CUBIC project aims to develop and validate at least 7 new circular by design biobased B2B intermediate semi-finished products:
- bioPA pellets
- bioPA micronized powder
- self-reinforced bioPA filaments/yarns
- bioPA UD-tapes
- bioPA organosheets
- bioCF endured filaments
- bioCF UD-tapes
The use of intermediate formats provides flexibility on the design and allows product designers to use them as selective reinforcement and matrix according to product needs. In addition, it permits to customise the materials obtaining end-products with increased quality and properties. B2B intermediates permit to boost manufacturing technologies for end-products based on unconventional/smart conformal technologies. In addition, to the operative innovations, digital innovations will be applied by the project’s partner IDENER, for the optimisation and smart control of materials processing using AI methods, support vector machine, genetic algorithm and artificial neural network. A database of bio-based polymers for B2B intermediates´ production and process simulation/optimisation will be created introducing CUBIC novel materials and recyclates for the very first time.
The main technologies in which the introduction of virgin and recycled biobased materials and their adaptation suppose a technological breakthrough are described below:
1.Melt spinning ofbicomponent-monomaterial self-reinforced composites followed by stamp forming or thermoplastic press consolidation.
Within CUBIC, two different routes will be explored:
- the development of monocomponent multifilaments of both high melting bioPA and low melting bioPA grades
- the development of bicomponent monofilaments with a core/ sheath structure where the core is a bioPA with a high melting point and the sheath is a bioPA with a low melting point
The core/ sheath ratio and titer of filaments will be adapted according to the end application. This technology will allow to obtain fibres able to compete with aramide ones (made of oil-based PA), obtaining high tenacity fibres in light sheet structures resulting in more impact resistant B2B intermediates.
2.Thermoplastic-Resin Transfer Moulding (T-RTM).
Within CUBIC project, novel grades of liquid bioPA precursors will be designed and developed to be processed in liquid composite moulding (LCM) technologies, in particular T-RTM. A challenge to overcome in CUBIC will be to optimise and control the whole temperature of the process without damaging the crystallinity of targeted structures.
3.Rotational moulding or rotomoulding.
Rotomoulding arises as an economical and free-to-design technology for the end application as long as the novel alternative bioPA-like suits in viscosity and permits adequate micronization. MOSES project’s partner, has experience in this technology with recycled and biobased polyolefins for large container parts and will bring knowledge and protocols to CUBIC.
4.Enduring impregnation in wet filament winding of bioCF.
Pre-impregnated semi-finished textile products (prepregs) usually consist of a flat textile reinforcement structure which is impregnated with the thermoset resin matrix. Instead of a textile sheet, it can also be a filament or other planar structure. In the CUBIC project, it is important not only to master the development of the 3R-CAN-bioepoxy formula, but also to ensure its application on top of targeted fibres and fabrics to ensure an industrializing manufacture process.
Within CUBIC, endured bioCF filaments, will be produced by project’s partner CIDΕTEC to obtain type IV pressure vessels for the first time. Thus, the pre-impregnation stage is integrated into the wet filament winding process, which is specific for this process. After the resin bath, the wet fibre application instrument moves back and forth along the length of a rotating mandrel, placing it onto the liner in a predetermined configuration. The bio-based 3R-CANs bioepoxy resin would allow manufacturing a new class of prepregs as ad-hoc cured prepreg filaments, that could still be valid for the fabrication of multilayered composite parts. This is referred in the project as an endured product, which makes it processable at room temperature and via a thermoforming process (by applying heat and pressure), making thermosets more accessible for high volume production manufacturing technologies.
In conclusion, CUBIC presents an innovative solution to improve the sustainability and circularity of complex products made of high-tech advanced multi-material composite structures, by developing novel biomaterials. The ultimate goal is to develop 100% circular by design biobased and recyclable thermoplastic and thermoset B2B intermediate products.
Click here to learn more about the project’s objectives and read the 1st article here. Also, you can watch CUBIC’s video on its YouTube channel.
