Projects

The Fraunhofer PREPARE project HATE-Fluor sets new standards in materials development: The goal is to produce fluorine-free elastomers as a sustainable alternative to fluoropolymers – high-performance, durable, and environmentally friendly. The newly developed materials offer maximum chemical and thermal resistance, particularly in sealing technology, for example in hydrogen systems or photovoltaic vacuum systems. Innovative antioxidants and optimized formulations ensure maximum stability – for future-proof solutions without fluorine.

Sustainable plastic recyclates and biodegradable polymers for nonwovens and roofing membranes: 1. Is it possible to recycle and additives different waste streams to produce high-quality recyclates, which in turn can be used to produce fibers and films that can be further processed into competitive nonwovens and films for roofing membranes? 2. Can fibers be produced from bio-based polymers that can not only be spun into nonwovens, but whose degradation in the environment can be adjusted and which do not pose a risk to the environment?

The FNR project “BioFlammschutz” has developed innovative, bio-based, and environmentally friendly phosphorus-containing flame retardants. These are intended to serve as an ecologically and economically advantageous alternative to the halogen-containing flame retardant additives currently in use, which are problematic from an ecotoxicological perspective. The new flame retardants were produced from cotton and wood cellulose and the inexpensive sugar alcohol erythritol using a method developed at Fraunhofer LBF. Their suitability was demonstrated in flame retardant applications for polyolefins and a partially bio-based polyamide.

Building insulation made from renewable raw materials has been state of the art for many years, but still accounts for only a small share of the insulation market because it has disadvantages compared to mineral products and foamed plastics, e.g., in terms of fire behavior, or because it is not available in the form of self-supporting panels. In the joint research project “OrganoPor_Fassade” funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK), experts from Fraunhofer LBF have further developed new bio-based, halogen-free, flame-retardant, self-supporting insulation boards that can be integrated into a composite thermal insulation system.

Advances in the development of improved quality plastic recyclates: reduction of unwanted odors. The focus is on equipping plastic recyclates with special plastic additives, known as odor scavengers or odor control additives. The newly developed method identifies and binds volatile compounds that are responsible for unpleasant odors. In addition, the influence of the compounds investigated on material stability was examined and evaluated. These innovations are crucial, as consumers are looking for high-quality, odorless products.

Sandwich elements are increasingly being used in the façades of industrial halls and cold stores. In the ReSaMon project, the BMWK is promoting optimized production of the elements. In the project, a consortium of seven partners is developing a non-destructive and non-contact measurement technology that can identify potential weak points and changes in material properties during the production process. Fraunhofer LBF is investigating the possibilities of data-based methods for detecting and localizing defects in conjunction with the developed measurement technology.

Battery solutions for ships are usually tailor-made and, if at all, for small series, which leads to high costs. In addition, a single battery type is used both to cover the high energy requirements, e.g., to maintain cruising speed, and for high power peaks, e.g., when loading in port. However, a single cell technology cannot meet both requirements. As a result, batteries are oversized by a factor of 2 to 10, which also leads to high costs. The EU joint project SEABAT has developed a hybrid concept based on the combination of high-energy and high-performance batteries with a novel converter concept.

Galley kitchens in commercial aircraft are central components of modern passenger aircraft. The future use of alternative energies for engines will lead to a significant reduction in the energy available in the cabin by 50%. Such a significant energy saving is only possible through a leap in innovation in catering equipment. In the GECO (Galley Efficient Catering Operation) project, the aircraft galley is being embedded in a new centralized system context, enabling the linking of process chains and the networking of previously stand-alone systems to unlock new synergies. Structural improvements with integrated solutions reduce weight and energy consumption in the aircraft galley, while manufacturing processes are also being rethought against the backdrop of a holistic product life cycle. The use of sustainable materials contributes to the goal of improving environmental auditing.

Advances in battery technology for electric mobility: The Accelerated Cell and Battery Testing AccCellBaT project improves virtualization, front-loading, and continuous verification and validation (V&V) in order to optimize battery design, costs, and time to market.

Components made of zinc die-cast alloys are used in various industries due to their high surface and component quality and the efficiency of the hot-chamber die-casting process. However, they are rarely used for components subject to high cyclic loads because they lack structural durabiity characteristics. To change this, the cyclic material behavior of various zinc die-cast alloys was investigated and summarized in a design concept.