Biodegradable Protein Thermoset Composition Low-Temperature Curing
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Solution Overview
Problem
Current methods for producing protein-based thermoplastic compositions require high temperatures and energy for processing, leading to inefficient production and lower output compared to synthetic plastics, and are limited in creating leather-like products without using synthetic resins.
Innovation Solution
A biodegradable protein-based thermoset composition is formed by mixing an essentially dry protein powder with an anhydrous liquid alcohol, allowing for thermosetting properties that simplify the manufacturing process, reduce energy costs, and enable the creation of edible and biodegradable products with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high temperatures and energy are used for processing protein-based thermoplastic compositions, then the processing capability is improved, but the energy consumption increases and production efficiency decreases
Solution Approach 1:
The patent changes the fundamental processing parameter from thermoplastic (high temperature melting) to thermoset (low temperature curing). The composition uses a protein powder mixed with a crosslinking agent that forms a thermoset network at low temperatures, eliminating the need for high-temperature extrusion and cooking processes while maintaining formability through controlled setting reactions
Solution Approach 2:
The invention utilizes a phase transition approach where the protein-based composition transitions from a moldable state (when mixed with crosslinking agent) to a set state (after curing reaction). This allows the material to be formed at low temperatures and then permanently set through chemical crosslinking, avoiding the repeated heating and cooling cycles required for thermoplastics
2Ease of manufacture
If high temperatures and shear forces are applied to protein-based compositions, then the material can be extruded and molded, but the production output is lower compared to synthetic plastics
Solution Approach 1:
The patent applies preliminary action by pre-mixing the protein powder with the crosslinking agent to create a composition that is ready for direct molding. The composition maintains its moldability during the molding process and then sets in place, eliminating the need for subsequent high-temperature processing steps and enabling faster production cycles
Solution Approach 2:
The invention replaces the mechanical extrusion-cooking system with a chemical setting system. Instead of using high-temperature melting and mechanical extrusion, the composition is formed by mixing and then sets through chemical crosslinking, allowing for simpler molding equipment and faster production rates similar to synthetic thermosets
3Strength
If synthetic resins are used to create leather-like products, then the mechanical properties and durability are improved, but the environmental friendliness and biodegradability are reduced
Solution Approach 1:
The patent creates a composite material system combining protein powder (collagen, casein, soy protein, etc.) with a crosslinking agent (glycerol, polyol, or carbohydrate). This composite provides leather-like mechanical properties through the protein matrix and crosslinked network, while remaining fully biodegradable and environmentally friendly as both components are natural, renewable materials
Solution Approach 2:
The invention embraces the concept of biodegradable, short-living products by using fully compostable protein-based materials that can replace synthetic leather and resin products. The material is designed to provide sufficient mechanical properties for its intended use lifecycle while being inherently biodegradable, eliminating long-term environmental persistence
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 thermoset composition simplifies the production process, reduces energy expenditure, and enables the creation of biodegradable and edible products with enhanced mechanical properties, such as moisture absorption and thermosealability, suitable for replacing synthetic resin-based products.
Implementation Method 1
a homogenous mixture of an essentially dry protein or protein-based powder and an anhydrous and liquid alcohol
Implementation Method 2
characterised by having thermoset behaviour
Data Source
AI summary
The present invention relates to biodegradable protein based thermoset compositions formulated from a powder of a dry and finely ground protein material, from which the water has been thoroughly removed, an anhydrous and liquid alcohol and other optional additives. The inventions also relates to the method for obtaining these compositions in which the components are homogeneously mixed, under controlled conditions of temperature and moisture, to obtain a homogenous and shelf-cohesive mass, that can be shaped in any predetermined form by diverse molding methods, being readily set through the application of a certain amount of heat during a short period of time, which enables it to turn into a solid shaped body or article through a very simple process.