Circular reuse and remanufacturing of glass fiber-reinforced composites for boards in transportation sector

GAIKER Technology Center

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A novel cost-effective process to directly reuse large curved EoL parts made out of polyester GFRCs has been developed.

The new technology involves reshaping large GFRC parts with curved geometry using pressure and temperature at the maximum deformation point of the polyester resin (i.e. at the glass transition temperature) without polymer degradation.

This process has been developed via two synergistic strategies: batch process (GAIKER) using a vacuum press molding machine and a semi-continuous process (ICAM) using an adapted twin-roll calendering machine. The reshaped parts have been used to develop technical boards for the transport sector as to validate the reshaping processes.

Depending on the thickness of the curved EoL, two different strategies have been followed: for reshaped parts with thickness > 5mm, a panel with appropriate finish coating has been developed; for reshaped parts with thickness < 5mm a sandwich structure with aluminum honeycomb core material has been developed.

Flattening composite pieces while staying under the maximum deformation point.
Exploiting the gained polymer flexibility without degradation depending on its glass transition.
Conserving the mechanical integrity of the reshaped composite parts.

Challenges

Classic recycling processes providing mechanically compromised materials.
EoL composites from marine and wind energy sector in increasing quantities.
Landfilling of EoL composite waste derived from the marine sector.

Solution

Flattened composite panels with little to no loss in bending performance.
EoL composites as sustainable manufactured sources in railway transport vehicles.
Cost-effective reuse of reshaped composite panels.