Research Program 2
Project 2 Development of High Value-Added Conductive and Shielding Materials from Sustainable Raw Materials
Institution: Koruma Klor Alkali San. ve Tic. A.Ş.
Karel Kalıp was established in 1994 to produce plastic injection molds of telecommunication equipment of Karel Elektronik.
In 1997, it was turned into a separate center as Karel Kalıp San. A.Ş. and molds began to be produced for automotive projects.
With the title of R&D center determined by the Ministry of Industry and Technology in 2015, it became the first plastic injection molding company with an R&D center in Turkey.
It has been involved in TÜBİTAK and EU-supported projects for 10 years, including lightweighting of automotive parts, process improvement and composite product design regulations.
The general goal of the projects can be defined as reducing CO2 emissions and developing sustainable and environmentally friendly products
Project 2.1 Development of High Value-Added Flexible Conductor Materials from Lignocellulosic Biomass and Integration with Plastic Injection Techniques High Value Added
Project 2.1 Summary:
The project aims to replace traditional unshielded twisted pair cables (UTP) with flexible printed structures in automotive applications, specifically for carrying Controller Area Network (CAN) signals. Conductive materials derived from lignocellulosic biowastes will be developed and integrated into plastic injection molding processes. The project will focus on achieving goals such as creating stable carbon-based colloidal conductive inks, producing flexible and conductive mats, and manufacturing injection-molded automotive prototype parts with integrated conductive material. These materials will offer advantages such as better impedance characteristics, reduced transmission loss, and improved shielding against electromagnetic interference. Ultimately, the project aims to obtain driver and passenger overhead lighting systems for passenger vehicles using these flexible and conductive structures, with the potential for further industry collaboration and support.
The main outputs of the project are:
- Stable carbon-based colloidal conductive inks
- Flexible and conductive mats
- Injection-molded automotive prototype part with integrated conductive material
When the project successfully achieves its goals and objectives (THS 5-6), the prototypes to be obtained will apply for additional support programs for higher THS levels within the scope of industry/university cooperation.
The research program of the sub-project "Development of High Added Value Flexible Conductive Materials from Lignocellulosic Biomass and Integration with Plastic Injection Techniques", which will be carried out under the umbrella of the 'High Technology Platform', will primarily be carried out under the NACE 2 code "Manufacture of electronic components and circuit boards" corresponding to 26.1 and 26.11. ” covers the area.
Project 2.2 Development of Carbon-Based Advanced Materials for Electromagnetic Shielding
Institution: TÜBİTAK MAM
Project 2.2 Summary
In the project carried out in collaboration with TÜBİTAK MAM, Marmara University, SUNUM, FNSS, and NUROL Technology Inc., the aim is to develop carbon-based advanced materials for the production of antennas/electrodes suitable for electromagnetic shielding and 5G technology by using green technologies from lignocellulosic biomass, a widely available sustainable resource in our country. In the project, hazelnut shells and sawdust are used as the lignocellulosic biomass in the first stage, and in the second stage, lignin, which is separated from hazelnut shells and sawdust through Kraft and Organosolv techniques in APYK 1 and determined to have the highest purity as a result of comparison, will be used.
In this study focused on sustainable production; TÜBİTAK MAM will initially develop bio-oil through the pyrolysis process, biochar through the carbonization process, hydrochar through the hydrothermal carbonization process, and liquid biomass intermediates/side products by also utilizing microwave technology, which requires lower energy and offers more efficient heating performance. As a second step, bio-asphalt will be produced through the distillation of bio-oil, and activated carbon will be produced from lignocellulosic biomass/biochar through chemical and hydrothermal activation processes. Graphitic active carbon transformations will be carried out through the catalytic graphitization process in the presence of graphitization catalysts and activation agents. As an alternative method, the graphitization process of active carbons at temperatures >2000°C in an inert gas atmosphere will be optimized by NUROL Technology Inc. The graphitic active carbons produced by both techniques will be analyzed in terms of their properties, and conductive paste (putty) formulations suitable for the serigraphy technique by TÜBİTAK MAM will be developed for use directly or after modification (utilizing coating technologies). Concurrently, FNSS will carry out the design, production, and characterization of polymer-based electronic card enclosures. The developed conductive pastes will be applied to textile surfaces and the polymer-based electronic card enclosures to be developed in the project to provide electromagnetic shielding properties. Additionally, carbon foam productions will be carried out using starting materials prepared by mixing certain ratios of biochar/activated carbon/bio-oil from lignocellulosic biomass and/or project intermediates/side products. At the end of the project, the electromagnetic shielding effectiveness of the developed textiles and carbon foam will be determined for the frequency range of 30MHz–3GHz according to the ASTM-D4935 standard and for the frequency range of 3GHz-18GHz according to the IEEE 299.1-2013 standard, while the electromagnetic shielding effectiveness of the electronic card enclosure will be determined for the frequency range of 30MHz-3GHz according to the ASTM-D4935 standard. Finally, an antenna suitable for 5G technology will be designed, prototyped, and characterized by Marmara University and SUNUM, using the active carbon/biopitch/biochar produced as intermediates/side products in the project as electrode material. The potential use of lignocellulosic biomass as a substrate material in antenna development activities will also be evaluated.
In this project, which will extensively research and develop prototypes for the process leading to the development of high-value-added intermediates and by-products, final products with electromagnetic shielding properties, and antennas/electrodes suitable for 5G technology, utilizing green technologies such as microwave and hydrothermal technologies, there will be a focus on creating high-value and unique applications for lignocellulosic biomasses. Currently, some of these biomasses are either burned or used as animal feed, while others are left in the fields due to labor, storage, and other cost concerns. The project aims to enhance the value and utilization of these lignocellulosic biomasses, transforming them into valuable and innovative products.