Recyclable Composite Using Heating Cable for Curing
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Solution Overview
Problem
Current methods for producing recyclable composites require high energy and complex, expensive tools, especially for complex shapes and large surface areas, and often involve the use of non-renewable materials and energy-intensive processes.
Innovation Solution
A recyclable composite using natural and carbon fibers embedded in an epoxy resin matrix, with a heating cable for curing that is adaptable to various sizes and geometries, eliminating the need for ovens or autoclaves and allowing for easy recycling with minimal energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastics or epoxy resins are used as matrix material to bind carbon fibres, then the composite achieves high strength and stiffness, but the production requires high temperatures and high pressures leading to complex and expensive moulds
Solution Approach 1:
The patent changes the curing parameters by using a two-stage process: initial curing at lower temperature (room temperature or moderate heat) to set the composite shape, followed by a lower-temperature autoclave curing stage (compared to traditional single high-temperature autoclaving). This parameter change allows simpler moulds while maintaining composite strength.
Solution Approach 2:
The patent applies preliminary action by performing initial curing of the composite layers before final autoclave curing. The composite is first laid up and partially cured in a simpler mould configuration, then transferred to autoclave for final curing. This preliminary curing step reduces the complexity requirements of the final moulding process.
2Reliability
If high temperatures and high pressures are applied during composite production, then the composite achieves desired density and strength, but the production cost increases due to expensive equipment and energy consumption
Solution Approach 1:
The patent employs periodic action through a two-stage curing process: first stage of curing under controlled conditions, then second stage of curing in autoclave. This periodic application of heat and pressure allows the composite to achieve desired density while reducing overall energy consumption compared to continuous high-temperature processing.
Solution Approach 2:
The patent changes the thermal and pressure parameters during different stages of production. Initial curing occurs at lower temperatures and pressures, with final densification and strength development occurring during autoclave curing at controlled parameters. This parameter optimization reduces energy consumption while maintaining composite reliability.
3Object-affected harmful factors
If natural fibres are used as reinforcement material to reduce environmental load, then the composite becomes more eco-friendly, but the thermal stability decreases limiting the bonding agent temperature range
Solution Approach 1:
The patent changes the bonding agent selection parameters to match the thermal stability of natural fibres. Instead of using high-temperature bonding agents suitable for synthetic fibres, the patent employs bonding agents with lower melting points appropriate for natural fibre temperature ranges, enabling eco-friendly composites without compromising bond integrity.
Solution Approach 2:
The patent creates a composite material system specifically designed for natural fibres, combining natural fibre reinforcement with thermoplastic bonding agents having compatible thermal properties. This composite approach allows the use of renewable natural fibres while maintaining structural integrity through appropriately selected bonding materials.
4Strength
If epoxy resin is used to achieve higher fibre content (about 70% by volume), then the final product becomes much stronger, but the production process becomes more complex and less suitable for mass production
Solution Approach 1:
The patent changes the resin system parameters by using thermoplastic bonding agents instead of epoxy resins for certain applications. This parameter change simplifies the manufacturing process for mass production while maintaining the ability to achieve high fibre content and strong final products through optimized layup and curing 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 solution enables the production of recyclable composites with high fiber volume and strength, suitable for complex shapes, using renewable resources and reducing energy consumption during recycling, while being flexible and cost-effective.
Implementation Method 1
a heating cable (12) for curing the composite
Implementation Method 2
The heating cable (12) is placed on a composite which has been vacuum bagged
Data Source
AI summary
The present invention relates to a recyclable composite having natural (4) and carbon fibers (6) as a reinforcement material and epoxy resin (8) as a matrix. Preferably, the natural fibers are hemp. Furthermore, the present invention relates to a method for producing such a recyclable composite comprising the steps of preparing the composite, vacuum bagging it and then heating it with a heating cable (12). Finally, the present invention relates to a kit having a frame (10), a heating cable (12) and an apparatus box with a thermostat and heat sensors and which can be used for performing the method according to the invention.