In response to growing environmental and safety demands, AIMPLAS the Plastics Technology Centre- is pioneering the development of sustainable flame-retardant composite materials for construction and mobility applications. Through two Valencian Institute for Competitiveness and Innovation (IVACE+i) funded initiatives REFUGI and NEOCOMP the organization is engineering next-generation coatings and composites that combine lightweight performance with enhanced fire resistance. These innovations aim to reduce the environmental footprint of conventional flame-retardant systems while improving material safety and durability in critical sectors.

On one hand, the main objective of the REFUGI project is to develop phosphorus-based flame retardants using mechanochemical processes, representing a step toward more environmentally friendly methods. These flame retardants are being integrated into varnish formulations specifically designed for use on wood. This strategy aims to improve the fire-resistant properties of coatings used in the construction sector.

Carolina Acosta, lead researcher in Mechanochemistry and Reactive Extrusion at AIMPLAS, explained: The use of flame-retardant varnishes has increased in recent years, as they offer a finish virtually identical to any wood coating, with the added benefit of greater fire resistance, delaying its spread and effects in the event of a fire. We are focusing on exploring different material sources to produce these flame retardants, prioritizing those that are renewable and recyclable.

This research, carried out in collaboration with the companies Omar Coatings and Decomader, aims not only to improve the efficiency of flame-retardant production but also to reduce the environmental impact associated with their manufacture and application.

The application of mechanochemistry for the production of these compounds represents an innovative and promising approach that expands the possibilities of green chemistry and sustainable manufacturing. We are looking for innovative ways to synthesize flame retardants using processes that minimize solvent use, require fewer resources and reaction times, and maximize efficiency. Additionally, we are also researching coating application technologies that allow for uniform and efficient distribution of flame retardants on wood substrates, added Acosta.

High-Performance Flame-Retardant Composite Materials

The NEOCOMP project, on the other hand, focuses on developing high-performance flame-retardant composite materials using advanced manufacturing technologies. This involves producing various parts through innovative industrial processes such as Dry Fiber Placement (DFP) and additive manufacturing. These composite materials must not only offer high performance in terms of mechanical strength, durability, and flame resistance but also significantly contribute to reducing the environmental impact in construction and mobility.