Defining requirements for new furan-based polymers: challenges and expected outcomes

In the dynamic landscape of polymer development, the FURIOUS project team is dedicated to defining a new set of furan-based polymers. This endeavour requires precision, creativity, and adherence to stringent requirements. 

In this article, we will present the FURIOUS demonstrators, outline their requirements and challenges, and discuss the solutions the consortium is developing. 

Before diving into the specifics, we will define common requirements, including standards and regulations, and their importance in the production of polymers and plastic products.

Standards for plastic packaging materials: what are they?

Standards for plastic packaging act as a rulebook to ensure that the plastic containers we use every day are safe, high quality, and environmentally friendly. These guidelines help companies ensure their plastic meets established requirements. They cover aspects such as material selection, testing to ensure proper functionality, and accurate labelling. Following these standards is crucial because it guarantees that the plastic packaging used for food and other products is safe, performs as intended, and is as eco-friendly as possible. 

The FURIOUS packaging prototype will also need to adhere to existing standards, as these apply to all types of materials, including newly developed ones.

Biomedical packaging: patients’ and workers' safety first

Biomedical packagings need to follow the requirements of the standard BS EN ISO 11607-1:2020+A11:2022 - Packaging for terminally sterilized medical devices - Requirements for materials, sterile barrier systems and packaging systems. They need to be puncture-resistant, resistant to bacterial colonization and contamination, resistant to gamma-ray exposure and sealable. 

At the current status, the end of life for biomedical packaging is incineration or landfill biomedical packaging. 

At FURIOUS, the developed novel materials should be mechanically or chemically recyclable to reduce waste during production, or biodegradable.

Electronic packaging: maintaining your devices in good shape

One of the main requirements for electronic packaging is to be antistatic. FURIOUS demonstrators will follow the rules set by the standard UNE-EN IEC 61340-5-3:2022 for the protection of electronic devices from electrostatic phenomena. Electrostatic discharge is one of the biggest contributors to the damaging of different types of electronic components and circuits. In order to tackle this problem, packaging for electronic devices needs to be designed in order to avoid any electrostatic discharge. This particular packaging is also usually made of two layers such as PET/LDPE and is landfilled or incinerated at the end of its life.

FURIOUS materials for electronic packaging need to be mechanically or chemically recyclable to reduce waste during production, or biodegradable. In addition, it needs to be thermoformable and sealable.

Car air filters: a breath of fresh air for plastic waste

Air filters need to be replaced once a year or every 15.000 km. Furthermore, not changing the filter can lead to the accumulation of dust and debris, restricting airflow to the engine, and thus reducing its efficiency and performance. The reduction of the efficiency of the engine, apart from potential engine damage, also increases the emissions of the vehicle. Replacing the filter ensures proper air intake, allowing the engine to run smoothly and efficiently.

The production of air filters needs to follow several standards, such as ISO/CD 16890-1 - Air filters for general ventilation. The standard encompasses various parts, specifically addressing particulate air filter elements for general ventilation with an ePM1 efficiency of 99% or less, meaning that the filter is able to capture fine particulate matter (PM) with a diameter of 1 micron or smaller.

Designing the filter and intermediate materials for compatibility with recycling processes is essential to promote the circular economy. FURIOUS materials for air filters will be antibacterials and electrospinnable. In addition, they will be recyclable, so their disposal will be easier for end-users, considering local waste management guidelines.

Plastic screens for vehicles: clear, durable and recyclable

Plastic screens need to follow UE regulations. The REACH Regulation (EC 1907/2006), in effect since 2007, aims to protect human health and the environment from harmful chemicals. It grants consumers the right to know if products contain harmful substances, which are often linked to serious health and environmental effects.

FURIOUS plastic screens need to be transparent or opalescent and need to serve as cabin interior lamp covers or control unit protection. Even if placed inside the cabin, the screen must have good resistance to UV and a degree of self-extinguishing V2, meaning it can stop burning on its own after the ignition source is removed. It also needs to have good heat resistance, good electrical insulation properties and to be recyclable.

Underwater devices: studying the seafloor without polluting it

Underwater devices are typically composed of thousands of complex parts, many of which are made from polymers that can be harmful to ocean ecosystems. In the FURIOUS project, we are focusing on developing sustainable polymers for three key systems/devices: a porous structure with an embedded spectrophotometer—a sensor that measures light transmission through the sensor, an anchor system, and a tethering system for data transmission. For the porous structure, it is essential to develop a polymer that is rigid, temperature- and UV-resistant, able to bond with other materials, has low water absorption, and is recyclable and biodegradable in the ocean after use.

The FURIOUS polymer designed for these underwater devices must meet several stringent criteria: it should not be brittle or become brittle in cold temperatures, have excellent UV resistance, and be biodegradable in underwater environments. However, it should not be biodegradable in specific cases, such as when used as a scaffold for environmental monitoring. It is hoped that the polymers developed through the FURIOUS project can be utilized in a broader range of underwater devices and technologies, contributing to a more sustainable marine ecosystem.

FURIOUS’s role in reducing plastic waste across industries

In conclusion, the FURIOUS project is at the forefront of developing innovative furan-based polymers that meet stringent requirements across diverse industries. From packaging for biomedical and electronic devices to car air filters and underwater sensors, the project demonstrates the versatility of these materials. By focusing on recyclability, biodegradability, and adherence to existing safety and environmental standards, FURIOUS aims to contribute to a more sustainable future while addressing the specific challenges each application presents. These advancements hold great potential to transform industries by reducing plastic waste and promoting circular economy practices.