Greener cleaner composites [extension]

The original 4-year Fellowship aimed to promote the use of bio-derived resins and polymers in aerospace applications. The Fellow successfully developed bio-derived resin formulations for an air cargo pallet, which can result in weight savings. The bio-derived resin's unique properties were achieved through the synthesis of new bio-hardeners, which slowed the reaction time and maintained high-performance characteristics.

Additionally, the Fellow discovered a method to further reduce the pallet's weight using an algorithm based on molecular dynamics. This breakthrough also has potential applications in aerospace potting and fixing compounds.

An extension to the Fellowship is proposed to (a) further commercialise a bio-derived air cargo pallet via certification by the Civil Aviation Authority and (b) address fire safety concerns more generally across the aerospace and automotive industries, particularly related to the transport of lithium-ion batteries for the electric vehicle industry. Thermal runaway events in batteries release flammable and toxic fumes, posing significant risks.

The challenge is to develop a lightweight, cost-effective material that can contain the energy blast and particulates releases during a thermal runaway event. The Fellow proposes exploring the use of a novel and intrinsically fire-retardant, bio-derived polymer derived from waste agricultural products, in combination with novel arrangements of fibres and particulates.

This sustainbable thermoset polymer has poor mechanical properties and toughness, and its curing mechanism is still not fully understood. The proposed extension aims to (a) improve the mechanical performance and durability of this new bio-thermoset, (b) investigate its foaming mechanism, and (c) simultaneously develop test protocols that more accurately reflect extreme battery thermal events and can demonstrate the potential of composite materials to combat the risks associated with batteries.

This extension will contribute to advancing sustainable and fire-resistant materials in both the aerospace and automotive industries, providing safer and greener solutions for battery containment and air cargo, while promoting the use of bio-derived polymers.