article · Results in Engineering
Researchers have developed and evaluated a novel hybrid polymer composite combining basalt and Kevlar fibres with agricultural bran filler particulates inside an epoxy matrix. Manufactured using a standard hand layup process, the resulting material exhibits strong resistance to thermal degradation, maintaining structural weight up to 350 degrees Celsius. It also delivers a low coefficient of linear thermal expansion, ensuring dimensional stability when subjected to thermal stress. Incorporating basalt fibres increases thermal conductivity to 0.79 W/mK, aiding heat dissipation compared to traditional epoxy resins. Furthermore, the material resists deformation under load up to a heat deflection temperature of 179 degrees Celsius. The combination of synthetic and mineral fibres alongside char-forming bran particulates enhances overall fire resistance, presenting an effective composition for demanding thermal environments.
Components used in high-temperature settings must endure severe heat without changing shape or catching fire. By integrating natural bran waste with robust basalt and Kevlar fibres, this research shows how common epoxy resins can be significantly upgraded. The resulting composite offers improved fire resistance and dimensional stability, supporting the creation of safer, more durable materials for thermal insulation.
The composite is positioned for applications in thermal insulation and protective materials requiring fire resistance and thermal endurance. Potential users include manufacturers of industrial insulation and protective structural panels. Because the material was fabricated and tested at laboratory scale using hand layup methods, it represents applied, early-stage research that requires further process scale-up and standard compliance testing before commercial deployment.
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• Thermal stability and flame-retardant properties of a hybrid polymer composite is evaluated. • Proposed composites show excellent thermal stability, with significant weight loss only above 350 °C. • A low coefficient of linear thermal expansion (CLTE) of 1.74×10⁻⁵ / °C indicates enhanced dimensional stability during temperature changes. • The composite demonstrates a thermal conductivity of 0.79 W/mK, significantly higher than standard epoxy resins, due to the efficient heat dissipation properties of basalt fibers. • Heat deflection temperature (HDT) testing reveals an impressive HDT of 179 °C, alongside improved flame-retardant properties, making the material suitable for thermal insulation applications. The development of advanced polymer composites with enhanced thermal stability and flame-retardant properties is essential for high-performance applications. This study aims to investigate a novel hybrid polymer composite reinforced with basalt and Kevlar fibers, integrated with bran filler particulates within an epoxy matrix. The composite was fabricated using the conventional hand layup technique, and its thermal and flame-retardant properties were systematically analyzed. Thermogravimetric analysis (TGA) revealed excellent thermal stability, with significant weight loss occurring only above 350 °C. The coefficient of linear thermal expansion (CLTE) was measured at 1.74 × 10⁻⁵ / °C, indicating superior dimensional stability under thermal stress. Thermal conductivity tests demonstrated an improved value of 0.79 W/mK, attributed to the efficient heat dissipation properties of basalt fibers. Heat deflection temperature (HDT) testing indicated a high HDT of 179 °C, showcasing resistance to deformation under heat. Furthermore, the composite exhibited enhanced flame-retardant capacity due to the synergistic effects of basalt and Kevlar fibers and the char-forming properties of bran fillers. The findings highlight the novelty of combining basalt and Kevlar fibers with bran particulates to achieve superior thermal and flame-retardant properties. This hybrid composite demonstrates significant potential for applications in thermal insulation and protective materials where high thermal stability and fire resistance are essential.
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DOI: 10.1016/j.rineng.2025.104207
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