Manufacturer Develops New Flame-Retardant and Biodegradable Panels

New Fire-Retardant and Biodegradable Panels

AIMPLAS completed the BRIGIT project in Europe following a 48-month research programme. The project involved 15 partners, including Cantabria University and Spanish company Green Source SA. Through this research, new-generation fire-resistant panels were obtained from biopolymers derived from by-products generated in cellulose pulp manufacturing in the paper industry, for use in trucks and buses. BRIGIT (Seventh Framework Programme grant agreement KBBE-2012-6-311935) began in August 2012. Throughout this programme, various topics were addressed, from the obtaining of biopolymers to formulation and modification to improve fire behaviour. Following the processing of the obtained biological compounds for panel production, the resulting products were installed in Solaris and Fiat trucks and buses. The economic and environmental efficiency of the new products was validated.

Innovative Bioplastics

To obtain these innovative panels, the project partners developed a new process to obtain bioplastics, particularly PHB (polyhydroxybutyrate) and PBS (polybutylene succinate), which are more ecologically sound than existing bioplastics. These products are obtained from by-products derived from cellulose production. Lead project researcher Miguel Ángel Valera stated: "The use of by-products from the cellulose production process as a source of sugars necessary to carry out the fermentation process of microorganisms producing PHB and succinic acid enables the integration of the processes required to obtain the biopolymers used in BRIGIT. In this way, savings are achieved in production costs."

Fire-Retardant Plastic

Using composite techniques, AIMPLAS mixed and modified both biopolymer blends to obtain a biocomposite with strict requirements. First, this product has the properties of being processable via extrusion with the mechanical and fire resistance demanded by the transport industry. However, unlike thermoset resins currently in use, it is completely biodegradable following grinding and additionally has the advantage of being compostable. Second, through continuous compression moulding, it is produced as multilayered panels consisting of biological adhesive sheets and natural fibres (replacing conventional glass fibre) and a lightweight cork core. In addition to being mounted as columns and side panels in trucks and buses, these 3D panels can also be used in trains, ships, vans and other vehicles for the transport of goods and passengers.