New commercially viable bio-resins thermosets derived from vegetable oils

05-Mar-07

Soon, a new, greener alternative to conventional thermosets will be available in the form of a new generation of ‘bio-resins’ – thermoset resins derived principally from vegetable oils such as rapeseed. Research supported by the Sustainable Technologies Initiative shows how the renewable polymers could offer a commercially viable alternative that would help manufacturers to meet tighter environmental regulations, that are competitive in price and performance and adaptable to existing composite manufacturing processes. In demonstration trials, the bio-resins performed well and matched that of petrochemical resins. The trials demonstrated that the process is capable of working on an industrial scale and commercialisation is expected to follow. The first applications are likely to be in selected insulation products, with future potential in industries ranging from electronics to automotive, construction materials, furniture, foundry and engineered wood products. In the REPLANT project, a research team from BC, the BioComposites Centre at the University of Wales, Bangor, who specialise in renewable plant technology, worked with industrial partners Cambridge Biopolymers, a contract manufacturer and a resin end-user. The project was supported by the DTI through the Sustainable Technologies Initiative, a programme to improve the sustainability of UK business. STI research aims to achieve economic growth and employment while safeguarding the environment and conserving natural resources. A key step was the development of a technique known as ozonisation to turn the vegetable oil into thermosetting resin. Patent applications have been made for the novel process technology, which is based on the use of ozone gas, and operates at ambient temperature. The clean, low effluent manufacturing process yields formaldehyde-free products with a high solids content of over 75%. Development of the new process is expected to appeal to thermoset manufacturers by making it easier for them to meet health and safety regulations in the workplace as well as demand from customers for greener products that are formaldehyde free.