recycloPreg – Energy-efficient production and processing of a recyclable and bio-based prepreg material with complete representation of the textile recycling process
Development of a sustainable circular process for bio-based and recycled fiber-reinforced composites, including fiber pretreatment, prepreg manufacturing, material characterization, simulation, and ecological assessment.
Project Partners
Robert Kraemer GmbH & Co. KG, University Reutlingen, SGL Technologies GmbH, CVT GmbH, Lamilux (associated)
Duration
01.11.2024 – 31.10.2027
Funding authority
German Federal Ministry of Research, Technology and Space
Motivation
A central aspect of the project is the complete consideration of the closed-loop process and the substitution of conventional epoxy resins and fiber materials made from fossil raw materials with sustainable alternatives. The closed-loop system of the fibers includes pre-treatment, processing in the component and return to the cycle. Natural fibers are used in a wet laid nonwoven to produce a prepreg material. To ensure consistent mechanical properties, energy-efficient drying processes and pre-treatment of the natural fibers are being investigated. A bio-based resin system enables the sustainable recovery of the fibers and is being optimized for use in the prepreg process. The project is also developing an energy-efficient manufacturing process for wet-laid nonwovens made from recycled fibers that minimizes energy and water consumption. The new bio-based materials are being examined as part of a comprehensive material characterization. These serve as the basis for the simulation, which is created for the holistic design of components. The aim is to map the entire cycle process in order to identify potential environmental impacts and reduce the ecological footprint.
Method
In this project, Robert Kraemer GmbH is developing a bio-based resin system for use in the prepreg process, while the production of hybrid fiber textiles with natural fiber content is being investigated by Reutlingen University with the expertise of CVT GmbH and Phönix NonWoven GmbH. The final production of the pregpreg is carried out by SGL Carbon. With the help of material characterization at the Chair of Carbon Composites (LCC) at the Technical University of Munich, simulation models for the new materials can be developed. The production of the demonstrator components with the developed material system will take place at SGL Technologies and Lamilux. The recycling process will be demonstrated using the demonstrator components in order to be able to carry out a holistic view of the recycling process. The developed materials, the fiber composites with recycled content, have many possible applications. One focus is on the automotive industry, where they can be used for components such as battery covers. Possible applications for the developed materials can be found in the caravanning sector or in the sports industry and the construction industry.
Acknowledgement
The chair thankfully acknowledges the funding provided by the German Federal Ministry of Research, Technology and Space in the initiative “Resource-efficient circular economy - circular sustainable textiles” for the project “recycloPreg - Energy-efficient production and processing of a recyclable and bio-based prepreg material with complete representation of the textile recycling process” (funding code: 033R409C).
Contact Persons
Philipp Seitenglanz, M.Eng.; Dipl.-Ing. Thomas Wettemann