To reduce its dependency on fossil raw materials, Covestro is looking to manufacture a growing number of products and their associated precursors from renewable raw materials. Working with four partners,(1) the company is aiming to develop bio-based reinforcing layers for solid wood construction materials to replace the petrochemical products used to date.
The polyurethane system, which is reinforced with cellulose fibers, is to be more than 90 percent bio-based, contain zero additives and exhibit excellent flame retardance and weathering resistance. The project is being supported by the German Federal Ministry of Food and Agriculture (BMEL) through the project sponsor, Fachagentur Nachwachsende Rohstoffe e.V. (Agency for Renewable Resources, FNR).
State-of-the-art solid timber construction techniques are increasingly coming to dominate our urban spaces. The main materials used to manufacture construction elements are cross-laminated timber and glued-laminated timber. Both materials consist of alternate layers of wood and thinly spread polyurethane resin. If aramid, glass or carbon fibers are embedded into the layers of resin, they create reinforcing segments that further enhance the stability of the construction elements.
Over the course of the recently launched project, the researchers want to find bio-based alternatives to the fossil-based resins and fibers that have been used to date. They are pursuing a combination of biogenous, aliphatic polyisocyanates and polyols based on vegetable oils. The resultant polyurethanes should exhibit low flammability and good weathering resistance, so that no special additives are needed to enhance either property.
When it comes to reinforcement, the scientists favor cellulose fibers such as those extracted from regenerated cellulose. “At the end of this process, we will have the first ever reinforcing materials for use in timber construction that are made up of at least 90 percent renewable raw materials,” says Dr. Paul Heinz from Covestro, who is coordinating the research project. This, he claims, will make state-of-the-art timber construction with cross-laminated and glued-laminated timber even more sustainable.
Continuous production by pultrusion
When it comes to manufacturing the construction elements, the project partners have opted for pultrusion, a continuous industrial production process for highly filled, continuous fiber-reinforced composite profiles. Pilot facilities run by the Fraunhofer Institute are being used to manufacture flat profiles for testing and optimizing the necessary tools and process parameters.
During the project, Sortimo will produce an industry-standard model component that will then be used to evaluate the technical, economic and ecological potential of the new material and production process for the construction industry. Beech wood is being used for the component, as this material is becoming available in growing volumes due to forest restructuring.
Information is available in the Projektförderung menu at www.fnr.de, the website of the project sponsor, under the following FKZ project ID numbers:
• 22022616 – Coordination, Modification of the Bio-Based Polymer Matrix
Covestro Deutschland AG
• 22003517 – Implementation of Development Work in an Industrial Demonstration Plant
Sortimo International GmbH
• 22003617 – Investigations into the Use of Bio-Based Reinforcing Fibers
German Institutes of Textile and Fiber Research Denkendorf (DITF)
• 22003717 – Process Development for the Production of Reinforcing Segments
University of Stuttgart, Institut für Kunststofftechnik (IKT)
• 22003817 – Running the Pilot Pultrusion Plant and Process Evaluation
Fraunhofer Institute for Chemical Technology (ICT)
With 2016 sales of EUR 11.9 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 15,600 people (calculated as full-time equivalents) at the end of 2016.
Find more information at www.covestro.com and www.fnr.de.
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(1) The partners are Sortimo International GmbH, the German Institutes of Textile and Fiber Research Denkendorf (DITF), the Institut für Kunststofftechnik (Institute for Plastics Engineering, IKT) at the University of Stuttgart and the Fraunhofer Institute for Chemical Technology (ICT).