Introduction

The patent is about FML (Fiber Metal Laminates) based on secondary Aluminium (with no structural function), closed-loop recyclable basalt biobased resin (based on polyfurfuryl alcohol), and an hybrid termoplastic-termoset interohace, optimising the process for maximising economic and environmental sustainability of fire-resistant composites for weight reduction in the automotive.
TRL 6

Technical features

The multi-material is made up of alternating layers of fiber-reinforced composite material and aluminum to create elements also for electronics and construction, such as battery containers, fire barriers, protections and supports for power electronics, i.e. components potentially subject to overheating due to the large amount of energy concentrated in small spaces. FML have been developed for lightening, looking for a compromise between production costs and times, performances, complex shapes production cost and times, recyclability. In these FML, aluminum is applied as an outer (or also intermediate) layer of the composite to enhance its fire resistance, as it acts as IR mirror against the heat source, preventing the decomposition of the resin, and barrier against air. To have good Al-composite adhesion, the Al must be perfectly clean, but to avoid rapid corrosion, a sol-gel surface finish must be developed, after the production of FML component, thus assuring corrosion protection without introducing combustible materials, nor interfering with recycling but also hardness and erosion resistance increase, and resistance to salt spray (NSS) and UV.

Possible Applications

• Electric car battery box and other mobility on rubber, rail or marine;
• Box for battery recycling;
• Renewable energies, H2 supply or fast charging;
• Integrated systems for campers, containers for construction sites or residential units off grid, off shore and oil & gas.

Advantages

• Use of aluminium at low thicknesses and in a ductile state;
• A mixed thermoplastic/thermoset polymer interface for better adhesion and initial sliding between layers, during warm pressing forming of component;
• Automotive lightneing;
• Increased fire resistance.