Sustainable production of high performance composite fibres

This project aims to reduce the total cost of carbon fibre composite production through the inclusion of sustainably produced technical fibres into CF/composites. The new fibres are produced largely from sustainable feedstocks whose base performance is dramatically enhanced by the first use of a new superheated ethanol impregnation process. This highly efficient step allows the production of stiff, light and strong fibres with excellent and broad resin and polymer compatibility. The improved compatibility is brought about by the impregnation of naturally sourced fibres with styrene and acrylate materials whose chemical properties are enhanced by the scaffold like support of the natural fibres whose structure they reinforce. The highly efficient process developed with the aid of FP7 funding results in low production costs enabling significant saving on CF composite production and an opportunity to extend the markets in which CF can be used. PJH technology can help meet the demand for lower costs. It seeks to demonstrate the scalability of its process, already proven at small scale, through a prototype development project which will deliver alternative feedstock at lower cost.
The project reduces the CF used and energy required to make composites. The incorporation of specially treated renewably sourced fibres into CF blends within composites reduces costs without reducing the mechanical properties of the end product. It also reduces the quantity of CF by up to 30% and energy costs by 20%. The process also reduces total CO2 emissions relating to CF production whilst allowing for the potential for additional material applications in the wider technical composite market potentially helping to significantly broaden the CF market. We now seek to scale-up the project by developing a prototype that can generate larger quantities of treated fibre for full industrial testing and to act as a test bed unit for the development and sale of larger scale equipment.