Periodic Reporting for period 1 - CUBIC (Improving the cirCUlarity of complex plastic multi-material composites using novel BIobased materials in B2B semi-finished produCts)
Periodo di rendicontazione: 2023-09-01 al 2025-02-28
The objective of CUBIC is to improve the sustainability and circularity of complex products made of high-tech advanced multi-material composite thermoset and thermoplastic structures, by developing novel circular biobased alternative materials. These materials are thought to be manufactured as B2B intermediate semi-finished products that once combined or assembled into final end-user products contribute to increase the renewable carbon-based flows uptake which are easily adaptable to new market products and demands, enabling the decentralisation in the European manufacturing industry and boosting a twin green and digital transformation. The novel approach on which CUBIC project relies is based on modularity or pre-fabrication: the development of high-tech biobased intermediate formats (filaments, sheets, organosheets and UD-tapes, pellets, powder...). The smart combination of these intermediates into a final end-product overcomes the current technical and environmental limitations to meet the demanding requirements of a specific sector or application where a single biobased material does not. The synergistic potential of composite materials will be multiplied by the possibility of combining different intermediate formats to pave the way for the integration and uptake of bio-based materials in mass customised manufacturing.
During the first 18 months of the project, the work has been focused on developing three bio-based materials: 3R-bio-epoxy system, bio-carbon fibre and different grades of bio-polyamide:
3R-bio-epoxy system: In a first stage, different biobased epoxy building blocks have been synthesized. Three of them have been upscaled to 120g scale and impregnation was tested. Then, dynamic biobased building blocks were also designed and synthesized. A dynamic biobased hardener is under development.
Bio-polyamide: four different bioPAs were developed using three different monomers to meet the processes requirements. In addition, analytical methodologies were refined to ensure accurate and reproducible characterisation of the materials.
Bio-based carbon fibre: several tests have been performed to develop carbon fibres from i) the dry-spinning process of lignosulfonate salts in water, and ii) melt and wet spinning of lignin-TPU blends.
But also, some work has been completed in developing intermediate formats from the bio-based materials synthesized in the project:
Micronized bioPA powder: reference and project bioPA have been micronised using different parameters and their particle size distribution has been analysed.
Self-reinforced bioPA yarns: benchmark polyamide grades have been extruded and tested.
Endured bio-CF filaments: first impregnation trials were conducted using bioEPO from the project and the first towpreg samples were obtained.
3R-bio-epoxy system: In a first stage, different biobased epoxy building blocks have been synthesized. Three of them have been upscaled to 120g scale and impregnation was tested. Then, dynamic biobased building blocks were also designed and synthesized. A dynamic biobased hardener is under development.
Bio-polyamide: four different bioPAs were developed using three different monomers to meet the processes requirements. In addition, analytical methodologies were refined to ensure accurate and reproducible characterisation of the materials.
Bio-based carbon fibre: several tests have been performed to develop carbon fibres from i) the dry-spinning process of lignosulfonate salts in water, and ii) melt and wet spinning of lignin-TPU blends.
But also, some work has been completed in developing intermediate formats from the bio-based materials synthesized in the project:
Micronized bioPA powder: reference and project bioPA have been micronised using different parameters and their particle size distribution has been analysed.
Self-reinforced bioPA yarns: benchmark polyamide grades have been extruded and tested.
Endured bio-CF filaments: first impregnation trials were conducted using bioEPO from the project and the first towpreg samples were obtained.
Within CUBIC project, two complex end-products which are neither sustainable nor recyclable have been selected to demonstrate the potential of the materials, intermediates and technologies developed, building up two value chains (in packaging and automotive sector) and opening replicability options in many others.
CUBIC project designs novel materials to obtain circular by design biobased and recyclable thermoplastic and thermoset B2B intermediates that permits eco-design of complex products adapting their intrinsic characteristics to novel unconventional manufacturing processes as new paradigm to advance the mass production of advanced products. These are divided into: i) innovations related to sustainable biobased materials, ii) unconventional manufacturing processes that permits the design, production and diversification of B2B intermediate products; and iii) the combination of the previous innovations give rise to the eco-design of Safe and Sustainable bt Design and circular end-products that permits the substitution of a multitude of current complex products which are neither biobased nor recyclabe at all.
The results will be demonstrated through the development and manufacturing of two products:
1. Pressure vessel for carrying gas. It is formed by a bioPA liner and a wrapping layer of endured 3R-CAN-bioepoxy and bioCF. It will be a 100% sustainable and circular product, being remanufacturable, recyclable and upgrading the waste hierarchy.
2. Automotive seats. It is formed by a bioPA organosheet infused with bioPA wetting coverture, manufactured by T-RTM technology. Showing a sustainable alternative (aiming at 100% biobased material) and being 100% recyclable through chemical recycling, upgrading in waste hierarchy.
The main innovations of the project are:
1. Sustainability related to material science: development of 100% biobased 3R-CAN-bioepoxy system, different biopolyamide grades and carbon fibre from lignin
2. Adapting manufacturing processes related to low maturity unconventional technologies that allows obtaining a broad range of novel B2B intermediates and final products: enduring impregnation in wet filament winding of bioCF, melt spinning of bicomponent-monomaterial self-reinforced composites followed by stamp forming or thermoplastic press consolidation, thermo-resin transfer molding and rotomolding
3. Reaching functionality through modularity; the manufacturing of B2B intermediate formats opens the possibility of developing a wide range of end-products
CUBIC project designs novel materials to obtain circular by design biobased and recyclable thermoplastic and thermoset B2B intermediates that permits eco-design of complex products adapting their intrinsic characteristics to novel unconventional manufacturing processes as new paradigm to advance the mass production of advanced products. These are divided into: i) innovations related to sustainable biobased materials, ii) unconventional manufacturing processes that permits the design, production and diversification of B2B intermediate products; and iii) the combination of the previous innovations give rise to the eco-design of Safe and Sustainable bt Design and circular end-products that permits the substitution of a multitude of current complex products which are neither biobased nor recyclabe at all.
The results will be demonstrated through the development and manufacturing of two products:
1. Pressure vessel for carrying gas. It is formed by a bioPA liner and a wrapping layer of endured 3R-CAN-bioepoxy and bioCF. It will be a 100% sustainable and circular product, being remanufacturable, recyclable and upgrading the waste hierarchy.
2. Automotive seats. It is formed by a bioPA organosheet infused with bioPA wetting coverture, manufactured by T-RTM technology. Showing a sustainable alternative (aiming at 100% biobased material) and being 100% recyclable through chemical recycling, upgrading in waste hierarchy.
The main innovations of the project are:
1. Sustainability related to material science: development of 100% biobased 3R-CAN-bioepoxy system, different biopolyamide grades and carbon fibre from lignin
2. Adapting manufacturing processes related to low maturity unconventional technologies that allows obtaining a broad range of novel B2B intermediates and final products: enduring impregnation in wet filament winding of bioCF, melt spinning of bicomponent-monomaterial self-reinforced composites followed by stamp forming or thermoplastic press consolidation, thermo-resin transfer molding and rotomolding
3. Reaching functionality through modularity; the manufacturing of B2B intermediate formats opens the possibility of developing a wide range of end-products