User:Kareycore/sandbox

NANOCORE is a 7th Framework Programme financed project. Its main scope is the development of a new and cost-effective production tecnology for sandwich estructures foam cored materials, with non-toxic flame retardants and enhanced mechanical properties. The primary reason for this new material development is to meet the current European requirements of the REACH legislation and achieve low fire, smoke and toxicity (FST) values, according to the International Convention for the Safety of Life at the Sea (SOLAS)regulation. Even the main objective is the application of this new technology to shipbuilding industry, it´s not expected to be restricted to this especific end, as other end uses such as the ones in the building industry are also pursued.



=PROJECT SUMMARY=

For a long time, the prescriptive rules of SOLAS regulations had excluded construction materials in commercial ferries and cruise ships different than "steel or equivalent", meaning that composite material could not be used in vessel construction parts such as superstructures, bulkheads, decksand deckhouses since they are combustible and release toxic fumes.

From 2002, a new rule in SOLAS allows construction with other materials than steel, since the can provide with same safety levels as if constructed according to the prescriptive rules for non-combustibility in steel. Further amendments were published in order to strengthen the fire protection arrangements of cabin balconies of passenger ships, entering into force on July 1, 2008. Fire safety has therefore been a central issue for the sector while developers of lightweight materials have been chasing the objective of improving fire resistance levels of composites compared to steel.

This new approach opens up the possibility of using light weight composites materials for other marine applictions than the military and those designed and operating under the High Speed Craft (HSC) Code, where composite materials have been used for more than 30 years in similar applications.

Most current flame retardant (FR) aditive systems used in polymeric foams are not able to meet these new standards. Polymeric foam core materials for sandwich construction, used to produce lightweight and stiff structures will require a new generation of FR additive systems in order to allow them to reduce smoke toxicity ad enable fire resistance properties.

The NANOCORE consortium will, therefoer, develop a new FR System for its use in PVC-based polymeric foams for sandwich core materials with low FST values and enhanced mechanical performance. This new FR system will be based on a combination of nanoparticles modified with a phosphorous FR in order to provide a dual FR system wich will have the following benefits:
 * Reduce weight percentage of FR due to a reduction of phosphorous loss during processing and the efficiency of nanocomposites
 * Enhanced foaming due to the action of nanocomposites as foam cell nucleation sites
 * Increased foam mechanical properties due to nanocomposites reinforcement
 * Achieving SOLAS regulations due to the combined FR funcionality os composites and phosphorous based FR

=MEMBERS OF THE CONSORTIUM=



7TH Framewor Programme requires a strong participation of small and medium sized enterprises (SME, and that they might come from at least 3 different countries. According to this specifications, members of the consortium, and their tasks on it are:


 * Plásticos Karey S.A., a Spanish SME who works in the PVC compounding industry. Responsible for the compounding of surfaced treated nanocomposites with polymeric base that will be used to form the foam core material.
 * Glonatech S.A., a Greek SME responsible for the supply of nanoparticles for the development os phosphorous based surface treadted nanocomposites.
 * Acciona(Spain), acts as an RTD Performer that works on the development of the base PVC foam material. Also acts as the consortium coordinator.
 * Instituto Tecnológico de Aragón (ITA)from Spain, acts as a RTD Performer which role is to develop the surface treatment of nanocomposites with phosphorous compounds.
 * CGS (Italy), as experts in fire certification of materials will test the NANOCORE developed foam against current fire standards and seek certification for it.

=SCIENTIFIC AND TECHNICAL OBJECTIVES=

The primary objective of this project is the development of a polymeric oam core material for its use in sandwich estructures. The material to be developed will have to meet the fire, smoke and toxicity (FST) requirements of the current regulations, and also achieve improvements on specific mechanical properties such as strength and stiffness by at least 10%, through the secondary function of the FR additive acting as a particulate reinforcement. Also the introduction of this composite in ship building will help to lighten the weight of ferries, decreasing the consumption of fuel during their crossings.

The successful outcome of the NANOCORE project is dependent on achieving a set of scientific objectives to provide with the knowledge needed to develope the technology to meet the project´s goals. Specifically:


 * The role of the surface chemistry of nanocomposites in determining thir dispersion behaviour in thermoplastic polymers and establishing the required surface properties to prevent aggregation and agglomeration of nanoparticles
 * The influence of surface modified nanoparticles on the foaming properties of thermoplastics
 * The role of morphology in determining the flammability of nanocomposites containing polymers and polymer foams
 * The synergistic flame retardant effects of combining organo phosphorous additives with nanoparticles in a thermoplastic foam polymer.

The specific technological objectives of project arising from the scientific objectives are:


 * Development of nanoparticles with phosphorous based compounds grafted onto the surface of the particles
 * Development of a process where nanoparticles are dispersed in the polymer by mechanically mixinf them into the molten polymer prior to foaming without affecting the ability to mould the polymer and where nanocomposite agglomeration is reduced to less than 5%
 * Development of a PVC based polumer containing modified nanoparticles which can be foamed using existing processing equipment; the viscosity of the PVC polymer containing nanoparticles prior to the foaming process won´t exceed a 10% of base polymer
 * Development of a PVC based foam incorporating less than 10% (w/w) of the developed nanocomposite particles with enhanced strength and stiffness at least 10% greater than the equivalent density of the unmodified foam
 * Development of a PVC based foam in which modified nanoparticles provide low FST values

The performance objectives for the production of NANOCORE new material are:


 * The foam will be formed into the desired shape (even by extrusion or moulding)
 * The production costs and end user costs have to be economically viable
 * Repeatable product quality of ≤5% variation
 * Reduction on energy consumption and CO2 emissions during foam production

=CURRENT STATUS OF THE PROJECT=

The project has passed the stage of enhancement of scientific knowledge, acquiring a deeper understanding of the scientific knowledge relevant to the developments that will take place during the rest of the work plan. In particular, scientific literature on the topic of surface modification of nanoparticles for its incorporation in polymer materials and current regulations and standards for the fire and mechanical procedures have been reviewed. Commercially available nanoclays have been chosen as first nanoparticles candidates and different types of onium compounds as organic modifiers for the nanoparticle surface modification. The nanoparticle modification with onium compounds has been successfully carried out as confirmed by different characterization techniques.

=REFERENCES=

=EXTERNAL LINKS=
 * 1) [] International Convention for the Safety of Life at Sea (SOLAS) 1974
 * 2) [] HSC Regulations 2004
 * 3) [] REACH overview