This chapter describes the industrial demonstration of the reuse of recycled fibers obtained by a thermal process. Four demonstrators are described in which both recycled carbon fibers and recycled glass fibers have been incorporated into different matrices. The automotive sector proposes 3 demo cases (Pedal Bracket, Front-end carrier and Cowl top support) with demanding mechanical and thermal requirements. These components were manufactured by injection molding with thermoplastic matrices. The construction sector proposes 1 demo case (Light transmitting single skin profiled sheet.) with mechanical and light transmittance requirements that was manufactured by continuous lamination. It is demonstrated that the incorporation of recycled fiber for these applications is technically possible, fulfilling the requirements demanded by each sector.
The main objective of Use Case 1 is the development of industrial demonstrators of new products incorporating mechanically recycled glass fiber composites. These demonstrators will determinate the technical feasibility and cost effectiveness for glass and carbon fibers recycling solutions. The demonstrators include structural parts like a ski by HEAD Sport and sanitary products like shower trays by Novellini where the recycling fibers are used for existing products. A series of design concepts have been developed supported by a design briefing and a co-design methodology for street furniture and similar products, where the recycled materials are already considered from the start of the design of the product.
Three different classes of thermosetting styrene-free resins were investigated to assess their suitability to constitute the matrix phase in the reformulation of composites reinforced with mechanically recycled glass fibers. Resin reactivity and mechanical properties after curing were compared to commercial styrene-based, unsaturated polyester resins. The polymeric resin, acting as a binder, could be properly selected depending on the desired reactivity, processability, and mechanical behavior. Some prototypal examples of reformulated composites with different types and contents of recycled glass fibers were produced and mechanically tested. The combination of the epoxy resin with up to 60 wt% of mechanically recycled glass fibers resulted in an increase of elastic modulus up to 7.5 GPa.
The involvement of designers in the sustainable transition from linear to circular economy is crucial since they significantly contribute to the realization of products and services. In the FiberEUse project, a multiple-step approach to co-design was employed, starting with the definition of a first and second design brief in order to clarify the task objectives for designers. This was followed by the description of the co-design process, which aims to engage designers to contribute innovative design concepts for recycled composites. By publishing design concepts in the feedback collection software module Idea Manager, designers and users were able to exchange information, insights, visions, and thoughts digitally. The Idea Manager comprises a feedback collection tool that supports a first assessment of design concepts. Depending on the design briefing and/or confidentiality agreements, the feedback collection and the assessment can either be done (stakeholder-)internally or publicly. A flowchart illustrates the multi-step approach of co-design within the FiberEUse project. The feedback collection process was aided by a progress analysis to detect new value chains for business cases. For the selection of product design concepts, a progress analysis partitioned into four main criteria, the following aspects are drawn on for assessment: (i) quantitative and qualitative production feasibility, (ii) closeness to market introduction, (iii) potential volume of the market, (iv) circularity, (v) type of market, (vi) service opportunities, and (vii) take-back/deposit systems. Aside from bringing out the advantages of co-design for consumers as well as production companies, this chapter also discusses general challenges of co-design and co-creation in a broader sense when intellectual property rights (IPR) are not respected appropriately. The participation in a publicly accessible co-design of concepts must be clearly communicated and accepted by each participant by agreeing to intelligible terms and conditions.
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