Case Study: The Innovation of S-2900ESQ
Quick-Set Epoxy with Enhanced Sustainability Qualities
Introduction
- Structural Adhesives Ltd have a well-established, rapid curing epoxy adhesive that is supplied to the cladding industry.
- However, in-line with their values and those of their clientele Structural Adhesives Ltd tasked Luma R&D Laboratories with the development of a more sustainable version of the product to be named S-2900ESQ
Challenge
- The needs of the construction industry have evolved and sustainability and longevity have become a much higher priority.
- Replacement of non-renewable raw materials with more sustainable alternatives is vital for continued production of goods such as adhesives. As is repurposing of the growing volume of waste material being generated by society.
Research and Development
- Luma R&D Laboratories aimed to curtail reliance on non-renewable raw materials by substituting a large portion of them with recycled glass and plastic sourced through one of their vast network of contacts.
- The Luma R&D Laboratories team also worked to reduced hazards of S-2900ESQ-Vita compared with the original product by removing a raw material that is a reproductive toxicant, without compromising on the performance of the product.
Testing and Certification
- Rigorous internal testing by Luma R&D Laboratories confirm the rapid bonding capabilities and indicate good weather resistance and durability of S-2900ESQ.
Impact and Applications
- S-2900ESQ contains approximately 45% waste material which reduces pollution. Once destined for landfill, these reclaimed materials now breathe new life into our product.
- This recycled material has been used to replace other fillers which are typically mined, thereby reducing the required amount of finite material and the energy required for the mining and processing of this material.
- S-2900ESQ is also presented in innovatively designed cartridges that are kinder to the environment, made from 99% post-consumer recycled (PCR) material.
Conclusion
- S-2900ESQ’s development journey was borne from Structural Adhesives Ltd.’s desire to provide a more sustainable alternative for a popular product. Luma R&D Laboratories not only delivered on improving the sustainability of the product but also the packaging, as well as maintaining the rapid cure, bond strength and durability and reducing the hazards of the product.
- S-2900ESQ is the first epoxy adhesive on the market that contains recycled waste material.
Case Study: The Development and Certification of
S-2825FRE Fire Rated Epoxy Adhesive
Introduction
- Legislation changes (a ban on the use of combustible materials on external walls of residential buildings above 18 m) sparked a push towards the need for products of lower combustibility.
- Only materials tested to BS EN 13501-1 and classified as A1 or A2-s1,d0 can now be used on residential buildings taller than 18 m.
- The remit of the project was to develop an A2-s1d0 rated epoxy adhesive for use in cladding systems.
Challenge
- Generic adhesives do not comply with the new government legislation as they inherently contain large amounts of carbon, which is combustible but is fundamental, as it is an element heavily involved in the bonding mechanism.
- We were presented with a paradox, without the carbon the adhesive does not bond as it should, however, the carbon burns severely.
Research and Development
- Luma R&D laboratories conducted research into the new regulations and tested an existing Structural Adhesives Ltd product as a benchmark.
- Luma know how much organic (combustible) content was in the existing product and therefore by knowing how this performed in the reaction to fire tests, there was a good indication of the levels or organic content that could reasonably be expected to meet the threshold of A2-s1d0 classification.
- Throughout the development process we made many modifications to the formulation until we were confident we had a product, S-2825FRE, that had all the attributes expected of an excellent construction adhesive.
Testing and Certification
- Rigorous external testing confirmed the durability and weather resistance of S-2825FRE verifying its suitability for use in harsh outdoor conditions.
- S-2825FRE was the first adhesive on the market to achieve A2-s1d0 classification according to BS EN 13501-1.
Patenting Process
- Steps were taken to secure a patent for S-2825FRE.
- Patenting this product offered Structural Adhesives Ltd several strategic advantages. It legally protected the innovation, ensuring the company has exclusive rights to use, manufacture, and sell the product, for approximately 20 years.
- This exclusivity allows the company to establish and maintain a competitive edge in the market, safeguarding the innovation and contributing to its financial and strategic strength.
Impact and Applications
- The launch of S-2825FRE enabled cladding companies with systems using an adhesive to supply to high-rise residentials once again.
- In the event of a fire, compared with adhesives previously used on high rise residential buildings, S-2825FRE will produce less heat, less flaming droplets and less smoke.
- Essentially S-2825FRE will contribute less to the spread of the fire providing more essential time for evacuation and firefighting methods.
Conclusion
- In summary the project was shaped by a change in legislation and the development of S-2825FRE satisfied an issued that no other product could solve.
- S-2825FRE remains a market leading technology and forms the basis of a range of A2-s1d0 products all developed by Luma R&D Laboratories.
Case Study: Transformative Technologies Project with Innovate UK
Introduction
- Overview of Structural Adhesives Ltd.: Committed to leading-edge research and development in adhesive and composite technologies.
- Introduction to the Project: Under the Transformative Technology banner and through support from Innovate UK, Luma R&D laboratories (Structural Adhesives Ltd working lab) were able to undertake research to develop a groundbreaking epoxy resin tailored for recyclability and exceptional performance in composite materials.
Challenge
- Industry Need: Demand for sustainable composite materials that maintain performance while being recyclable at end-of-life.
- Project Objectives: Focus on creating an epoxy resin for use in composites that not only performs exceptionally in terms of mechanical properties but also breaks down efficiently at end-of-life without significant degradation of the recovered fibres.
Research and Development
- Formulation Process: Luma R&D laboratories utilised technology with specially inserted cleavable bonds with a variety of other innovative raw materials to develop a formulation for an epoxy composite resin matrix.
- Innovations: Through several rounds of modification, the formulation was adjusted until the mechanical and thermal properties were comparable to those of industry standard epoxy composite resins.
Testing and Certification
- Validation: The epoxy resin formulated by Luma R&D Laboratories was used by the National Composites Centre (NCC) to manufacture a carbon fibre composite panel.
- Rigorous testing: The mechanical and thermal properties of the composite panel underwent rigorous testing by both the NCC and the University of Loughborough. Additionally, the recovered carbon fibre from the recycling process was scrutinized.
Impact and Applications
- Project Impact: The carbon fibre panel was manufactured using the resin formulated by Luma R&D laboratories was proven to behave similarly to standard composites with the benefit of improved recyclability. The recovered fibres were tested and were showed to be of excellent quality with no significant difference to virgin fibres in their dimensions or mechanical properties.
- Applications Demonstrated: Effective in various uses, particularly where end-of-life recyclability is critical, such as the wind energy and automotive industries amongst others.
Conclusion
- Project Recap: Luma R&D Laboratories undertook an innovative research project into a design-for-recycle epoxy resin for the manufacture of composites. The team demonstrated the proof-of-concept for the recycling process and the quality of the recovered fibres alongside the suitable mechanical and thermal properties of the formulated resin.
- Future Outlook: Potential expansion into broader applications, and collaboration with industry partners to refine and enhance product capabilities.
This case study highlights Luma Labs’ commitment to pioneering sustainable adhesive and composite solutions and their capability to engage in high-level research and development projects supported by bodies like Innovate UK. This project addresses current demands for high-performance, sustainable composite materials and sets new standards for the recycling of composite materials.