Proof of Concept of Energy Efficient Processing Technology for Wool Natural Fibre Composites to Create a Sustainable Modular Construction Panel (EEWC-ModularPoC)

EEWC-Modularity建议研究1）羊毛基复合材料的技术和商业可行性2）快速和具有成本效益的开放式腔压机（OCP）复合材料加工技术3）所得技术作为可持续建筑材料的适用性。最终目标是在不到10分钟的循环时间内生产阻燃、编织羊毛基复合材料部件，而不使用预浸料、高压釜或昂贵的工具。EEWC-Modularity提出大幅降低加工能源和资本成本，使羊毛基复合材料能够在轻质模块化建筑应用（家庭办公室、教室、食品店、农业等）中经济高效地商业化。目前英国复合材料产品市场价值43.9亿英镑（2019年Lucintel为Innovate UK提供的报告），到2030年有机会增长到120亿英镑（参考：英国复合材料市场研究）。增长最快的行业是航空航天25%的复合年增长率，石油和天然气55%的CARG和建筑11%的CARG（参考：国家复合材料中心）。为了满足这一不断增长的市场，拟议的EEWC模块化项目将为一系列复合材料模块化建筑产品提供灵活且具有成本效益的制造工艺。EEWC模块化OCP工艺非常灵活，可以实现更大的定制化并快速进入新市场。该加工站将由一个高压和高温柔性EPDM隔膜工具组成，用于在一个开放式腔体工具中将低粘度生物树脂强制固化成干燥织物。创新的EEWC模块化OCP工艺旨在实现低于2%的空隙率，具有极快的循环时间，并且与许多替代的高压釜生产系统相比，能量成本显著降低（在不使用自动化生产单元的情况下至少降低50%）。

EEWC-ModularPoC proposes to research 1) the technical and commercial feasibility of a wool-based composite 2) a rapid and cost effective Open Cavity Press (OCP) composite processing technology 3) the suitable of the resultant technology as a sustainable construction material. The ultimate aim is to produce a fire retardant, woven wool, based composite part within a sub 10 minute cycle time without using prepreg, an autoclave or expensive tooling. EEWC-ModularPoC proposes to provide a significant reduction in processing energy and capital cost to enable wool-based composites to be cost effectively commercialised in lightweight modular construction applications (home office pods, classrooms, food outlet, agricultural etc.) and other low-medium volume applications.The current UK £4.39bn composite product market (2019 Lucintel report for Innovate UK) has the opportunity to grow to £12bn by 2030 (Ref: UK Composites Market Study). The highest growth sectors are aerospace 25% CAGR, oil & gas 55% CARG and construction 11% CARG (Ref: National Composites Centre). To meet this growing market the proposed EEWC-ModularPoC project will provide a flexible and cost effective manufacturing process for a range of composite modular construction products.The EEWC-Modular OCP process is extremely flexible to enable greater customisation and rapid entry to new markets. The processing station will consist of a high pressure and high temperature flexible EPDM diaphragm tool to force and cure low viscosity bio-resin into a dry textile in an open cavity tool.The innovative EEWC-Modular OCP process aims to achieve a void content of less than 2%, with extremely fast cycle times, and at significantly lower energy costs (at least 50% less without the use of an automated production cell) than many alternative autoclave production systems.