Postponed differentiation of reinforced composites
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity in the reinforced polymer composite chain due to the need for customized sizing compositions for specific matrix materials leads to a wide variation, resulting in a heterogeneous structure and deterioration of mechanical properties, making it beneficial to simplify the process with a reduced number of sizing compositions that can be used with a wide range of components without changing the manufacturing process.
Innovation Solution
A chemical treatment is applied to the reinforcement fibers or fabrics, including surfactants, low melting point polyamides, and reactive compounds, to increase compatibility with various matrix materials, such as thermoset and thermoplastic materials, allowing for postponed differentiation and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If customized sizing compositions are used for specific matrix materials, then compatibility between reinforcement and matrix is improved, but device complexity and supply chain organization become more complex
Solution Approach 1:
The patent applies universality by developing a single standardized sizing composition that can be used across multiple matrix material types (thermoset, thermoplastic, and combinations). This eliminates the need for customized sizing compositions for each specific matrix material, thereby reducing plant and supply chain complexity while maintaining compatibility. The sizing composition contains components designed to work effectively with various matrix materials without requiring separate formulations.
2Reliability
If multiple sizing compositions are used for different matrix materials, then compatibility is improved, but manufacturing process complexity increases
Solution Approach 1:
The standardized sizing composition is designed to be universally applicable to thermoset, thermoplastic, and combination matrix materials. This single composition replaces multiple customized sizing compositions, simplifying the manufacturing process by eliminating the need to select and apply different sizing compositions for different matrix types, thereby reducing process complexity while maintaining effective compatibility.
3Reliability
If customized sizing compositions are used for each matrix material, then bonding compatibility is improved, but the number of sizing compositions and variety of components increases
Solution Approach 1:
The patent reduces the number of sizing compositions from multiple customized formulations to a single standardized composition. This standardized sizing composition contains a specific set of components (including compatibilizers, coupling agents, and lubricants) that are designed to provide effective bonding compatibility across thermoset, thermoplastic, and combination matrix materials, thereby eliminating the need for a large variety of specialized sizing compositions.
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 chemical treatment enhances compatibility and mechanical performance by at least 15% compared to conventional composites, reducing the need for multiple sizing compositions and improving the bonding between fibers and matrix materials, leading to standardized forming processes and cost reduction.
Implementation Method 1
the chemical treatment includes one or more of a surfactant, a low melting point polyamide, a reactive compound, and a plasma
Implementation Method 2
the chemical treatment includes one or more of a surfactant, a low melting point polyamide, a reactive compound, and a plasma
Implementation Method 3
the chemical treatment includes one or more of a surfactant, a low melting point polyamide, a reactive compound, and a plasma
Data Source
AI summary
A reinforced composite is provided that includes at least one planar fiber reinforcement or fabric formed from a plurality of fibers. The fiber reinforcement or fabric has a first side and a second side. The reinforced composite further includes a chemical treatment coated on at least one of said first side and second side and a matrix material.