Composite Cork Reinventing Cork

 

Composite Cork: Reinventing Cork

The success of the Composite Cork Business Unit is based on advanced technological research and a permanent focus on innovation which has made it possible to enhance the potential of cork. This business unit proposes unique, ground-breaking solutions using a 100% reusable material and is an international leader in the research, development and production of new composite cork solutions.

The BU’s passion for innovation is evident in projects that experiment with cork to launch new real world applications.

For example, in the context of the METAMORPHOSIS project, the BU’s research into the properties of cork involving some of the world’s most renowned designers and architects, has spawned solutions that make it possible to implement visionary proposals, and has thereby expanded the limits of this raw material to previously unimaginable levels.

The strategy of combining R&D with highly qualified engineering processes, has generated new products and new applications for cork-based composite materials, many tailor-made, that meet the requirements and exceeding the expectations of some of the world’s most demanding industries and most reputed institutions.

Key projects recently pursued by this business unit's R&D+I department included

the development of a new cork composite for the European Space Agency (ESA)’s IXV mission,

a new cork-based material for a mega installation at the Tate Modern’s prestigious Turbine Hall Gallery in London, and

a revolutionary concrete-and-cork composite used in the Lisbon Cruise Terminal, which is considerably lighter than standard concrete but delivers the thermal and acoustic insulation of cork.

Lightness is also a key dimension of an innovative solution designed by this BU for the maritime industry. By developing a new cork composite for application on the decks of river cruise ships, it has been possible to achieve a significant weight reduction, complemented by excellent thermal insulation and passenger comfort, thereby delivering obvious benefits for safer and more reliable shipping and cleaner oceans.

Part of the R&D effort is dedicated to the challenge of technologically enhancing cork’s natural characteristics through maximisation of the use of natural raw materials and / or biomass derivatives. New ground-breaking resins and manufacturing technologies for these products and solutions are also being developed.

The building industry is one of the principal beneficiaries of this innovative drive to seek alternative solutions to synthetic materials, which guarantee maximum performance. New solutions developed by this BU include:

Acousticork - a range of subwoofer and anti-vibration solutions that bring nature to the heart of the city;

Corkwall - an ecological wall covering that uses the elasticity of cork to deliver tremendous potential for the rehabilitation of building façades, by combining insulation and final finishing functions in the same product; and

Expandacork - a range of expansion joints that uses the properties of cork to absorb the expansions and contractions of concrete buildings.

The challenge of innovation in the Composite Cork Business Unit has led to the development of cooperation programmes with universities, partnerships and consortium projects.

One example is the AEROFAST project, in the framework of which this BU has created a new material for spacecraft thermal shields designed for a future unmanned mission to Mars. The project was led by EADS / Astrium and involved demanding requirements in terms of cork’s thermal protection. The Composite Cork BU was responsible for studying and developing an innovative and resistant cork-based thermal protection formulation. In this context, new resins and additives, in particular fibres, were tested to improve thermal resistance performance.

The success of the project, which was continued in the Ablamod project, is a guarantee of the continued use of cork in space missions during the 21st century, as shown by the recent successes in launching the Delta IV rockets, one of Boeing's most advanced projects, and Vega, the latest rocket from ESA – the European Space Agency, both of which incorporated materials supplied by Corticeira Amorim.

In the field of ground transportation, there has also been major work on important innovation projects, such as Siemens' new Inspiro surface metro system. In terms of future transport systems, it is worth mentioning the concepts of IBUS, ISEAT and Life – the last of which won an international "Crystal Cabine Award".

The BU’s commitment to R&D+I has ensured that cork-based solutions are increasingly comprehensive and surprising.

For example, in the world of sport, new cork granulate infills used in synthetic turf systems have helped make artificial turf more similar to natural turf, and increased its performance.

A similar situation exists for surfboards (such as the MBoard cork board, especially designed for the surfer Garrett McNamara to face the big waves of Nazaré) and equipment for other water sports, where cork’s unique properties have consistently made it possible to overcome the most demanding challenges.