CO2mposite: Recycling of CO2, Carbon Fiber Waste, and Biomaterials into Composite Panels for Lower Embodied Carbon Building Materials

"SkyNano, Endeavor Composites, and The University of Tennessee Knoxville propose to develop a composite panel that contains CO2-derived carbon nanotubes (CNTs), recycled carbon fiber waste, and bio-derived natural fibers that exhibits excellent mechanical and functional properties, while maintaining a carbon-negative footprint on a cradle-to-gate and cradle-to-grave basis. By the end of the Phase I and Phase II STTR effort, the team proposes to develop and test the composite panel, which is envisioned to be applicable for interior wall coverings, non-load bearing interior walls, exterior facades, and ceiling panels. Phase I of this effort will focus on the proof of concept for this material architecture, basic mechanical testing, and a preliminary LCA evaluation. Phase II will be centered on optimization of all material constituents, functional and mechanical testing, a study on recycling of the material for end-of-life processing and management, and collaboration with a team from the sister FOA for a full scope LCA on the composite. To address the growing climate crisis and the increased activity in the construction industry which contributes significantly towards total greenhouse gas emissions, SkyNano and Endeavor Composites herein propose to rely on core competencies in the production of CO2-derived carbon materials from electrochemistry (SkyNano) and the fabrication of sustainably-approached composite panels using well-dispersed recycled fibers (Endeavor Composites) to create CO2mposites: composite panels for the building industry that rely on a multi-scale materials approach combining recycled carbon fibers diverted from the landfill, directly utilized CO2 via electro-reduction into solid carbon additives, and biomaterials such as bamboo fibers."