Researchers in Switzerland have unveiled a recyclable epoxy resin that enables reuse of composite materials in aircraft and wind turbines.
Scientists in Switzerland have recently come up with a recyclable epoxy resin that could greatly slash plastic production from aircrafts, cars and wind turbine s which until now were almost impossible to reuse.
Led by Arvindh Sekar, PhD, a researcher at Empa’s Advanced Fibers laboratory in St. Gallen, the team collaborated with the Swiss Federal Laboratories for Materials Science and Technology to find a way to recycle epoxy-based thermosets without compromising their strength.Epoxy resin is a clear, robust polymer that’s widely used in coatings, adhesives, as well as fiber-reinforced composites found in aviation, automotive manufacturing, sports equipment and renewable energy infrastructure. When cured, traditional epoxy can not be remelted or reshaped. This left disposal by incineration or landfill as the end-of-life options. To address the issue the team created a new epoxy resin that can be reprocessed and chemically recycled, while also being flame-retardant and straightforward to manufacture.A recycling breakthroughWhile many plastics such as PET, HDPE and PVC are recyclable to a degree, epoxy resin isn’t. It belongs to a group of polymers, known as thermosets, whose long molecular chains are cross-linked, meaning they cannot be melted down again after initial curing. “Today, we only have two options for disposing of epoxy resin: incineration or landfills,” Sekar stated. Yet, this durable plastic is widely used in coatings and adhesives, as well as in fiber-reinforced materials combined with carbon or glass fibers for aircraft, car parts, sports equipment and wind turbines.To overcome these limitations, the researchers successfully created a phosphorus-based recyclable epoxy resin. “Phosphorus-based additives are commonly used as flame retardants,” Sekar continued. “Normally, they are simply mixed into the epoxy resin as a powder.”The researchers subjected the flame-retardant polymer to fire tests.Credit: EmpaBy integrating the phosphorus-containing polymer directly into the epoxy before curing, the team made a flame-retardant, reprocessable and chemically recyclable resin. The phosphorus plays a dual role. Not only does it improve fire resistance, but it also allows the polymer’s internal cross-links to shift when heat is applied.This means the cured epoxy can be ground into powder and reshaped multiple times using heat and pressure, through a process known as thermomechanical recycling. “We have carried out ten such recycling cycles, and the epoxy has not lost any significant mechanical strength in the process,” Sekar pointed out. At the same time, in fiber-reinforced composites like carbon-fiber aircraft parts and wind turbine blades, the epoxy can be dissolved to recover fibers with little to no damage. “In addition to the fibers, we can also recover over 90 percent of the epoxy and phosphorus,” Sekar said. From landfills to reuseWhile chemical recycling is energy-intensive and requires solvents, the scientists stressed it should be used only when thermomechanical recycling is not possible. For fiber composites, however, there has been no viable alternative until now.“Chemical recycling should always be the last resort,” Sekar said in a press release. “Thermomechanical recycling is preferable wherever possible.” The scientists have spent several years refining the material and have now optimized the production process for industrial-scale manufacturing. They are actively seeking commercial partners to bring the technology to market. According to the researchers, early applications could potentially include indoor and outdoor coatings, where fire resistance and durability are critical. Researcher Arvindh Sekar, PhD, with the epoxy resin that is both flame-retardant and recyclable.Credit: EmpaWind turbine construction is another promising application. Epoxy adhesives play a significant role in joining blades and structural elements, but also pose major challenges during maintenance and decommissioning.Wind turbines are particularly vulnerable to fire caused by lightning strikes or electrical faults. “In addition to improving fire safety, our material would facilitate maintenance and component replacement because it can be reshaped under the right conditions even after curing,” Sekar concluded. The study has been published in the Chemical Engineering Journal.
EMPA Epoxy Resins Innovation Phosphorus Physics Recycling Science Sustainability Wind Turbine
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