Covestro & Partner Recover Raw Materials by Chemical Recycling of PU Foam

Covestro and Recticel demonstrate the two main raw materials originally used in flexible polyurethane (PU) foam from mattresses can be recovered by chemical means to a high level of quality and purity from the outcome of Europe-wide research project "PUReSmart".

For the first time, a flexible foam sample has now been produced from fully recycled polyol and toluene diisocyanate (TDI), respectively. Both raw materials were obtained in Covestro’s pilot plant in Leverkusen.

Polyol & TDA Recovery by Chemolysis:

Unlike other chemical processes for recycling PU flexible foam, the process does not use fossil-based polyol. It requires only the pre-sorted foam from mattress waste, a glycol and an additive. During chemolysis, the polyol and toluene diamine (TDA), the precursor to TDI, are recovered in high purity and yield.

After reprocessing, they can be used again as often as required for the production of new PU flexible foams. This ensures a sustainable circular economy for PU flexible foam with a reduced CO2 footprint.

"With this we have fully achieved the goal of developing a technology to chemically recycle these products and convert polyurethane into a high-quality recycled material," says Bart Haelterman, R&D director at Recticel. "For the first time in history polyurethane is truly fitting into a circular economy." The European Union funded the PUReSmart project with six million euros over a four-year period under its Horizon 2020 research and innovation program (agreement No. 814543).

Development of Flexible Foam Recycling:

Building on the PUReSmart project, Covestro is working with partners from the waste management industry to drive the further development of flexible foam recycling through to industrial use.

"Our goal is to turn waste into valuable raw materials and to anchor the principle of the circular economy in our company and along the value chain with our partners to achieve this," says Christine Mendoza-Frohn, head of Performance Materials Sales EMEA & LATAM of Covestro.

"That’s why we make innovative recycling a priority. We call this ongoing Evolution of Recycling: Evocycle® CQ. The first initiative of this kind is dedicated to the chemolysis of PU mattress foam and is called 'Evocycle® CQ Mattress'. This underlines our willingness to further invest in this technology," says Mendoza-Frohn.

Source:Covestro/specialchem

Visit MY BLOG http://polymerguru.blogspot.com

#polyurethane #polyurethanefoam #recycling #circulareconomy

#mattresses #wastemanagement

Today's KNOWLEDGE Share: Translucent composite tiles

Today's KNOWLEDGE Share:

Translucent composite tiles for natural lighting and energy savings!

More than reducing the electricity bill, companies can improve their work environment by including these GFRP tiles, which have high thermal resistance, on their buildings!

In addition to opaque composite roof tiles, Planefibra is adding translucent versions to its product offerings, highlighting their advantage in providing natural lighting to reduce electricity use, while blocking direct solar radiation to prevent overheating in buildings. According to the company’s website, the translucent tiles are made from glass fiber-reinforced polyester and have UV protection film on both sides.

“Natural lighting strengthens the sustainable profile of companies because consuming less, under any circumstances, preserves the environment. It is also an important ally in improving workplace conditions,”

Depending on the dimensions of the building, the season of the year and the incidence of sunlight, that companies are able to reduce their energy bill by up to 95% with lighting during business hours when using its composite tiles. “To obtain this result, the ideal is to cover 10% of the shed area with translucent tiles.

With a minimum useful life of ten years, composite tiles have high thermal resistance. That is, even in places where the incidence of sunlight is high, there is said to be no risk of the roof deforming. Another advantage is the production of custom-made tiles, which adapt to the various existing roofing models. “Add to that the price, on average, 30% lower than polycarbonate tiles, the main competitor of those made of composites.

Source: CompositesWorld/ #managingcomposites #thenativelab
Visit MY BLOG https://lnkd.in/fcSeK9e

#composites #polyester #gfrp #tiles #lighting #roofing

Today's KNOWLEDGE Share: Solar Panels burning:

Today's KNOWLEDGE Share:

Solar Panels burning:
Solar panels typically do not burn on their own. However, if a malfunction or failure occurs within the solar panel system, it can lead to overheating and potentially cause a fire. This can happen due to a variety of reasons, such as faulty wiring, damage to the panel itself, or an electrical surge.

It's worth noting that incidents of solar panel fires are relatively rare and usually occur due to improper installation or maintenance. To prevent fires, it's essential to have a professional installer properly set up and maintain the solar panel system, ensuring all components are functioning correctly and safely. Additionally, it's important to follow proper safety guidelines when handling and installing solar panels.

Source:Capstone/renewable Energy experts
Visit MY BLOG https://lnkd.in/fcSeK9e

#solarenergy #solarpanels #maintenance #electrical #safety #burn
#solar #alternativeenergy #renewableenergy

Today's KNOWLEDGE Share:Lubricant:

Today's KNOWLEDGE Share:

Lubricant:

Some molding compounds contain a so-called "external lubricant". It is essentially a second immiscible polymeric material with a much lower viscosity.

What happens when you mold such materials ?

In extrusion things are quite obvious. The hydrodynamic forces push the dispersed lubricant to the surface of the die where they can act as expected and promote slip of the major phase polymer.

In Injection Molding the combination of the Fountain flow, moving inner flow layers to the very edge, and the presence of a frozen skin, create a more complex situation.

The high shear layer where lubricant will accumulate is INSIDE the frozen skin ! While this can still help to reduce the pressure to fill, this situation will also induce a serious risk of blistering/delamination.

This delamination was well known for instance in the Xenoy grade made of PC/PBT. But other compounds, containing for instance a silicon based lubricant, will produce the same result, as reported by some of my customers.

So, keep in mind that the lubricant (possibly necessary at the outer surface of the molded part if the intention is to control friction coefficient) doesn't quite go where you'd hope to see it.

Note that this delamination can also occasionally be observed in pure HDPE if the molecular weight is high enough. In this case the low molecular tail (waxes) will accumulate at the frozen skin interface, promoting delamination.

Source:Vito Leo

Visit MY BLOG http://polymerguru.blogspot.com

#injectionmolding #lubrication #plastics #polymerscience #medicaldevices #delamination #extrusion

Today's KNOWLEDGE Share:Failure Analysis of PC hub

Today's KNOWLEDGE Share:

Failure Analysis of PC hub

I recently completed a failure analysis on a polycarbonate hub used to secure a steel tube. A number of parts had cracked while undergoing engineering use testing in the laboratory. The fractographic examination, which included scanning electron microscopy (SEM), revealed fracture surface features that indicated that the parts failed though the application of stress at a high strain rate. It was concluded that the engineering testing produced rapid mechanical overload, in which the stresses exceeded the short-term strength of the material. Plastic materials, including polycarbonate, can undergo a ductile-to-brittle transition associated with high strain rate events.

The high strain rate failure mechanism was specifically identified in the SEM images by the presence of features known as river markings. They extended out from and bounded the crack origin. The crack origin area also displayed a relatively smooth texture, which was indicative of a brittle fracture mode. The cracking initiated with a design corner (yellow circle), which likely acted as a point of stress concentration.

Source:The Madison Group

Visit MY BLOG http://polymerguru.blogspot.com

#failureanalysis #plastics #fractography #SEM #polymerscience #materialsscience #polycarbonate #plasticengineering #crack #stress #fracture

Today's KNOWLEDGE Share: TYPES OF FIBERS

Today's KNOWLEDGE Share:

TYPES OF FIBERS

The different fiber types that can be used as reinforcement phases in composite materials.

Today we would like to share with you the definitions and examples of the most common fibers used in the industry! 

Carbon fibers are long and thin strands of material with about 0.005-0.010 mm in diameter, composed mostly of carbon atoms (more than 90% content). The carbon atoms are bonded together in microscopic crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment makes the fiber incredibly strong for its size. 

Glass fiber is a non-metallic material made from extremely fine fibers of glass. The base ingredients of glass fibers are forms of silica, mainly sand, limestone, stone ash and borax. It is also considered the oldest, and most familiar, performance fiber. 

Aramid (short for “aromatic polyamide”) fibers are synthetic fibers in which the fiber-forming substance is a long-chain synthetic polyamide that has at least 85% of the amide linkages attached directly to two aromatic rings. Its molecules are linked by strong hydrogen bonds that transfer mechanical stress very efficiently, making it possible to use chains of relatively low molecular weight. The most famous aramid fiber is DuPont's Kevlar. 

Polymer fibers are a subset of artificial fibers, which are based on synthetic chemicals rather than arising from natural materials by a purely physical process. Examples: PE fibers (Dyneema, Spectra), PP fibers (Innegra), PET fibers, polyester fibers and many others. Aramid fibers are also considered polymeric. 

Natural fibers are fibers that are produced by geological processes, or from the bodies of plants or animals. Examples: Hemp, jute, flax, kenaf, basalt, cotton,lyocell etc. 

Other fibers that we can mention: Boron fibers, metallic fibers (aluminum, titanium, steel) and ceramic oxide fibers. 

Now imagine the amount of possibilities when it comes to creating hybrid fabrics! 

Source:#managingcomposites #thenativelab

Visit MY BLOG http://polymerguru.blogspot.com

#composites #fibers #fiberglass #carbonfiber #kevlar #lyocell #jute #flax #cotton #metallicfibers #dyneema #petfiber #basalt #hemp

Solvay Launches New High-heat Polymer for EV Battery Components

Solvay has announced the introduction of a new high-heat and flame-retardant grade in the company’s Xydar® liquid crystal polymers (LCP) portfolio, which is designed to meet critical safety demands in EV battery components.

Retains Insulation Upon Exposure to 400°C for 30 Minutes:

The new Xydar® LCP G-330 HH material addresses challenging thermal and insulation requirements and is targeted particularly at battery module plates of EV models operating with higher voltage systems.

“As automakers are moving from 400V to 800V on next-generation electric vehicles, new regulations in Europe, China, the United States and other countries are increasing the demand on battery components to withstand temperatures from 300°C to 1000°C for an extended window of up to 15 minutes,” states Brian Baleno, head of marketing, Transportation at Solvay Materials. “Appropriate materials are expected to retain a level of electrical insulation protection that will provide sufficient time for passengers to exit the vehicle in a thermal runaway event. Our new Xydar® LCP grade combines this high safety potential with exceptional processability."

Xydar® LCP G-330 HH is a glass-filled LCP for injection molding capable of retaining its electrical insulation upon exposure to 400°C for 30 minutes. Xydar® LCP is an inherently flame-retardant polymer, without the use of halogen or bromine additives. In addition, it offers exceptional flowability and helps battery designers achieve thinner parts than possible with incumbent battery module insulation materials, such as polycarbonates or aerogels. It has been successfully tested with plates molded in typical dimensions of 100 x 150 x 0.5 mm.

Extends Portfolio of Battery Solutions:

Xydar® LCP has a proven fit in many electrical and electronic as well as coating applications. Besides automotive lighting components, sensors, solenoids and connectors, advanced examples in e-mobility include thin-wall slot liners used in the rotor design of an electric drive traction motor.

Xydar® LCP G-330 HH extends the portfolio of Solvay’s battery solutions, which also includes Solef® PVDF for binders and separators, Ryton® PPS for coolant line connectors and vents, and Amodel® PPA for connectors and busbars.

Source: Solvay/Omnexus.specialchem.com

Visit MY BLOG http://polymerguru.blogspot.com

#solvay #lcp #polymers #evbattery #insulation #electrical #electronics #materialsscience