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Development of an innovative bio-based resin for aeronautical applications
| Project identifier: | EU_BONUS_12-1-2012-0026 |
|---|---|
| Project coordinator: | Marosi György |
| Coordinator department: | Department of Organic Chemistry and Technology |
| Duration: | 2012. August 1. – 2014. February 28. |
| Total cost of the project: | 101.495.684 Ft |
| Total cost of BME (project funding): | 101.495.684 Ft (15.224.965 Ft) |
Objectives
Due to the high quality requirements of this field this challenge is much larger than in other industrial segments, therefore the use of functionalized plant oils alone as bio-components of matrices in aeronautical composites is not enough. According to our concept flame retarded special hybrid thermosetting polymer system has to be prepared using bio-based components. Innovative combination of new ideas of resin synthesis including click chemistry and sol gel reactions (providing flexibility of organic component balanced with hardness and thermal stability of the inorganic component), patented environmentally friendly reactive flame retardant components and modification of natural fibre by (patented) organic chemical and/or enzymatic method will result in bio-based epoxy composites of highly enhanced performance. The knowledge of a recently patented idea will be adapted to improve the recyclability of thermosetting bio-composites. The robustness of the technology will be ensured by process controlled reactors equipped with unique spectrometric feedback. The team of proposers includes various research groups of Budapest University of Technology and Economics (BME), whose activities (preparative green chemistry, enzymatic reactions, reactive fire retardancy, hybrid bio-composites, and innovative structural and mechanical evaluation) complete each other. The experiences of the proposers acquired in realization of another current CleanSky project represent a good starting point for achieving the required scientific and technical quality.
Results
The development tendency of the replacement of traditional mineral oil-based plastics with innovative bio-based resin systems is nowadays characteristic for many segments of the industry; however, for aeronautical applications (interiors and/or structures) the challenge is much larger than elsewhere. To meet this challenge, in most cases, a flame retarded special thermosetting polymer system has to be prepared using bio-based components. Thermosetting resins have a number of advantages, such as high modulus (stiffness), high heat distortion temperature and excellent solvent resistance, therefore in this project bio-epoxy resin composites with these advantages were planned to develop.
The project aims at providing replacement for petroleum-based plastics, conventionally used for aeronautical applications (internal and external elements as structural materials), through development and synthesis of new and innovative bio-based composites. Because of extreme working conditions in the field of aeronautical applications, the quality and safety requirements are considerably high; therefore researchers face major challenges in fulfilling them.
The new type of epoxy biomaterials to be produced in the frame of this project must meet the high requirements of aviation. In the course of the synthesis different types of carbohydrates are used as starting materials, which are renewable biomaterials and do not compete with the food industry. There is a possibility for producing them economically from sorghum furthermore in the recent decade large oversupply of sugar supports the industrial utilization. Innovative chemical methods are used for manufacturing resin components in order to improve the properties of the resin, including mechanical stability, reduced combustibility, and reduced water uptake. The process of component synthesis is designed considering the principles of green chemistry, energy efficiency, opportunities to scale up, environmental and health protection. Qualification and selection of the right combination of compounds needs to be verified based on complex criteria including the structural, chemical, physical and mechanical properties, flammability, and ageing features. For applying biocomposites as structural materials natural fibre/fabric is planned to be used. These composites need to achieve improved mechanical strength thus their efficiency must be optimized by surface treatment. Resin system selected during the project will be up-scaled using newly developed, Raman spectrometer response governed computer-controlled reactor.