Synthesis, characterization, and recycling of bio-derivable polyester covalently adaptable networks for industrial composite applications

Fiber-reinforced polymers (FRPs) are critical for energy-relevant applications such as wind turbine blades. Despite this, the end-of-life options for FRPs are limited as they are permanently cross-linked thermosets. To enable the circularity of FRPs, we formulated a bio-derivable polyester covalently adaptable network (PECAN), sometimes referred to as a polyester vitrimer, to manufacture FRPs at >1 kg scale, which is accomplished as the resin is infusible (175–425 cP at 25°C viscosity), can be cured at 80°C within 5 h and is depolymerizable via methanolysis yielding high-quality fibers and recoverable hardener. The FRPs exhibit a transverse tensile modulus comparable with today’s wind relevant FRPs (10.4–11.9 GPa). Modeling estimates a resin minimum selling price of $2.28/kg and, relative to an epoxy-amine resin, PECAN manufacture requires 19%–21% less supply chain energy and emits 33%–35% less greenhouse gas emissions. Overall, this study suggests that redesigned thermosets can yield beneficial circularity.