Periodic Reporting for period 2 - FOREST (Advanced lightweight materials FOR Energy-efficient STructures)
Período documentado: 2024-06-01 hasta 2025-05-31
To provide innovative green composites for sustainable & safer transport applications developing bio-based polymers, recycled fibres & new routes to synthesise green additives.
It proposes:
1. A critical study of sustainable indicators for biocomposite & analysis of the end-user requirements.
2. Adapting the new resins’ chemistries to the highly bio-based version & recovering fully recycled carbon fibre fabrics & validating at lab-scale the new semi-finished products.
3. Evaluating their potential to be manufactured by efficient OoA technologies applied to biocomposites & testing them at lab-scale & pilot plant level.
4. Tailoring the selected materials & processes route to demonstrate their technical feasibility & life-cycle sustainability at demonstration scale.
5. Establish a criterion for circular economy.
It proposes:
1. A critical study of sustainable indicators for biocomposite & analysis of the end-user requirements.
2. Adapting the new resins’ chemistries to the highly bio-based version & recovering fully recycled carbon fibre fabrics & validating at lab-scale the new semi-finished products.
3. Evaluating their potential to be manufactured by efficient OoA technologies applied to biocomposites & testing them at lab-scale & pilot plant level.
4. Tailoring the selected materials & processes route to demonstrate their technical feasibility & life-cycle sustainability at demonstration scale.
5. Establish a criterion for circular economy.
Among the main technical activities and results achieved, a significant progress developing a range of formulations of each of the the bio-based resins containing variable bio-content has been done and successfully tested at laboratory scale . BASF has manufactured several PA6 batches of <40 % of bio-based content within a range of viscosities for AIMPLAS to define the right grade for carbon fiber impregnation. ARKEMA has studied several monomers (mainly Sartomer and Cardolite) to obtain acrylic Elium resins with up to 24 % of bio content, which show good reactivity. BITREZ has the capacity to achieve 100 % bio-benzoxazines, although they have revealed that higher aromaticity favored improved thermal performance yet many of the high bio-content compounds detracted from the favored thermal properties the bio-content affects the curing and mechanical properties. IFAM has screened a range of benzoxazines by compression moulding to assess the best performance in terms of curing time/temperature vs. mechanical properties. On the other hand, AIMPLAS has achieved significant progress in the synthesis of bio-based PEC flame retardant by a mechano-chemical continuous method in terms of bio-based precursors supply and process stability. Last batches produced are being processed and their flame retardant properties studied by CLARIANT. Moreover, AIMPLAS has obtained poor yields developing an intrinsically flame retardant (FR) acrylic DOPO-based compound, which has led to synthesize DOPO-morpholine variants to add by mass into the resins. The fire resistance performance of these compounds is now being tested in combination with the resins and looking at possible synergistic effects with commercial FR alternatives. GEN2CARBON has developed fully recycled carbon fiber mats of grammages (50, 100, 200, 300 GSM), which have been tested in all different resins and processes. They have also started recycling long carbon fiber yarns aiming to be able to obtain continuous yarns shortly.
Preliminary designs of the demonstrators and the OoA manufacturing processes have been defined considering the critical requirements of the components and the current regulations. Also, JVERNE has started testing Elium based organosheets in a compression molding process with successful results. Moreover, JVERNE has initiated the overmoulding of these composites with thermoplastic compounds manufactured by AIMPLAS based on bioPA6 reinforced with Elium composites scrap. AIMPLAS has developed bioPA6-based UD-tapes with continuous carbon fiber and tested performance of different layups.
Preliminary designs of the demonstrators and the OoA manufacturing processes have been defined considering the critical requirements of the components and the current regulations. Also, JVERNE has started testing Elium based organosheets in a compression molding process with successful results. Moreover, JVERNE has initiated the overmoulding of these composites with thermoplastic compounds manufactured by AIMPLAS based on bioPA6 reinforced with Elium composites scrap. AIMPLAS has developed bioPA6-based UD-tapes with continuous carbon fiber and tested performance of different layups.
The FOREST project brings several groundbreaking results that extend beyond the current state of the art, with significant potential impacts across various industries. Key achievements include the development of sustainable flame retardants, bio-based resins, and innovative manufacturing processes, each offering distinct advantages in terms of performance, sustainability, and market competitiveness.
One of the primary results is the development, improvement, and validation of sustainable flame retardants. These biocomposites and flame retardants present a competitive alternative to traditional products, reducing reliance on petrochemical-based materials. The potential impact lies in creating eco-friendly, high-performance materials suitable for a wide range of applications. Market uptake will require further research, testing in real environments, and direct commercialization efforts.
The project also advanced the development and industrial production of a bio-acrylic Elium resin, a bio-based, recyclable liquid thermoplastic resin. This innovation offers a sustainable alternative to conventional resins, with significant implications for reducing environmental impact. To ensure market uptake, further research and process adaptations for various customer groups are necessary.
Another notable achievement is the development of basis resin formulations to enhance property profiles and meet industry processing requirements for continuous carbon fiber-reinforced PA pultrudates. This non-reactive, partially crystalline thermoplastic with bio content is tailored for continuous composite production. Successful market adoption will involve developing products, engaging with existing customers, and proving the resin's processability and performance.
The project has also made significant strides in bio-based benzoxazine formulations and their scalability. This new matrix system offers enhanced performance compared to current systems while reducing reliance on petrochemicals. Its potential impact includes providing a sustainable, high-performance material for composite parts. Further research and additional project applications will be necessary for market uptake.
Finally, the manufacture and development of flame retardant formulations using biobased materials represent a pioneering advancement. The project developed the first FR technology based on bio-based phosphorus, offering a fully renewable solution. This technology is ready for commercialization, with the potential to revolutionize the flame retardant market.
One of the primary results is the development, improvement, and validation of sustainable flame retardants. These biocomposites and flame retardants present a competitive alternative to traditional products, reducing reliance on petrochemical-based materials. The potential impact lies in creating eco-friendly, high-performance materials suitable for a wide range of applications. Market uptake will require further research, testing in real environments, and direct commercialization efforts.
The project also advanced the development and industrial production of a bio-acrylic Elium resin, a bio-based, recyclable liquid thermoplastic resin. This innovation offers a sustainable alternative to conventional resins, with significant implications for reducing environmental impact. To ensure market uptake, further research and process adaptations for various customer groups are necessary.
Another notable achievement is the development of basis resin formulations to enhance property profiles and meet industry processing requirements for continuous carbon fiber-reinforced PA pultrudates. This non-reactive, partially crystalline thermoplastic with bio content is tailored for continuous composite production. Successful market adoption will involve developing products, engaging with existing customers, and proving the resin's processability and performance.
The project has also made significant strides in bio-based benzoxazine formulations and their scalability. This new matrix system offers enhanced performance compared to current systems while reducing reliance on petrochemicals. Its potential impact includes providing a sustainable, high-performance material for composite parts. Further research and additional project applications will be necessary for market uptake.
Finally, the manufacture and development of flame retardant formulations using biobased materials represent a pioneering advancement. The project developed the first FR technology based on bio-based phosphorus, offering a fully renewable solution. This technology is ready for commercialization, with the potential to revolutionize the flame retardant market.