The influence of biocarbon structure modification on the mechanism of reducing the flammability of polymer composites

The project aims to develop multifunctional materials modified with the use of graphitic biocarbon fillers (BioC). The designed materials could provide a cheaper and safer alternative to the currently used petroleum-based carbon fillers. Compared to the standard methods of graphite manufacturing, the proposed catalytic pyrolysis of biomass can represent a more effective approach to obtaining cost-competitive and green production. The project goal is to substitute the petroleum-based carbon source with a sustainable and cost-efficient one, aiming to tailor the graphitic structure through an innovative process to cover a wide range of applications. In the literature, a broad range of biomass and biomass co-products from different industries/biorefineries have been used to develop a biobased carbon (or biocarbon) by pyrolysis. Some examples of biomass sources are perennial grass, wood, or lignin. Biocarbon has already proved to be an excellent substitute for carbon black for different applications, such as polymer blending and capacitors. In the case of polymer engineering, it even gives better results depending on the matrix, permitting an increase of the amount of filler up to 30 or 40% in some cases, without completely sacrificing the thermo-mechanical properties.

Highly graphitic carbon is made from graphene, which is currently called the material of the next century and is around 200 times stronger than steel, lightweight, flexible, and more conductive than copper. The potential application covers a wide area, from electronics to the automotive industry. Graphitic carbon and other allotropes could be the major reinforcing component of many polymer composites. Using biographite to produce lightweight components will lead to a revolution in many industries.

The main aspect of the novelty of the research planned within the project is the proposed concept of using biocarbon structures with a controlled degree of graphitization as additives in polymer filler systems that limit the flammability of composite materials. In previous studies, biocarbon additives (BioC) were treated as materials with waste characteristics, which could be a cheap, bio-based alternative to mineral fillers. However, industrial biomass pyrolysis processes do not allow for the production of materials with characteristics similar to petroleum-derived carbon fillers, such as carbon black and graphite, due to the unstable composition and low level of graphitization of the biomass structure. The discussed project aims to develop a process for the production of stable polymer filler systems based on waste BioC, where the main area of application will be additive manufacturing (3D printing). The aim of the project is to develop materials with reduced flammability. Previous research has been aimed at improving material properties in general without specifying a specific modification goal. Current work has confirmed the great potential of using BioC as a flame-retardant component, which directs the planned work.