Recycled FRP Structural Tiles for Low-Resin Composite Panels
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Solution Overview
Problem
Conventional rotor blade manufacturing faces challenges with infusion quality issues and waste generation due to inefficient supply chains and high resin absorption in core materials, leading to increased waste and cost in producing larger blades.
Innovation Solution
A method using a compression mold assembly to form structural tiles from recycled fiber reinforced polymer materials, which are melted and cured to create grid structures with optional top skins, reducing waste and resin usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional infusion processes are used for larger rotor blade production, then rotor blades can be manufactured with structural reinforcement, but infusion quality issues occur and repair time increases
Solution Approach 1:
The patent changes the manufacturing process parameters by switching from infusion processes to compression molding with thermoplastic materials. This parameter change eliminates infusion quality issues while maintaining structural reinforcement capabilities through the compression molding process and thermoplastic material properties.
Solution Approach 2:
The patent utilizes phase transitions of thermoplastic materials (solidifying from melted state under heat and pressure) to form structural components. This phase transition approach replaces the infusion process, eliminating associated quality issues while achieving the required structural reinforcement.
2Strength
If conventional core materials are used in composite sandwich panels, then structural panels can be formed, but significant waste is generated during manufacturing and resin absorption increases
Solution Approach 1:
The patent applies the discarding and recovering principle by using recycled thermoplastic materials instead of virgin core materials. This recovers waste materials from previous manufacturing processes and reuses them in new structural panels, significantly reducing waste generation while maintaining structural integrity.
Solution Approach 2:
The patent uses composite materials formed by combining recycled thermoplastic materials with fiber reinforcements. This composite approach creates structurally sound panels while utilizing recycled content, reducing both waste generation and resin absorption compared to conventional core materials.
3Strength
If conventional core materials are used in composite sandwich panels, then structural panels can be formed, but resin absorption increases by close to 10%
Solution Approach 1:
The patent recovers and reuses thermoplastic materials that would otherwise be discarded, forming structural panels without requiring additional resin absorption. The thermoplastic materials themselves serve as the structural medium, eliminating the need for high resin absorption associated with conventional core materials.
Solution Approach 2:
The patent employs thermoplastic materials that can be processed and formed directly without requiring additional resin systems. This approach reduces material consumption and eliminates the need for large quantities of resin absorption, as the thermoplastic material itself provides the structural function.
4Strength
If manual or traditional manufacturing processes are used for rotor blades, then structural components can be formed, but production efficiency decreases and costs increase
Solution Approach 1:
The patent changes the manufacturing parameters by adopting compression molding processes with thermoplastic materials, which enable automated production. This parameter change improves productivity and reduces costs while maintaining structural component integrity through the controlled heat and pressure application in compression molding.
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
This approach enables leaner, automated manufacturing processes with reduced waste and resin consumption, improving the structural integrity of rotor blades and other applications.
Implementation Method 1
applying pressure and heat to the compression mold assembly to heat the plurality of fragments of recycled fiber reinforced polymer material such that the recycled fiber reinforced polymer material melts within the cavity
Implementation Method 2
allowing the melted recycled fiber reinforced polymer material to cure to form the structural tile
Data Source
AI summary
A method for forming a structural tile for use in a composite panel includes providing a base plate of a compression mold assembly. The method also includes placing a grid structure mold of the compression mold assembly atop the base plate. The grid structure mold defines a cavity having a desired shape for a grid structure. Further, the method includes filling the cavity of the grid structure mold with a plurality of fragments of recycled fiber reinforced polymer material. Moreover, the method includes placing a cover plate of the compression mold assembly atop the grid structure mold to apply pressure to the grid structure mold. The method also includes applying heat to the cover plate to heat the plurality of fragments of recycled fiber reinforced polymer material such that the recycled fiber reinforced polymer material melts within the cavity. In addition, the method includes allowing the melted recycled fiber reinforced polymer material to cure to form the structural tile.