Design of Reusable Components for Composites Circular Economy
Topic(s) : Special Sessions
Co-authors :
Stefan CABA (GERMANY), Justus VON FREEDENAbstract :
Composites are one of the materials under major concern for circular economy. The composition as a mixture of at least two different materials - fibers and matrix - prevents the simple recycling of components. On the other hand, the properties of the parts depend on the length of the fibers leading to reduced strength at classical shredding processes for recycling.
Hence, reuse enabled by repair and remanufacturing of composites are seen as preferred. These strategies require a purpose driven design. The components on the one hand need to show durability not nonly for one, but all the planned life cycles. Here, in particular carbon fiber composites are offering ideal properties. On the other hand the integration into the product must be designed for detaching. This influences not only the design of the part itself, but also the value chain and the connected business models.
The study was carried out for automotive components. First a selection of detachable joining solutions was examinated under the goal to achieve both high performance during the use phase and simplified detaching. Here, in particular detachable adhesive connections could be examinated e.g. composed of standard adhesives and thermally expandable particles. The results show a good usability in all areas of the body-in-white as well as for interior components.
The selection of parts for reuse is another critical factor, since recovery, testing and remanufacturing are cost generating processes. It could be shown that the components on the one hand must show a high value and on the other hand the processes must be promoted by a dedicated design. The study includes 3 different vehicles providing use-cases for modular design for reuse. Selected components are battery housing, seating structure, leaf spring, crash elements and a vehicle main structure.
Life-cycle assessment show that lightweight design without reuse options does not lead to more sustainable vehicles, because the mass savings are usually overcompensated by high carbon footprint of resin and fibers. It could be shown that already a first reuse leads to savings in comparison to standard vehicles.
Economically the success strongly depends on the business model. While a use in customer vehicles shows many issues, fleet vehicles offer better recovery rates and lower logistics costs.
The study presented summarizes the outcomes of three projects dealing with reuse of composite parts. It gives indications for future vehicle design for circular economy enabled by composites.
Hence, reuse enabled by repair and remanufacturing of composites are seen as preferred. These strategies require a purpose driven design. The components on the one hand need to show durability not nonly for one, but all the planned life cycles. Here, in particular carbon fiber composites are offering ideal properties. On the other hand the integration into the product must be designed for detaching. This influences not only the design of the part itself, but also the value chain and the connected business models.
The study was carried out for automotive components. First a selection of detachable joining solutions was examinated under the goal to achieve both high performance during the use phase and simplified detaching. Here, in particular detachable adhesive connections could be examinated e.g. composed of standard adhesives and thermally expandable particles. The results show a good usability in all areas of the body-in-white as well as for interior components.
The selection of parts for reuse is another critical factor, since recovery, testing and remanufacturing are cost generating processes. It could be shown that the components on the one hand must show a high value and on the other hand the processes must be promoted by a dedicated design. The study includes 3 different vehicles providing use-cases for modular design for reuse. Selected components are battery housing, seating structure, leaf spring, crash elements and a vehicle main structure.
Life-cycle assessment show that lightweight design without reuse options does not lead to more sustainable vehicles, because the mass savings are usually overcompensated by high carbon footprint of resin and fibers. It could be shown that already a first reuse leads to savings in comparison to standard vehicles.
Economically the success strongly depends on the business model. While a use in customer vehicles shows many issues, fleet vehicles offer better recovery rates and lower logistics costs.
The study presented summarizes the outcomes of three projects dealing with reuse of composite parts. It gives indications for future vehicle design for circular economy enabled by composites.