Application of NAtural fibre reinforced COMPOsites in harsh

Applications of Natural Fibers
in Composites
Dr. Egidija Rainosalo, Technology Centre KETEK Ltd
4.05.2011
1941: Henry Ford designed and built
a car from compression-molded 70%
cellulose fibers, including industrial
hemp, mixed with a resin binder . He
designed it to run on hemp biomass
fuel.
Apparently they were pretty sturdy:
Below is a guy beating on the trunk
with an axe, he failed to leave a
mark.
The total weight of the plastic car is about 2,000 pounds, compared with
3,000 pounds for a steel automobile of the same size."- December 1941
issue of Popular Mechanics.
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Main Drivers
 Support of Policy – US: Public procurement, Japan: Quotas, EU:
Lead Market Initiative, Targets? Quotas? (more details are
discussed later); many countries ban non-biodegradable plastic
bags.
 Customers – are interested in more sustainable materials and
products; bio-based materials and products have (still) the image to
be a sustainable option
 Multinational companies – using bio-based materials and
products because of positive marketing effects (“sustainable
company”); because of limited supply of bio-based materials
multinational companies often try to get exclusive access.
 SME – realising more and more bio-based solutions for niche
applications, some could develop to mainstream markets (like in
food packaging)
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Outline
• What are natural fibers?
• What are the properties of natural fibers?
• Market of products with natural fibers in
Europe and Finland
• Where to use natural fibers?
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Classification of Fibers
Natural
fibers
Plant
Abacá · Bamboo · Coir · Cotton · Flax (Linen) · Hemp · Jute · Kapok ·
Kenaf · Piña · Raffia palm · Ramie · Sisal · Wood
Animal
Alpaca · Angora · Bison down · Byssus · Camel hair · Cashmere · Catgut ·
Chiengora · Guanaco · Llama · Mohair · Pashmina · Qiviut · Rabbit · Silk ·
Sinew · Spider silk · Wool · Vicuña · Yak
Mineral
Asbestos
Celullose
(Regenerated cellulose
fibers)
Synthetic
Acetate, triacetate · Art silk · Bamboo · Lyocell (Tencel) · Modal · Rayon ·
Viscose
Mineral
Glass · Carbon (Tenax) · Basalt · Metallic
Polymer
Acrylic · Aramid (Twaron · Kevlar · Technora · Nomex) · Derclon ·
Microfiber · Modacrylic · Nylon · Olefin · Polyester · Polyethylene
(Dyneema · Spectra) · Spandex · Vinalon · Zylon
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Properties of some fibers
Density g/cm3
Tensile
strength, MPa
Elongation at
break, %
E-Modulus,
GPa
Moisture
absorption,
%
E-Glass
2.54-2.6
900-3500
1.8-3.2
72-73
-
Carbon
1.75
2600-6500
1.3
100-700
Kenaf
1.5
350-600
2.5-3.5
40
Hemp
1.48
300-900
1.6
30-70
8
Jute
1.46
400-800
1.8
10-30
12
Sisal
1.33-1.45
510-700
2.2-2.9
9-38
11
1.51
400
3-10
12
8-25
1.4-1.5
500-1500
1.2-2.4
50-80
7
1.5
700-800
13-15
20
8
Fiber type
Cotton
Flax
Rayon
Properties of some fibers
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Exploration of Properties
• Flax to increase the
thickness with the same
weight -In the middle of
the laminate
• Consequently, the stiffness
of the composite will
increase
• Coefficient of thermal
expansion is close to the
one of carbon; allowing
compatible associations in
hybrid structures with
carbon fibers
• Vibration damping reduced
as well as impact resistance
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Exploration of Properties
•Reduce the risk of injury
•Increase the gameplay
(sport)
•Decrease the bursting
risk
•A better productivity
(wind blades)
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Mechanical Properties of Composites
Injection Moulding
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Type of reinforcement available
•
•
•
•
•
Pellet
Non-woven
Roving-twistless yarn
Yarn
Fabric: woven or knitted – same weaving
patters as with glass fiber or carbon fiber
are available
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Some Process Technologies
Extrusion
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Wood Plastic Composites
Automobiles – Construction and Furniture – Industrial and Consumer Products
Extrusion & Injection Moulding
Source: Werzalit 2007, nova-Institut 2007, IKEA 2007, Domna 2008
WPC Market volume world
> 1,5 Mio. t (2010)
•
•
North-America: > 1 Mio. t
China: > 200.000 t ( 2015: 5 Mio. t)
•
Europe ca. 170.000 t (Germany: 70.000 t)
- Construction & Furniture: ca. 120.000 t
- Automotive: ca. 50.000 t
•
Double-digit growth per year
•
North-America / Europe: Using by-products from the wood
industry
•
Asia: Using all kind of cellulosic by-products from forest and
agriculture
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BMW 5
Series
 Total amount: > 40,000 t/a (EU)
Fibr
e
> 90% compressing moulding
 Fibre use: > 25,000 t/a (EU)
Flax, Hemp, Kenaf, Jute, Sisal, Coir
 Established and stable market with a
new potential
 New trends
- Showing the natural fibres under
transparent films or lacquers
- Using bio-based polymers
From 50-60% bio-based to 100% biobased
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Non-woven
fleece
Naked door
Finished
door
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+
« FlaxPly »
for direct
processing
=
Epoxy resin +
hardener
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Racing Boat
•Sandwiches reinforced with flax
and core of the sandwich is of
Corecell™(*).
•One to two plies of UD flax fabrics
(215 g/m2, nominal thickness
0.96mm) used in the laminate
sequence depending on the areas.
•A taffeta of glass E integrated in
the hull’s bottom planking.
•A very light yet rigid and very strong
fiber.
•In total, flax fiber constitutes 50% of
the weight of the boat’s
reinforcement. It accounts for 75 to
80% of the hull and the deck’s
reinforcement.
•A high environmental added-value.
IDB Marine de Tregunc shipyard in France
4.05.2011
Products in Finland
Novoplastik – flax/PLA (corn suggar)
Joensuun Meskari Oy- Kupilka sarjan tuoteet
Flaxwood
All-Plast Oy
UPM
Muut
Ekolite
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Why to use natural fibers?
Special properties other fibers don’t have
Low density, leight weight structures
High energy absorption
Comperatavily high modulus can be used in stiff but not lad bearring
stuctures
Low thermal expansion, can be combined with e.g. carbon fiber
High environmental added value!
Material production has less environmental impact
Leighter structures comparring to glass fiber composites structures 
Reduced fuel consumption during transportation
More fuel efficient end product in e.g. transport applications
Increased recycling possibilitiesbetter energy recovery, no large amount
of slag
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Used references
1.
2.
3.
Bio-Composites. Technologies and Applications. Presentation of Michael Carus, NovaInstitut GmBH, Kemi 26.01.2011
(http://www.ketek.fi/anacompo/materials_kemi_january_2011/)
Natural fibers in thermoset composites. Presentation of Francois Vanfleteren, Lineo, Kemi
26.01.2011 (http://www.ketek.fi/anacompo/materials_kemi_january_2011/)
Internet google search
Other OSKE material which might be interesting to read:
http://www.ketek.fi/oske/Luonnonkuitukomposiittien_tarveselvitys_Loppuraportti_julkinen.pdf
http://www.ketek.fi/oske/Kestavan_kehityksen_mukaiset_materiaalit_pakkausteollisuudelle.pdf
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Kiitos!
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