Design, manufacturing and process integration of nano-structured carbon enhanced lightweight composites

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Lightweighting is the determining factor in selecting the best material for an application among different choices. It is especially important for transport industries, where weight directly influences energy requirements and fuel consumption. Synthetic or natural fibres have been used to reinforce polymeric matrices to achieve a balance between the light weight and performance of composites. The key to success in improving the properties of composites is an adequate surface treatment of the fibres for an optimum interaction with the polymeric matrix. However, the high density of the synthetic fibres and inherent qualities of natural fibres limit the reduction of the composite weight or reduce its performance. The goal of the proposed research is to use engineered bio-carbon materials and a modified foaming technology to design a new generation of lightweight structural composites with high thermal and flame resistance for the aerospace and automotive industries. Catalytic pathways will be used to produce and extract graphite-like sheets from biochar (renewable carbon), followed by surface treatment of the sheets to improve their interaction with the polymeric matrices. We expect that using nano-scale graphite sheets will improve the mechanical, thermal, and barrier properties of the polymers. Principles of materials science and thermodynamics will be applied to incorporate the nano-carbon materials at the interphase of a polyethylene (PE) and polypropylene (PP) blend to increase their compatibility and improve the overall properties of the blend. This engineered composite will have several applications in manufacturing automotive and aerospace interior parts. In order to further reduce the weight and increase the sound and thermal insulation properties of the composite, a batch foaming technique will be developed to control the size, density, and shape of the voids in the composite, as well as optimize the quality and performance of the product. The developed materials and processing will be used to make prototypes of an air duct manufactured by Hutchinson Aerospace & Industry (Montreal) used in aircrafts, and an integrated engine beauty cover and insulating foam used in Ford (Windsor) vehicles.