Innovative Coatings and Adhesives for Recycling (I-CARE)

Lead Research Organisation: University of Sheffield
Department Name: Chemistry

Abstract

Polymers are all around us and although they are an integral part to the development of the global economy, many materials are only used once. Waste production in the UK is a significant issue with 80% of materials used in manufacturing products ending up as waste, landfill approaching capacity and a 40% increase in consumer waste projected between 2016 and 2020. Against a backdrop of sustainability and the need to reduce environmental impacts, recycling, re-use and remanufacture are becoming ever more important. This Fellowship will develop smart polymers that provide high performance and also enable recycling, which will be a unique approach in the UK to a circular economy. The goal of the programme is to work with academic and industrial partners to develop a key body of knowledge via high quality underpinning science and correlating the molecular architecture of the new materials with their basic physical properties and the application performance important to the end use, in addition to designing the relative compatibility between polymers to optimise their form and ultimate properties.

Planned Impact

Industrial Partners and Supply-chain
As the Fellow has an extensive industrial background there are opportunities to capitalize on these networks by working with companies across the supply chain who will benefit from this research. Companies in the supply chain will cover polyurethane and acrylic coatings and adhesives, including manufacturers of raw materials, manufacturers of polymers and users of polymers. A significant outcome of the project will be the development of new smart polymers and a strengthening of the UK (and wider) supply chain by underpinning technical capability with the development of advanced materials for manufacture, which are sympathetic to the environment from a life cycle impact perspective and reductions in waste.

Environmental benefits
Waste production in the UK is a significant issue with 80% of materials used in manufacturing products ending up as waste, landfill is approaching capacity and a 40% increase in consumer waste is projected between 2016 and 2020. The development of smart polymers that provide high performance but also mitigate environmental impacts will play key role in contributing to UK society helping to achieve waste reductions and CO2 emission targets, which are also legislated at the European level (Waste Framework Directive and the EU Climate and Energy Package 2020).
As this programme includes a collaboration with the Jaguar Land Rover and their supply chain the research will contribute to their light-weighting agenda to increase fuel efficiency and to reduce CO2 emissions. Light-weighting is an effective way of cutting greenhouse gas emissions as it has significant potential to contribute towards meeting European targets to reduce emissions by 20% by 2020.
 
Description 1st demonstration that reversibly crosslinked adhesives can be thermally triggered to separate substrates and re-used repeatedly to produce the same performance. The materials are potentially industrially scalable.

Very high bond strengths from new thermoplastic adhesive materials (unusual).

Design of new routes to crosslinked materials which are thermally reversible, including Incorporation of non fossil fuel resources.

Potential to adapt the design of reversible polymers to be suitable for other materials/applications, i.e. not only adhesives but e.g. for elastomers and composites.
Exploitation Route Initial findings published in high impact journal (Green Chemistry)
As progress develops, the intention is to use the knowledge generated
- to develop dialogue with potential collaborators interested in polymers which perform in service but which can be re-used at the end-of-life.
- to develop collaborations with other academic partners.
Sectors Aerospace, Defence and Marine,Construction,Energy,Environment,Transport

 
Description Doctoral Training Programme
Amount £80,000 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2022 
End 04/2026
 
Description EPSRC Doctoral Training Centre
Amount £80,000 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2018 
End 09/2022
 
Description Faculty of Science - Funded Studentship
Amount £80,000 (GBP)
Organisation University of Sheffield 
Sector Academic/University
Country United Kingdom
Start 10/2021 
End 03/2025
 
Description New Functional Thermoplastic Polymers to Enable Recycling
Amount £70,000 (GBP)
Funding ID 2297687 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2018 
End 03/2022
 
Description New Thermoplastic Polyurethanes for Security Applications
Amount £90,000 (GBP)
Funding ID 2298895 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2019 
End 09/2023
 
Description Polyurethane Foams as Synthetic Soils for Horticulture: food quality and end-of-life recycling
Amount £90,000 (GBP)
Funding ID 2559088 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2020 
End 04/2024
 
Description "Plastics, Redefining Single Use" (EPSRC) as part of the Plastics Research Innovation Fund (PRIF) followed by "Many Happy Returns" (NERC) 
Organisation University of Sheffield
Department Grantham Centre for Sustainable Futures
Country United Kingdom 
Sector Academic/University 
PI Contribution Part of the Management Steering Group and helped to develop a Proof-of-Concept on Re-Use involving both behavioural and technical studies. Identified that an Industrial Packaging Expert (Sarah Greenwood) with detailed applied knowledge would provide a strategic advantage to the PRIF project. Arranged employment for this expert via additional HEIF funding via (a) short-term consultancy contract and (b) a 12 month fixed term contract (£60,000). With my support, Sarah fully achieved what was planned in the original business case: 1. Led a Proof-of-Concept study on reusable packaging, collaborating with key external stakeholders - including M&S and Unilever. 2. Supported external credibility of the PRIF output via her involvement as a known Packaging Expert, including being co-author of publications. 3. Helped secure a successful UoS bid to the ISCF Wave 3 on Sustainable Packaging, "Many Happy Returns" funded by NERC The aim of the "Many Happy Returns" research is to make sustainable reuse of plastic packaging mainstream by identifying the best reuse model for different contexts, exploring the optimum materials, process and technologies for smart reusable plastic packaging systems, and developing practices to encourage reuse. My role is to use my expertise and design critical experiments to evaluate the durability of different materials in order to select the best for re-use.
Collaborator Contribution Competency and Capability Teams (CCT) were built in the following areas: 1. Technological Feasibility. 2. Environmental and Techno-economic Assessment. 3. Understanding social change. 4. Enabling behavioural, organisational, and social change. By engaging stakeholders from a range of businesses (polymer producers, packaging manufacturers, FMCG companies, retailers,recyclers) and policy makers (DEFRA, BEIS) via a number of workshops, Proof of Concept Studies (PCS) were developed on three topics: 1. Re-use (v recycling) of consumer waste. 2. Medical Waste. 3. Agricultural waste.
Impact Paper presented at PRIF conference and article submitted for publication. The project draws together existing expertise from 15 academic departments across all five faculties of the University (Science; Engineering; Social Science; Medicine, Dentistry and Health; Arts and Humanities).
Start Year 2019
 
Description ReDisCoveR - identifying opportunities for sustainable composites - Recycling, Disassembly, Circular Materials 
Organisation National Composites Centre (NCC)
Country United Kingdom 
Sector Private 
PI Contribution Contribution to discussion around the 24 projects that have been scoped. In particular focus on reversible joints helping to identify potential for two projects; one looking at exploiting readily available technologies and another demonstrating feasibility of lower TRL technologies.
Collaborator Contribution Experts from industry, academia, and High Value Manufacturing Catapult - representation from the aerospace, automotive, rail, marine, renewables, oil and gas, defence, and fashion sectors. This whole supply chain representation indicates just how universal the topic of circular economy and end of life is within the composites industry, and begins to demonstrate the scale of the opportunity. Invaluable insight from industry experts, helping to shape the direction of the programme moving forwards.
Impact Proposals will be developed for funding application
Start Year 2019
 
Description 13th European Adhesives Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presented my Fellowship and initial results on reversible adhesives

Had follow up with a potential collaborator
Year(s) Of Engagement Activity 2022
 
Description Discussions with CPI and NCC, part of the HVMC Catapult 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Meeting to discuss Fellowship and awareness of my activity.
NDA's to be arranged and invited to talk at both CPI and NCC
Year(s) Of Engagement Activity 2022
 
Description Materials Research Exchange 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Post-docs attended to promote the activity of our group and scope interest in sustainable materials. A number of useful contacts were made which have been followed up by invitations to other events and additional requests for further information.
Year(s) Of Engagement Activity 2020
 
Description RSC conference, Formulating for Adhesion 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation about the Fellowship and initial results, to engage potential interested parties.

Interest from a number of different organisations to follow up
Year(s) Of Engagement Activity 2022
 
Description SURFEX annual coatings exhibition, June 2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Approx 30 people attended with a following discussion about a potential meeting under NDA
Year(s) Of Engagement Activity 2022
 
Description Sustainability of Adhesion and Adhesives, December 2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Presentation of work on reversible adhesives to potentially enhance re-use of materials
Year(s) Of Engagement Activity 2022
 
Description Visit to National Composites Centre May 2022 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Industry/Business
Results and Impact Following virtual meetings, visited the National Composites Centre
Presented our first proof of concept on reversibly crosslinked adhesives
Discussed needs for sustainable composites and how we might collaborate in future
Year(s) Of Engagement Activity 2022