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New CO2 plastics by Bayer MaterialScience
Bayer MaterialScience is testing a new initiative technology and conducting research in the area of using greenhouse gas carbon dioxide (CO2) as a component in plastics. The CO2 supplied by the power generation industry is to be used for the production of high-quality foams, replacing a portion of the petroleum usually used as a raw material. The pilot plant at Chempark Leverkusen has been using CO2 from an RWE lignite-fired power plant in Niederaußem outside of Cologne to produce a chemical used for the production of the high-grade plastic polyurethane. Industrial production of the CO2-based precursor is scheduled to begin in 2015. Polyurethane is specified for use in many types of mass produced products, including; mattresses, furniture, automotive components, as well as building, and refrigerator insulation.
Their “Dream Production” research initiative is one of the award winners in this year’s “365 Landmarks in the Land of Ideas” competition (the pilot plant at Bayer’s Leverkusen site is one of the “Selected Landmarks 2012”). Each year this competition (under the patronage of the German President) honors 365 ideas and projects that make a sustainable contribution to Germany’s future viability. It has been held each year since 2006 and is sponsored in part by the “Germany – Land of Ideas” initiative. The winners chosen by a panel representing science, industry, politics and the media are considered “indicators of Germany’s strong culture of innovation and a reflection of important future trends.” With 2010 sales of EUR 10.2 billion, Bayer MaterialScience is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials. The main segments served are the automotive, electrical and electronics, construction and the sports and leisure industries.
Ecor® is all recycled content and no glue
Meet Ecor®… It’s an, environmentally friendly board material which has some pretty cool properties. Ecor® products represent a new generation of strong, lightweight materials. To get technical, their product line is categorized as an “3-dimensional engineered molded fiber” (or 3dEMF if you like acronyms). Ecor® uses a variety of sustainable 100% recycled post‐industrial, post‐consumer and agricultural by‐products and requires no adhesives in the wet forming process. The resulting product is a non‐toxic and versatile material with significant profit potential along with a host of positive economic, social and environmental implications. The company uses formaldehyde‐free, non‐toxic ingredients with zero off gassing. Their material is up to 4 times stronger than other products of similar weight. Ecor® claims approximately 1/4 of the weight of comparable products which can significantly reduce shipping costs, injury, and handling or damage claims. They use a wide array of readily available, low cost, raw material sources. Ecor® has the ability to form this new material into compound curves and an almost limitless variety of shapes.
The process that produces Ecor® panels is similar to the “wet” process used for many years to produce paper and cardboard. Ecor® creates a wet fiber “stew” or matrix similar to paper pulp, which can be formed in a flat or corrugated mold to a uniform thickness. Water is extracted from the fiber matrix, first using suction, then by using heat and pressure, which are applied in a process that allows the cellulose fibers to form naturally strong and pliable bonds. The Company’s proprietary manufacturing technology for processing, molding, and bonding new and recycled cellulose fibers (wood, plants, recycled paper, etc). Their production technique achieves equal to, and even, far superior fiber adhesion, panel strength, and uniformity when compared to traditional “dry‐process” products. One main differentiator is that Ecor® material uses no toxic additives. In fact, Ecor® uses no additives at all, and therefore, no petroleum‐based products. To add to this amazing environmental attribute, the wet production process allows for a much broader range of potential raw material sources.
Inexpensive bio-based materials for solar panels
BioSolar, Inc. is an innovative company who has developed a cutting-edge technology which has the potential to reduce the cost of solar panels. They make bio-based materials from renewable plant sources which are included in the production of photovoltaics. Many companies in the solar industry use the strategy of exploring increased efficiency to reduce cost for the end user. BioSolar takes a different approach to the financial return model of solar panels. Their strategy is to replace petroleum-based plastic photovoltaic panel components with durable, long-lasting bio-based components.
Materials made by BioSolar can be used directly in conventional manufacturing systems, such as injection molding and thin-film roll-to-roll, to create a “superstrate” layer, substrate layer, backsheet as well as module and panel components. Whether solar cells are produced using crystalline silicon, amorphous silicon or other solar technologies, BioSolar can help reduce the cost per watt through the use of more cost-effective construction materials. Their company is offering and developing a comprehensive line of low cost bio-based films and resins to replace higher cost solar panel components. Their products include materials such as “BioSolar Backsheet”, “BioSolar Thin Film Substrate”, “BioSolar Superstrate”, and “BioSolar Plastic”. Some products are commercially available at this time and others are under development, with anticipated release in the near future.
UPACKS shipping material by Patrick Sung
Patrick Sung developed a concept he’s calling UPACKS (which stands for Universal Packaging System). The modular concept is targeted towards the packaging and shipping industry. It utilizes a flat cardboard sheet of recycled material which is capable of conforming to a variety of different shapes. The trick of the material is in the scored/perforated pattern made on the sheet.
His simple concept makes use of cleaver design thinking and utilizes an everyday material, making it unusual, valuable, and engaging. The cardboard can also of course, be recycled itself. The intent of combining a faster way to pack with simplicity, cost efficiency, and recycling are all great aspects of the idea. No word as to weather Patrick will be taking his concept to market anytime soon but we like what we see here…
Enviro graffiti by Anna Garforth
Anna Garforth is a London-based artist who works with a diverse range of materials. She uses her skills to create unique and experimental work from sustainable materials and processes. So far her artworks have been used for public events, community projects, workshops, campaigns, publications and exhibitions both nationally and internationally. With a strong background in design and illustration, she is able hand-work moss into beautiful lettering. She also makes cookie dough into edible posters and rubbish into typographic wonder. Amazing work if you ask us!
Paper Alarm Clocks by Joon&Jung
Joon&Jung is a multi-disciplinary design studio based in Eindhoven. Their design methodology is human-based and they strive to design using simple concepts. They focus on making products which are attractive and functional. Their mission is to design for society while telling a unique story. Their Paper Alarm Clock is made from collected paper and the inside electronics of a 2nd hand alarm clock. They have been developing 2 versions of the Paper Alarm Clock (one with a white theme, and one in black). The designs have mechanical buttons which are wired up to take advantage of the reused radio electronic components.
The team at Joon&Jung draw inspiration from the world that surrounds them and their daily experience. They have a diverse background. Their team has studied design in Korea as well as the Netherlands. For the design of their Paper Alarm Clocks, they were motivated to create a valuable object from reclaimed electronics that could also be mass produced.
The first release of their designs for this clock were presented at the Stockholm Furniture Fair at the Designboom Mart. Both versions of the Paper Alarm Clock feature an LED clock display that emits light from behind. While very experimental as a consumer product at this stage, there’s a hint that this design idea can be successful on a larger, production scale with further refinement and a consistent stream of reused electronic components. We haven’t seen too many designers attempt to tackle the pressing issue of e-waste and applaud Joon&Jung for initiating this inspiring project!
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