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Design for Sustainability in Highly Flame Resistant Phenolic Sheet Molding Compound


Title: Design for Sustainability in Highly Flame Resistant Phenolic Sheet Molding Compound

Authors: Hugh MacDowell

DOI: 10.33599/nasampe/c.23.0088

Abstract: The sustainability of raw materials used in fiber reinforced polymer composites has become a major focus for customers, governments, and corporations globally as an integral component in meeting overall international climate regulatory targets. Although timelines and definitions for sustainability differ across the polymer industry, there is consensus that limiting the amount of newly extracted materials in polymer composites is beneficial to reducing the overall environmental impact of composite products. Phenolic sheet molding compound (SMC) presents a unique opportunity to dramatically increase the total sustainable content over conventional unsaturated polyester and vinyl ester resin SMC. This is first achieved by creating an ultra-low free formaldehyde phenolic resin with 85% recycled and biobased content. Additional sustainable additives are used to maintain the overall sustainability of the glass fiber SMC composite. The resulting Sustainable Phenolic SMC has a total sustainable content of over 30 % by weight, a glass fiber composition of 55 % by weight, tensile modulus >18 GPa, tensile strength >115 MPa, and 30 minute burn char strength of >200 N at 3 mm thickness. Sustainable Phenolic SMC shows potential to significantly increase the overall sustainability of polymer composite products in a host of flame resistant applications, including battery enclosures for electric vehicles.

References: 1. UN Sustainable Development Goal #12 “Ensure sustainable consumption and production patterns”, 2. Paris Agreement to the United Nations Framework Convention on Climate Change, Dec. 12, 2015, T.I.A.S. No. 16-1104. 3. European Commission, “Changing how we produce and consume: New Circular Economy Action Plan shows the way to a climate-neutral, competitive economy of empowered consumers”, March 11, 2020, 4. “Advances in ATH benefit composite products”, (2003), Reinforced Plastics, Volume 47, Issue 8, Pages 44-46, ISSN 0034-3617, ( 5. Londoño Zuluaga, C., Du, J., Chang, H. M., Jameel, H., and Gonzalez, R. (2018). ""Lignin modifications and perspectives towards applications of phenolic foams: A Review,"" BioRes. 13(4), 9158-9179. 6. “Innovation Outlook: Renewable Methanol”, 7. ISO Standard 527-1:2019(E), 2019, “Plastics — Determination of tensile properties”, ISO, 8. ISO Standard 178:2010(E), 2010, “Plastics — Determination of flexural properties”, ISO,

Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000088

Pages: 12

Price: $24.00

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