Porous Polyester Composite via Random Network Structure
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Solution Overview
Problem
Conventional thermoplastic composite materials face challenges with mechanical strength, sound absorption, thermal insulation, weight reduction, and recycling due to the incompatibility between reinforced fibers and thermoplastic resins, requiring additional processes and increasing production costs.
Innovation Solution
A porous single resin fiber composite material is developed using a random network structure formed by polyester-based fibers with different elongation rates and melting points, bound by a third polyester-based resin, which enhances mechanical strength, sound absorption, and thermal insulation while simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fibers or carbon fibers are used as reinforced materials to improve mechanical strength, then the mechanical properties are enhanced, but the compatibility with thermoplastic resins is poor requiring additional crosslinking agents and surface treatments
Solution Approach 1:
The patent uses polyester fibers as the reinforced material, which are chemically homogeneous with the polyester resin matrix. This eliminates the compatibility issues between dissimilar materials (glass/carbon fibers with thermoplastic resins), removing the need for crosslinking agents and surface treatments while maintaining mechanical strength.
Solution Approach 2:
The patent extracts and eliminates the incompatible components (glass fibers, carbon fibers, crosslinking agents, surface treatment materials) from the composite system, retaining only the compatible polyester fiber-resin combination to simplify the manufacturing process.
2Strength
If glass fibers are used as reinforced material to improve mechanical strength, then the strength is enhanced, but environmental issues and handling problems occur when glass fiber is exposed on the surface
Solution Approach 1:
By using polyester fibers that are chemically identical to the polyester resin matrix, the patent ensures that the reinforced material and matrix are compatible, eliminating the surface exposure problems associated with glass fibers while maintaining structural integrity.
3Strength
If different materials (glass fiber and thermoplastic resin) are used to create Fiber-Matrix structure to improve mechanical properties, then the strength is enhanced, but the compatibility between materials is low requiring additional crosslinking agents
Solution Approach 1:
The patent employs polyester fibers combined with polyester resin, creating a homogeneous material system where the fiber and matrix are chemically compatible. This eliminates the need for crosslinking agents and simplifies the manufacturing process while achieving the desired mechanical strength.
4Productivity
If conventional thermoplastic composite materials are manufactured using mixing and extrusion processes to improve productivity, then the production efficiency is enhanced, but the additional processes for fiber-resin separation and surface treatment increase production costs
Solution Approach 1:
The patent removes the unnecessary intermediate steps (fiber-resin separation, surface treatment) from the manufacturing process by using chemically compatible polyester fiber-resin combination, thereby reducing process complexity while maintaining productivity.
Solution Approach 2:
By combining the reinforced fiber and matrix material into a chemically compatible system (polyester fiber with polyester resin), the patent merges the functions of reinforcement and bonding into a single integrated material system, eliminating the need for separate treatment processes.
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 porous single resin fiber composite material exhibits excellent mechanical strength, sound absorption, thermal insulation, and weight reduction, with improved compatibility and recyclability, and reduced production costs, making it suitable for various applications.
Implementation Method 1
a binder for binding the first fibrous particle and the second fibrous particle
Implementation Method 2
the first fibrous particle has an elongation rate higher than that of the second fibrous particle
Implementation Method 3
a random network structure including pores
Implementation Method 4
a random network structure including pores
Data Source
AI summary
Provided is a porous single resin fiber composite material comprising: a first fibrous particle; a second fibrous particle; and a binder for binding the first fibrous particle and the second fibrous particle, wherein the first fibrous particles and the second fibrous particles are bound by the binder so as to form a random network structure including pores, the first fibrous particle is a polyester-based fiber including a first polyester-based resin, the second fibrous particle is a polyester-based fiber including a second polyester-based resin, the binder includes a third polyester-based resin, the first fibrous particle has an elongation rate higher than that of the second fibrous particle, and the melting point of the second polyester-based resin is higher than the melting point of the third polyester-based resin.