Fraunhofer Institute for Production Technology IPTResearch project "TherMono"
Recyclable materials for green lightweight production
In its European Green Deal, the European Union is aiming to create a climate-neutral Europe by 2050. Important steps towards implementing this political initiative are the efficient use of raw materials in lightweight construction production and the development of sophisticated recycling concepts. Lightweight construction materials such as composites, however, are often difficult to recycle as they consist of several materials with different properties. In the TherMono research project, Fraunhofer IPT and its project partners are developing sandwich materials that are not only recyclable, but can also be produced while saving resources.
Thermoplastics as a mono-material are recyclable
The two application scenarios underlying the project are furniture construction for interiors and the wall construction of transport vehicles. For cost or functional reasons, wood processing companies often use chipboard or wood fiber boards that are held together with binders and coatings made of formaldehyde resins. When heated, these wood composites produce CO2 emissions, which should be avoided. The box bodies of trucks often consist of sandwich materials with steel or glass fiber-reinforced plastic top layers and polyurethane, polypropylene or polystyrene foam cores. The material combinations used to date are difficult to recycle and there is no recycling in production.
In the TherMono project, recyclable thermoplastics that can be thermally joined without additional adhesives are used for both the cover layers and the core materials. As only one class of plastic is used in the entire sandwich, materials can be recycled at the end of their product life. In this way, the TherMono project contributes to reducing greenhouse gas emissions over the long term and using raw materials efficiently.
Heat and separate the foam core
In the project, Fraunhofer IPT is responsible for developing a heating system that does not melt the foam core of the sandwich, but only heats it to such an extent that it can be formed without collapsing. In addition to providing the system technology, Fraunhofer IPT is also developing the forming process, which consists of the following process steps: heating, transfer to the pressing system and shaping. Furthermore, Fraunhofer IPT will develop and implement end-to-end process chain networking for quality assurance.
Project partners
- Fraunhofer Institute for Production Technology IPT, Aachen, Aachen
- REHAU Industries SE + Co. KG, Erlangen
- TENOWO GmbH, Hof
- sustainable AG, München
Funding
The TherMono research project is funded by the Federal Ministry of Economic Affairs and Energy (BMWE) as part of the Lightweight Construction Technology Transfer Program (TTP LB).
Funding reference: 03LB2081A