AIMPLAS Develops Sustainable Flame-Retardant Coatings and Composites to Enhance Mobility Safety

In fields such as construction and mobility, it is crucial to obtain materials with good mechanical properties, lighter weight, and enhanced fire resistance. According to foreign media reports, the Spanish Plastics Technology Centre AIMPLAS is actively carrying out two major projects funded by the Valencian Institute for Competitiveness and Innovation (IVACE+i) and supported by the European Regional Development Fund (ERDF). These projects aim to sustainably develop new flame-retardant coatings and composite materials to improve safety in the home and transportation sectors.

On one hand, the main goal of the REFUGI project is to develop phosphorus-based flame retardants using mechanochemical processes, marking a significant step towards more environmentally friendly production technologies. These flame retardants are incorporated into varnish formulations specifically designed for wood, aiming to enhance the fire resistance of coatings used in the construction industry.

Carolina Acosta, Chief Researcher in the field of Mechanochemistry and Reactive Extrusion at AIMPLAS, stated: "In recent years, the use of flame-retardant varnishes has been on the rise, as they provide surface treatment effects almost identical to various wood coatings, while also offering excellent fire resistance. They can slow down the spread of fire and reduce fire hazards. Current research focuses on exploring different material sources, with priority given to renewable and recyclable materials for the production of these flame retardants."

This study was carried out in collaboration with Omar Coatings and Decomader Furniture, aiming to improve the production efficiency of flame retardants while reducing the environmental impact during their manufacturing and use.

Acosta stated: "Applying mechanochemistry to the production of these compounds is an innovative and promising approach that expands the possibilities of green chemistry and sustainable manufacturing. We are exploring multiple optimizations in flame retardant production through innovative synthesis processes, including minimizing solvent use, reducing resource consumption and reaction time, and maximizing process efficiency. Additionally, we are researching coating application techniques to achieve uniform and efficient distribution of flame retardants on wood-based substrates."

(Source: AIMPLAS)

High-performance flame-retardant composite materials

On the other hand, the NEOCOMP project focuses on developing high-performance flame-retardant composite materials using advanced manufacturing technologies. This involves producing various components through innovative industrial processes such as dry fiber placement (DFP) and additive manufacturing. These composite materials are required not only to exhibit excellent mechanical strength, durability, and flame retardancy, but also to significantly reduce environmental impact in the construction and transportation sectors.

Jaime Lozano, a researcher at AIMPLAS in the field of construction and renewable energy, stated: "We are developing new composite materials aimed at meeting requirements for energy efficiency, circularity, mechanical performance, and flame retardancy, thereby helping to reduce the environmental impact of industrial activities and promoting the transition towards a greener, more circular economy."

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, on one hand, support the efficient production of preforms with complex geometries; on the other hand, they enable the production of customized composite parts that combine enhanced mechanical properties, higher fatigue resistance, and excellent fire performance. This will open up new opportunities in sectors such as construction, automotive, and aerospace.

Industrial engineering service provider and composite product manufacturer Ziur Composites and 3D technology solutions company IT3D are collaborating on this research, aiming to significantly reduce environmental impact and improve fire safety in key mobility and construction infrastructure.