Nanofibril Technology for advanced manufacturing of next generation of high performance plastic composites

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In this project, we would like to develop the scientific and technological base for the manufacture of nanofibrillar composites (NFCs) with various materials combinations. As the use of plastics will only continue to grow due to manufacturing demand increases and the replacement of metals with plastics, NFCs present an outstanding solution to alleviate these issues. We believe that the use of NFCs will be easily adopted into current, everyday plastic manufacturing processes. This will have a widespread societal impact due to reduced energy and material consumptions. The long-term objective of this proposal is to commercialize the nanofibril technology and the materials combinations for everything between consumer goods and high-performance applications. By evaluating the market requirements, we can tailor our projects to fulfill any needs. Accordingly, we seek to uncover the basic fundamentals in nanofibril technology. Consequently, two approaches will be taken; stiffening with stiff nanofibril, and toughening with elastomeric nanofibril. We thus wish to develop advanced manufacturing technologies for the fabrication of composites with well-dispersed nanofibrils (diameter of 50 nm and below). The data from this research project will ultimately serve as a blueprint for developing commercially-viable, cost-effective, and eco-friendly advanced manufacturing technologies to produce lightweight and `greener' polymer nanocomposites. These composites will have improved mechanical properties and will be able to create higher quality foams. The discoveries that will result from our work will establish a basis for ongoing R&D that will yield cutting-edge, high-performance plastic and composite products as well as their associated manufacturing technologies. Our findings will have a direct and positive impact on Canadian industries and their ability to compete on global markets. The planned research activities will also provide the participating HQPs with well-rounded knowledge and an unparalleled training experience. Due to their unique nanofibrillated morphology, these advanced composites will open up new avenues in the development of high-value products with unprecedented properties. In addition to the improvements in mechanical properties, it has been demonstrated that the presence of well-dispersed nanofibril enhances its foamability. While a notable reduction in part weights has been achieved by replacing conventional materials with injection-molded polymer composites, the ability to induce a uniform foam structure within the final product will further promote both material and weight savings. This will benefit the aerospace, automotive, and mass transportation industries. Apart from polyolefins, the in-situ fibrillation technology can be extended to other material combinations, including self-reinforced polymer composites, engineering plastics, bio-compatible/bio-degradable plastics, and elastomers.