Recyclable Hybrid Composite Materials for Weight Reduction
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Solution Overview
Problem
Modern composite materials face challenges such as non-recyclability, brittleness, and high costs, necessitating the development of materials with tunable physical properties and improved recyclability.
Innovation Solution
A composition comprising a matrix material made from a polyester resin or polymer combined with a mixture of inorganic and organic fibers, where the fibers include carbon and polyethylene, respectively, and the matrix material is derived from reacting an anhydride with an epoxy, forming a thermoset material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal materials are used, then strength and durability are ensured, but weight increases and recyclability decreases
Solution Approach 1:
The patent employs composite materials combining polyester thermoset matrix with hybrid fiber reinforcements (carbon fibers and polyethylene fibers). This composite structure achieves high strength-to-weight ratio by integrating the high strength properties of carbon fibers with the ductility and recyclability of polyethylene fibers, while the polyester thermoset matrix provides structural cohesion and environmental stability.
2Weight of moving object
If traditional composite materials are used, then weight is reduced, but recyclability is lost
Solution Approach 1:
The patent enables recyclability through a systematic recovery process where the polyester thermoset matrix is chemically degraded to recover the fiber reinforcements. The polyethylene fibers can be melted and reprocessed, while carbon fibers are cleaned and reused, creating a circular economy model that recovers valuable materials from composite waste.
Solution Approach 2:
The patent utilizes chemical parameter changes by selecting a polyester thermoset matrix with specific chemical bonds that can be selectively degraded under controlled conditions. The matrix material's chemical composition is designed to allow decomposition while leaving the fiber reinforcements intact, enabling separation and recovery processes.
3Strength
If hybrid fiber compositions are used, then mechanical properties are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the fiber reinforcement into distinct categories (carbon fibers and polyethylene fibers) with different functions. Carbon fibers provide high strength and stiffness, while polyethylene fibers provide ductility and impact resistance. This segmentation allows for optimized performance in specific application zones while simplifying the overall manufacturing process through standardized fiber handling procedures.
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 achieves enhanced mechanical properties, improved recyclability, and reduced manufacturing costs, making the composite materials suitable for replacing traditional steel materials.
Implementation Method 1
the matrix material is derived from reacting an anhydride with an epoxy
Data Source
AI summary
The present disclosure relates to a composition that includes a matrix material constructed of at least one of a polyester resin, a polyester polymer, and/or a combination thereof and a plurality of fibers, where the plurality of fibers includes a first portion of an inorganic fiber and a second portion of an organic fiber, and the plurality of fibers and the matrix material are in physical contact.