Natural Fibre Composites - · PDF fileA UK-owned producer of natural fibre non-wovens 90%...
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Transcript of Natural Fibre Composites - · PDF fileA UK-owned producer of natural fibre non-wovens 90%...
www.ecotechnilin.com Natural Fibre Composites
www.ecotechnilin.com
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A UK-owned producer of natural fibre non-wovens
90% automotive, 5% construction, 5% aerospace
Turnover 2014: 10.5M€; 40 employees
French non-woven factory established in 1995
UK Technical Centre set up in 2007
Very innovative: several pieces of associated IP
Non-wovens are sustainable, affordable and lightweight
Expanding into Eastern Europe, Mexico & North America
EcoTechnilin
Accepted European market leader in natural fibre non-wovens
www.ecotechnilin.com
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Cultivation Fibre Preparation Consolidation into mats
Part forming by Tier1 End user applications
Process overview
Automotive Aircraft
Non-wovens made by ET Flax grown by farmers Fibres extracted by coops
Impregnation/Coating
We advise on the whole process but this is our core activity
www.ecotechnilin.com
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Yvetot, France Needle-punch plant
EcoTechnilin locations
Huntingdon R&D facility
Biocomposite expertise Group HQ
Non-woven expertise + fibre knowledge
www.ecotechnilin.com
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1
Non-woven production
EcoTechnilin deliveries
Non-woven distribution Current automotive projects
Today
www.ecotechnilin.com
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Thermoplastic non-wovens flax/PP or glass/PP production
Flax/PP from 600 to 2400 g/m2
• 30% lighter than injection moulding
• Cold tools => lower investment
• One-shot process => faster process
We produce FibriPlast for the following vehicles:
Door panels Trunk trim Instrument panel Parcel shelves Mercedes E class Opel Insignia Mercedes Smart Renault Megane
VW Golf Kia Ce’ed Renault Clio
Ford Kuga Mercedes C class Renault Captur
Ford Transit Nissan Qashqai Mercedes Smart
Citroen C4 Toyota Aygo
Truck cab interiors Toyota Avensis
Volvo + new Renault Magnum Audi A8
www.ecotechnilin.com
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Fibres as non-woven flax mats
• Weights from 300 to 2400 g/m2
• Very low environmental impact
We supply FibriMat direct to large building companies for use as an underlay below wooden floors
We have supplied FibriMat to some companies for use with polyurethane for parcel shelves (eg Audi and Jaguar)
We convert most FibriMat into pre-preg which we call FibriPreg
Thermoset biocomposites flax non-woven/PFA bioresin
www.ecotechnilin.com
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Study conducted for flax non-woven flooring underlay
Eco impact of flax fibres
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PFA-based Bioresin
Sugarcane Sugar
Bagasse also
Corncobs Oat, rice hulls Nut husks, shells Olive residue
Biomass-based resins
Construction
High pressure laminates
www.ecotechnilin.com Eco impact of PFA bioresin
LCA analysis
PFA BioResin
Calculated using the CML2 shadow price method Comparison to a phenolic and a polyester resin
PFA BioResin
www.ecotechnilin.com
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Previous developments with flax/PFA sugar-based bioresin have excellent properties:
• Lightweight
• Low cost
• Fast process
• Formable material
• Good impact resistance
• Mechanical performance
• Good Fire Smoke Toxicity
Door trim Flax/bioresin
Seat back Flax/bioresin
Load floor Flax/bioresin
Ceiling tile Flax/FR bioresin
FibriPreg - thermoset flax / PFA sugar-based bioresin
www.ecotechnilin.com
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• Lightweight and robust
• Good Fire Smoke Toxicity performance
• Good mechanical performance (9G pull test)
• Fast manufacturing process
• Mouldable / formable material
• Abrasion resistance (for runners)
• Low Cost
Bonus properties requested
Ultra-fast curing time + low-energy process
100% bio-sourced (65% sustainable), very low eco-impact
Galley cart requirements
www.ecotechnilin.com
Fibre property Flax E glass Basalt S2 glass Carbon
Density (g/cm3) 1.54 2.5 - 2.7 2.6 - 2.8 2.5 1.74 - 1.8
Elastic modulus (Gpa) 70 - 80 74 75 - 100 83-86 200 - 250
Temperature range (oC) 200 460 600 300 500
Tensile strength (Mpa) 1,400 - 1,600 3,100 - 3,800 2,800 - 4,000 4,020 - 4,650 2,700 - 3,750
Energy consumption (kWh) 0.7 8 - 15 5.5 - 9 8 - 15 36 - 81
CO2 emission (kg) -6.4 4 - 8 3 - 5 4 - 8 20 - 45
Ultimate elongation (%) 2.4 - 4.1 4.7 2.8 - 3.2 5.3 1.2 - 1.6
Moisture absorption (%) 7 0.1 0.03 0.1 0.1
Price (€/kg) 1 1 - 2 3 - 5 10 -15 18 - 40
Fibre cost and properties
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FibriRock: Flax + basalt + PFA bioresin (30/35/35)
External panels comprise FibriRock sandwich
so FibriRock skins outside Nomex core
Drawer runner panels are moulded from a
single-thickness sheet of FibriRock
FibriRock Biocomposite
www.ecotechnilin.com
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Smartcart weighs 10.5 kg
The lightest 50kg-rated cart by 6.5 kg
1kg weight saving saves 150$/year
FibriRock sandwich panels 6mm thick 2,300 gsm
FibriRock runner panels 1mm thick 1,000 gsm
FibriRock system <8kg in SmartCart
Lightweight and robust
www.ecotechnilin.com
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Lightweight and robust
9G pull test simulates load on secured carts
SmartCart secured
with only left latch
1340 kg of force
used to pull cart
Force on rear plate 7.2kN Force on front plate 5.9kN
13,100N applied for 3 seconds
Test repeated with right latch on same carts. No visible damage
www.ecotechnilin.com
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Tests on 6mm sandwich panel for galley cart
Excellent heat release figures -> use cheaper films and finishes
First time AIM engineer had ever seen sample during smoke test!
No detectable toxins
Fire Smoke Toxicity
Test Units Result Criteria Burn length inches 2.3 < 6 Drip exiting time seconds 0 < 3 Heat release rate kWmin/m2 15 < 65 Max heat release rate KW/m2 18 < 65 Smoke emission DS max 10 < 200 Toxic gas emission v.low
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Fibres and resin flow in hot tool
Runner panel formed in 45 seconds
Edges of sandwich panels are pinched and sealed
Surfaces around fixings are recessed to improve performance
Each 4mm fixing can withstand 1300 N of lateral force
Allows SmartCart to be produced quickly… no adhesives/bonding
Mouldable / formable
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Organic fibres hold resin in position during high temp curing
FibriRock sandwich panels form in 150 seconds
Single-thickness runners formed in 45 seconds
Existing honeycomb composites take between
45 minutes and 3 hours to cure Use of natural fibre + (bio)resin as structural adhesive system -> natural fibres are hollow and hold 4x more resin
Process times
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Processing cost
Conventional cycle for aerospace sandwich composites
Load Heat/gel Cure Cool
Composites take between 45 minutes and 3 hours to cure 1 set of parts per tool heating cycle… energy inefficient FibriRock 150 second cycle Tool stays hot
www.ecotechnilin.com
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FibriRock Awards
Sustainability Award JEC Composites, Paris
10-12 March 2015
Food Service Equipment Aircraft Interiors, Hamburg
14th April 2015
Innovation in Composites Advanced Engineering, NEC, UK
4th November 2015
Materials Award Materialica, Munich 20th October 2015
www.ecotechnilin.com FibriRock summary
• Lightweight and robust Lightest 50kg-rated cart
• Fire Smoke Toxicity Class-leading heat release
• Mechanical performance Lightest to pass 9G pull test
• Fast manufacturing process 150 second cycle time
• Mouldable / formable material Sealed sandwich edges
• Abrasion resistance (for runners) No wear after 200k cycles
• Low Cost - materials Cheaper fibres/resins process Press stays hot equipment No autoclave, fast cycle operation Lightweight -> fuel saving
100% bio-sourced (65% sustainable), very low eco-impact
www.ecotechnilin.com Natural Fibre Composites
FibriRock: Harnessing the properties of Mother Nature!