Recycling Unsaturated Resin Prepreg Scrap via Co-Molding
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Solution Overview
Problem
The composites industry faces challenges in effectively recycling and repurposing scrap prepreg materials, particularly those containing epoxy resins, due to their instability and reduced chemical reactivity when stored at room temperature, leading to waste and environmental issues.
Innovation Solution
A process involving the recovery of unsaturated resin prepreg scrap, combining it with a second resinous thermosetting component, and co-molding under elevated temperature and pressure to create a composite part, utilizing unsaturated polyester or vinylester resins with thermally-activated peroxides and free radical inhibitors to enhance mechanical properties and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If epoxy prepreg is stored at room temperature, then handling convenience is improved, but chemical reactivity deteriorates due to crosslinking reactions
Solution Approach 1:
The patent changes the resin system from epoxy to unsaturated polyester or vinylester resins, which have different chemical properties that allow room temperature storage without crosslinking. This parameter change in material composition resolves the contradiction by providing both handling convenience and maintained chemical reactivity.
Solution Approach 2:
The patent treats prepreg scrap as a viable recycling material rather than waste, creating a short-term storage solution at room temperature. By using unsaturated resins that don't crosslink at room temperature, the scrap can be stored and reused without degradation, effectively creating a disposable-friendly system that maintains material value.
2Object-affected harmful factors
If prepreg scrap is landfilled, then environmental impact is reduced, but material value is lost
Solution Approach 1:
The patent implements a recovery system for prepreg scrap by combining it with additional fiber and resin to create new composite parts. Instead of discarding the scrap to landfills, the system recovers and repurposes the material, simultaneously reducing environmental impact and preserving material value through cyclic reuse.
Solution Approach 2:
The patent changes the physical and chemical parameters of the scrap material by combining it with additional components (fiber, resin, catalyst) to transform it from waste into a viable raw material for new parts. This parameter change enables the scrap to be reused without environmental harm or material loss.
3Stability of the object's composition
If epoxy prepreg is refrigerated, then chemical stability is improved, but handling difficulty increases due to stiffness
Solution Approach 1:
The patent changes the resin chemistry from epoxy to unsaturated polyester or vinylester resins, which have fundamentally different temperature-dependent properties. This parameter change eliminates the need for refrigeration while maintaining chemical stability, thereby improving handling ease without sacrificing stability.
4Object-generated harmful factors
If prepreg scrap is recycled through combustion, then harmful factors are reduced, but material properties are lost
Solution Approach 1:
The patent recovers both the fiber and resin components of the scrap material rather than combusting them. The fiber is reused as reinforcement and the resin is reused as matrix material, thereby recovering mechanical properties while avoiding the harmful emissions of combustion.
Solution Approach 2:
Instead of combusting the scrap to eliminate harmful factors, the patent converts the scrap into a beneficial resource by reusing it as raw material. This transforms the potential harm of waste disposal into the benefit of material recovery and reuse, preserving mechanical properties in the process.
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 method effectively recycles and reinforces prepreg scrap, enhancing mechanical properties and stability, allowing for the creation of high-quality composite parts with improved shelf life and environmental sustainability by avoiding the need for refrigeration and reducing waste.
Implementation Method 1
utilizing unsaturated polyester or vinylester resins with thermally-activated peroxides and free radical inhibitors
Implementation Method 2
co-molding the prepreg scrap and resinous thermosetting component together under a pressure of 25 to 4000 psi and at a temperature of 100-400° F.
Data Source
AI summary
A process for preparing a composite part, the process comprising: recovering unsaturated resin prepreg scrap; combining the recovered unsaturated resin prepreg scrap with a second resinous thermosetting component; and co-molding the prepreg scrap and resinous thermosetting component together under a pressure of 25 to 4000 psi and at a temperature of 100-400° F.