Periodic Reporting for period 1 - TESCOM (Tailored Lightweight Sandwich Composites with Multifunctional Properties and Good Designability: From Molecule-design to Structure-properties Relationship)
Período documentado: 2020-09-01 hasta 2022-08-31
In our TESCOM project, attention was put into how to improve the mechanical properties and flame retardancy of sandwich composites, both are related to the safety and are vital for some application in the aeronautic area and railway vehicles. Moreover, the new composite strategies was designed to endow the lightweight sandwich good designability and recyclability.
This project develop a novel recyclable lightweight foaming composites and sandwich composites which bring significant impact on European Society.
In this proposal, we are developing a new strategy that the lightweight core of sandwich composites can be recycled and reshaped, which endows good designability and recyclability for sandwich composites. High flame retardancy is only a selective challenge as well. The proposed way will improve the fire safety and multi-functions of lightweight composites, develop more energy-efficient and environmentally friendly composite products, and contribute to the scocial benefits of European Community. The proposed project will significantly contribute to the development of European expertise in high performace lightweight mateirals. In performing the research described in this proposal we are in fierce competition with other groups, but based on the strong complementary knowledge between Fellow and host we are confident that this proposal will be able to compete with the ongoing research efforts around the world and positively contribute towards European excellence in this area.
Objectives and overview of the action:
(1) To prepare a next generation sandwich composites that in-situ preparing the lightweight foam during the hot-press molding of sandwich composites.
(2) To reduce the glue waste during the manufacture of sandwich composites
(3) The polymer matrix can be tailored to improve the mechanical properties and fire performance of foaming cores
(4) The structure of foaming core can be tailored to improve the mechanical properties and fire retardant performance of foaming core and sandwich composites
(5)To establish the structure-property relationship between polymer matrix and composites; to reveal the mechanisms of performance improvement.
This project develop a novel recyclable lightweight foaming composites and sandwich composites which bring significant impact on European Society.
In this proposal, we are developing a new strategy that the lightweight core of sandwich composites can be recycled and reshaped, which endows good designability and recyclability for sandwich composites. High flame retardancy is only a selective challenge as well. The proposed way will improve the fire safety and multi-functions of lightweight composites, develop more energy-efficient and environmentally friendly composite products, and contribute to the scocial benefits of European Community. The proposed project will significantly contribute to the development of European expertise in high performace lightweight mateirals. In performing the research described in this proposal we are in fierce competition with other groups, but based on the strong complementary knowledge between Fellow and host we are confident that this proposal will be able to compete with the ongoing research efforts around the world and positively contribute towards European excellence in this area.
Objectives and overview of the action:
(1) To prepare a next generation sandwich composites that in-situ preparing the lightweight foam during the hot-press molding of sandwich composites.
(2) To reduce the glue waste during the manufacture of sandwich composites
(3) The polymer matrix can be tailored to improve the mechanical properties and fire performance of foaming cores
(4) The structure of foaming core can be tailored to improve the mechanical properties and fire retardant performance of foaming core and sandwich composites
(5)To establish the structure-property relationship between polymer matrix and composites; to reveal the mechanisms of performance improvement.
In the frame of this project, click polymerization method was used to synthesis a novel unsaturated polyester (UP) as a polymer matrix for the new tailored foaming composites. However, this attempt was failed, then a novel benzoxazine vitrimer (BO) resin was chosed to replace the UP resin. As a result, a novel tailored and recyclable foaming composites based on the BO resin was successfully prepared, which can be used as the core of sandwich composites. As a result, a lightweight BO vitrimer based foaming composites was prepared. It is bendable due to the introduction of S-S dynamic bond, which is crucial for preparing curved sandwich composites. The molding process of sandwich composites is less limited by the foam core as well. Furthermore, the BO foam can be reshaped into a curved structure under high temperature, and the curved structure can be fixed after cooling down, which based on the reversible generation-break principle of BO vitrimer dynamic S-S bonds.
The structure of foaming core can be tailored to improve the mechanical properties and fire retardant performance of foaming core and sandwich composites. The compressive strength of BO foam is lower than expected when it composed of 4 layer foaming sheets. With the increase of foaming layers, both density and compressive stress were increased. It shows that the compression stress of BO foam with 5 layers is in the same level with commercial plastic foam. This result suggests that the tailored structure of BO vitrimer foam brings good designability of the foam and the final sandwich composites. Furthermore, intumescent flame retardant was used to improve its fire performance as well.
After many attempts we found that the UP resins is not suitable for the two-step foaming process and it wasted almost 9 months of our time. Fortunately lots of experiences in foaming process were obtained and finally we found the right polymer matrix that the vitrimer with dynamic bond can be used to support the two-step foaming process. Moreover, we designed a benzoxazine vitrimer that was good match with our requirements in flame retardant performance and good recyclability. We tried our best to complete the preliminary exploratory work and prepare a prototype. Most of the major parameters of the novel recyclable and bendable foaming composites were investigated and an EU patent was submitted in July 2022. As a result, some papers are not yet published, but are planned to be submitted within 2022.
The structure of foaming core can be tailored to improve the mechanical properties and fire retardant performance of foaming core and sandwich composites. The compressive strength of BO foam is lower than expected when it composed of 4 layer foaming sheets. With the increase of foaming layers, both density and compressive stress were increased. It shows that the compression stress of BO foam with 5 layers is in the same level with commercial plastic foam. This result suggests that the tailored structure of BO vitrimer foam brings good designability of the foam and the final sandwich composites. Furthermore, intumescent flame retardant was used to improve its fire performance as well.
After many attempts we found that the UP resins is not suitable for the two-step foaming process and it wasted almost 9 months of our time. Fortunately lots of experiences in foaming process were obtained and finally we found the right polymer matrix that the vitrimer with dynamic bond can be used to support the two-step foaming process. Moreover, we designed a benzoxazine vitrimer that was good match with our requirements in flame retardant performance and good recyclability. We tried our best to complete the preliminary exploratory work and prepare a prototype. Most of the major parameters of the novel recyclable and bendable foaming composites were investigated and an EU patent was submitted in July 2022. As a result, some papers are not yet published, but are planned to be submitted within 2022.
In this project, we finally found a novel way to prepare a vitrimer based lightweight foam with good designability and flame retardant performance, which has high potentials to be used in the interior parts of aircraft, railway vehicle and automotive. So we design to apply for a patent firstly.
Within the frame of this project, the following innovative activities have been carried out:
- Method of synthesis of high performance benzoxazine vitrimer resin with high glass transition temperature (Tg).
- Method of preparation of recyclable and bendable BO vitrimer resin with high thermosatibilty compared with commercial polymer foam.
- Method of preparation of recyclable and reshapable sandwich composites.
After we submitted the patent application and disseminated our findings on the Linkedin of IMDEA Materials, several companies have noticed it and shown their interests.
I have participated in a Workshop Insight Gravity - ‘Market validation of IMDEA Materials' technologies’ organized by project manager’s office of IMDEA Materials in 05,Oct, 2022.
Furthermore, we will also hold a number of technology transfer seminars to find a best partner to promote this technology from lab to industry:
IMDEA Materials-Airbus workshop in recyclable lightweight composites;
IMDEA Materials-Abet Laminati S.p.A. workshop in recyclable lightweight composites.
Within the frame of this project, the following innovative activities have been carried out:
- Method of synthesis of high performance benzoxazine vitrimer resin with high glass transition temperature (Tg).
- Method of preparation of recyclable and bendable BO vitrimer resin with high thermosatibilty compared with commercial polymer foam.
- Method of preparation of recyclable and reshapable sandwich composites.
After we submitted the patent application and disseminated our findings on the Linkedin of IMDEA Materials, several companies have noticed it and shown their interests.
I have participated in a Workshop Insight Gravity - ‘Market validation of IMDEA Materials' technologies’ organized by project manager’s office of IMDEA Materials in 05,Oct, 2022.
Furthermore, we will also hold a number of technology transfer seminars to find a best partner to promote this technology from lab to industry:
IMDEA Materials-Airbus workshop in recyclable lightweight composites;
IMDEA Materials-Abet Laminati S.p.A. workshop in recyclable lightweight composites.