Users of poly- and perfluorinated alkyl compounds (PFAS), also known as “perpetuity chemicals”, are under pressure due to regulatory proposals from the European Chemicals Agency (ECHA). This also affects the use of fluoroelastomers, whose economic significance is enormous. Fraunhofer experts initiated the “HATE-Fluor” project at the beginning of February. Together, they want to develop high-performance elastomer compounds to replace fluoropolymers in certain technical applications. Various industries can benefit from this, including manufacturers of semi-finished and finished parts as well as companies in plant and mechanical engineering, medical technology, clean room and semiconductor technology, chemical process technology and electrical applications.
Many companies are looking for alternatives to polyfluorinated and perfluorinated alkyl compounds (PFAS), as their possible uses in the future are uncertain and voluntary commitments are expected. PFAS are found in everyday products such as coated pans, pizza boxes and outdoor jackets, as well as in medical technology, heat pumps and batteries. While there are already fluorine-free substitutes for some everyday applications, there is a great need for new individual solutions to replace fluoropolymers for technical applications that have to withstand extreme conditions.
PFAS replacement: coated elastomers and customizable modular solutions
In the newly initiated “HATE-Fluor” project, teams of experts at the Fraunhofer Institute for Structural Durability and System Reliability LBF and the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM will develop fluorine-free coated elastomers and offer customizable modular solutions to meet the growing market demand. The solution comprises three main steps: improving the thermal stability of fluorine-free elastomers with novel antioxidants, producing customized elastomer formulations and developing a coating system to protect the elastomer from oxidative and chemical attack. The modular structure of this system, consisting of lacquer and plasma coatings, is intended to cover a broad spectrum in the field of fluorine-alternative seals. The target properties are determined by the areas of application of the fluoroelastomers that are being replaced in the project.
Bundled Fraunhofer expertise
In the “HATE-Fluor” project, the Fraunhofer Institute for Structural Durability and System Reliability LBF is concentrating on the development of high-performance elastomers as a replacement for fluoropolymers in technical applications. One focus is on improving the thermal and thermo-oxidative stability of fluorine-free elastomers using innovative antioxidants. In addition, application-optimized elastomer formulations are being developed to ensure maximum resistance and optimum adhesion. This is complemented by the formulation of a coating system for the elastomers. The latter is being developed at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM to protect the material from oxidative attack and chemical degradation.
Fraunhofer IFAM is also working on the coating of these elastomers within the project to improve their friction reduction and barrier properties. A particular focus is on the development of polyimide coatings in combination with layered silicates that prevent the permeation of harmful gases and moisture. These coatings are used in particular for high-performance electronics and other demanding applications. In addition, the modification of the phyllosilicates is being investigated to reduce the permeation of water vapor and oxygen through the coating by up to 99%. The application of these coatings shows significantly reduced ageing and prevents dendrite growth as a result of harmful gas exposure.
The Fraunhofer Institutes LBF and IFAM combine their expertise to develop new solutions and application-ready technologies. Both institutes already have extensive expertise in PFAS substitution thanks to many years of development and project work. The “HATE-Fluor” project is funded by the Fraunhofer-Gesellschaft as part of the PREPARE program and will run for three years.
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