AIIMPLAS Develops Sustainable Flame Retardant Composites

On one hand, the main objective of the NEOCOMP project is to develop high-performance flame-retardant composites using advanced manufacturing technologies. This involves producing various parts through innovative industrial processes such as dry fiber placement (DFP) and additive manufacturing. These composites must not only deliver high performance in terms of mechanical strength, durability, and flame retardancy but also make significant contributions to reducing the environmental impact of construction and transportation.

Specifically, NEOCOMP will develop flame-retardant thermoplastic adhesives for dry fibers, unidirectional dry fiber tapes for DFP, and continuous reinforced 3D tows. These new manufacturing methods will, on one hand, enable the efficient production of preforms with complex geometries, and on the other hand, will be capable of producing customized composite parts with improved mechanical properties, higher fatigue resistance, and excellent fire resistance. This will bring new opportunities to fields such as construction, automotive, and aerospace.

Ziur Composites and IT3D are collaborating on this research to significantly reduce environmental impact and enhance the fire safety of key transportation and construction infrastructure.

On the other hand, the REFUGI project aims to develop phosphorus-based flame retardants using mechanochemical processes, representing a step towards more environmentally friendly methods. These flame retardants are being integrated into varnish formulations specifically designed for wood. The strategy aims to improve the fire resistance of coatings used in the construction sector.

Carolina Acosta, Chief Researcher in Mechanochemistry and Reactive Extrusion at AIMPLAS, explained: "In recent years, the use of flame-retardant varnishes has increased because they offer finishes almost identical to any wood coating while providing greater fire resistance, delaying the spread and impact of fires. We are focusing on exploring different material sources to produce these flame retardants, prioritizing those that are renewable and recyclable."

This study was carried out in collaboration with Omar Coatings and Decomader, aiming not only to improve the efficiency of flame retardant production but also to reduce the environmental impact associated with the manufacturing and application of flame retardants.

"The application of mechanochemistry in the production of these compounds represents an innovative and promising approach, expanding the possibilities of green chemistry and sustainable manufacturing. We are looking for innovative methods to synthesize flame retardants using processes that minimize solvent use, require fewer resources and reaction time, and maximize efficiency. Additionally, we are researching coating application techniques to enable flame retardants to be distributed evenly and effectively on wood substrates," Acosta added.

These two projects are part of the IVACE+i funding program, which is carried out in collaboration between the technology centers and companies of the Valencian Community, intended for non-economic R&D projects in 2024, funded by the EU ERDF under the 2021-2027 operational program.