A Cheshire-based cleantech start-up is developing next generation low carbon composite materials that aim to be cheap enough to be used in the braking systems of mass market cars.
Carbon Ceramics Ltd has been set up to research and develop new
low emission carbon composite materials for transportation and energy applications. It was launched by Julio Faria, who founded Surface Transforms plc, the UK’s leading manufacturer of
high performance brakes made from carbon fibre reinforced ceramic composite materials (CRFCs).
CRFCs are used in various forms for automotive, railway and aircraft brake applications and are even used for rocket propulsion because of their very high heat tolerance and lightweight, low maintenance properties. They can withstand temperatures of over 2,000°C and are 70 per cent lighter than cast iron. However, they are also prohibitively expensive for mass-market applications. Manufacturing CRFCs is also an energy intensive process, something Faria said is unsustainable going forward.
"The planet needs us to move urgently towards sustainable
transportation technologies," he said.
Disc brakesHe told
GreenWise his start-up was developing carbon composite materials that would not only be low emitting but also cheap enough to be applied in disc brakes for mass market cars.
"At the moment carbon brakes are right at the top of the industry. We want to bring the costs down so they can be used in a Ford Fiesta," said Faria.
While Carbon Ceramics could see some of its products ready for commercial application within the next three years, they are not expected to find their way into the disc brakes of standard cars for another seven to eight years.
Faria described the environmentally friendly materials being employed to produce Carbon Ceramic’s new family of ultra light, super strong composites as "top secret", but he did confirm that they would incorporate "lots of
recycled materials" including "recycled feedstocks".
Energy consciousThe company, meanwhile, is researching innovative
production processes that will cut down the time and cost it takes to manufacture carbon ceramic brakes and make the process more
energy efficient.
"Currently it can take three months to produce carbon ceramics and there is a process called 'carbon vapour infiltration’ that is 90 per cent energy inefficient," he explained. "We want to bring the production time down to a couple of days and be energy conscious from the outset – looking at the energy profile first and using the technology to match."
£80,000 grantCarbon Ceramics is working with Manchester University and other experts around the world to find and test those technologies and has just been awarded an £80,000
grant by the North West Regional Development Agency to continue its
research and development.
Faria said the end product would be " alot cheaper and greener and better and something the end user will be happy to use."
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