overview
Problem
Existing methods for recycling excess non-crimp fabric material result in a random mat product with reduced strength compared to the source material, and often lead to waste being sent to landfills.
Innovation Solution
A method involving cutting the fabric into substantially parallelogram-shaped pieces, aligning and attaching them to a carrier veil using an adhesive activated by heat and pressure, to form a patch material with improved structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If excess non-crimp fabric material is recycled into random mat product, then material utilization is improved, but the strength of the resulting material is reduced
Solution Approach 1:
The fabric is divided into multiple pieces that are substantially parallelogram in shape, allowing them to be arranged and attached in a structured manner that preserves fiber alignment and structural integrity, rather than being randomised into mat product
Solution Approach 2:
The method creates a composite structure by attaching fabric pieces to a carrier veil using adhesive, forming a multi-layer composite material that combines the strength of aligned fibers with the binding matrix material, achieving both good strength and material utilization
2Ease of manufacture
If conventional manufacturing processes are used for non-crimp fabric, then production is simplified, but excess fabric is wasted and sent to landfill
Solution Approach 1:
The fabric is cut into parallelogram pieces and arranged on the carrier veil before the adhesive is applied, allowing for efficient use of material and minimal waste from the outset, rather than dealing with waste after production
Solution Approach 2:
Instead of discarding excess fabric to landfill, the method recovers and reuses it by cutting into parallelogram pieces and attaching them to the carrier veil, transforming waste into useful material
3Loss of substance
If excess non-crimp fabric is separated and formed into random mat multi-layer fleece, then recycling is achieved, but the resulting material has reduced strength
Solution Approach 1:
The fabric is segmented into parallelogram pieces that maintain fiber alignment, unlike random mat fleece where fibers are separated and randomized, thus preserving structural strength while achieving recycling
Solution Approach 2:
The method changes the geometric parameter of the fabric pieces to substantially parallelogram shape, which allows for optimal arrangement and alignment on the carrier veil, maintaining fiber orientation and structural integrity while enabling recycling
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 structure exhibits mechanical properties such as tensile strength, compression, flexural, and shear strength that are 50-70% of the source non-crimp fabric material, with flexural strength retaining 80-85% of original values, thus offering a more efficient and environmentally friendly material utilization.
Implementation Method 1
attaching the pieces to the carrier veil to form the material including the pieces and the carrier veil
Implementation Method 2
exposing the adhesive to a temperature of 110 degrees Celsius
Implementation Method 3
a pressurizer, in communication with the controller, to increase pressure, wherein the heater and the pressurizer are configured to apply heat and pressure to an adhesive to adhere the pieces to the carrier veil
Data Source
AI summary
A material is formed by dividing a fabric into pieces that are substantially parallelogon in shape, the fabric having multiple parallel fibres. The pieces are placed, for example, with a pick and place machine, adjacent to each other on a carrier veil with fibres of adjacent of the pieces in substantial alignment. The pieces are attached to the carrier veil to form the material, the material including the pieces and the carrier veil.