Properties, production methods and applications - sentationer2014/overview_of... · PDF...
Transcript of Properties, production methods and applications - sentationer2014/overview_of... · PDF...
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Overview of biocomposites
Properties, production methods and applications
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Benjamin Hornblow, Lyngby, 03-12-2014
Overview
• Natural fibres
– Types
– Production
– Fabrics
• Bio-based resins
• Natural fibre composites
– Manufacturing
– Properties
– Sustainability
• Biocomposites market in the EU
• Applications
• Conclusion 2
What are biocomposites?
• Formed by a matrix (resin) and a reinforcement particle or fibre
• At least one part derived from biological origins
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Types of natural fibres
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Plant stem anatomy and fibre separation
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Plant stem cross section
Fibre structure and dimensions
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Natural fibre structure
Fibre dimensions and aspect ratio
PlantFibre average length
(mm)
Fibre average diameter
(µm)Aspect ratio
Cotton 18 20 900
Flax 33 19 1750
Hemp 25 25 1000
Jute 2 20 100
Kenaf 70 100 700
Fibre physical properties
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Fibre density
From fibres to yarn
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Twisted bundle
Wrapped bundle
From yarn to fabric
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Unidirectional
Biaxial ±45°
2x2 twill weave
Hopsack weave
Bio-based matrix materials
• Made from renewable biomass such as vegetable fats and oils, starches and microbiota
• Can also be blended with petroleum based resins
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Thermoset resin properties
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Epoxy resin comparison
Polyester resin comparison
PropertyStandard epoxy
(Pro-set INF 114)
100% Biobased epoxy
(Super SAP INH)Comparison
E-modulus (GPa) 3.7 3.3
Tensile strength (MPa) 56 59 -
Viscosity at 23°C (mPas) 267 360
PropertyStandard polyester
(Reichhold Polylite 413-575)
25% biobased polyester
(Reichhold Envirolite 31430-50)Comparison
E-modulus (GPa) 3.3 3.2-3.5 -
Tensile strength (MPa) 67 60-75 -
Viscosity at 23°C (mPas) 160-175 180-200
Manufacturing of NFC
• Essentially the same as for synthetic fibre composites
• Drying of fabric before processing is recommended
• Typically fast infusion and good wet-out
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Laminate characteristics
• Brown-gold appearance (flax fibre laminates)
• Low fibre volume fraction (30-35%)
• Typically higher porosity than synthetic fibre composites
• Easy to trim and drill holes
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Prepreg material
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UD - Flaxpreg
44% FVF
Laminate stiffness properties
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UD Laminate stiffness UD Laminate specific stiffness
33% FVF
56% FVF
60% FVF
Laminate damping properties
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Fibre damping
Three orders of magnitude higher damping
High vibrations In carbon layer
Damped vibrations In flax layer
Carbon layer
Carbon layer
Flax layer
Carbon/flax-fibre lamiante Source: Lineo flax fibres reinforcements
Laminate aging and degradation
• Water wicking through exposed fibres (untreated)
• Degradation due to water absorption and UV light
• Influenced by matrix material and surface coating
• Limited information available
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Test series planned at
FORCE Technology
Sustainability of NFC
18 Source: Composites Evolution
Fibre mat production energy
Claim 50% reduction in carbon footprint
Summary of NFC properties
• Advantages
– High specific stiffness (better than glassfibre composites)
– Good vibration damping
– Low embodied energy / carbon foot print
• Disadvantages
– Variability (growth conditions, plant anatomy, etc.)
– Low fibre volume fraction (approx. 30-45%)
– Degradation from moisture and UV light (TBD)
– Limited mechanical properties data
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EU composites market (2012)
20 Source: bioplastics MAGAZINE [03/14] Vol. 9
Industrial applications
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Automobiles Wood Cotton Flax Kenaf Hemp
Industrial applications cont.
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Buhler Versatile hood 100% Flax-fibre 100% Bio-based epoxy
Sport and leisure
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Artengo tenis racket 25% flax fibre – 75% carbon fibre
Schwinn Vestage bicycle 80% flax fibre – 20% carbon fibre
Sports and leisure cont.
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Notox surfboard 100% flax fibre 100% bio-based resin
Swift flax fusion canoe Flax/kevelar fibre Bio-based vinylester
Hemp sunglasses 100% hemp fibre (CSM) 100% bio-based resin
Sports and leisure cont.
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C-Tech fairing 100% Flax-fibre Epoxy pre-preg
Conclusion
• NFC are finding their niche markets:
– Light structural applications (stiffness driven)
– Sound and vibration damping applications
– Low environmental impact consumer products
• Supply chain is growing and maturing:
– Multiple fabric suppliers
– Variety of bio-based resins available
– Some pre-preg fabrics available
• Cost:
– Fabric costs vary substantially – dependent on volume, weaving, supplier etc.
– Natural fibre fabrics will approach the price of glass fabrics (long term forecast)
– Bio-based resins only slightly more expensive (for low volumes)
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Thank you!
Fibre mechanical properties
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Fibre stiffness Fibre strength
Laminate strength properties
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UD Laminate strength UD Laminate specific strength
Forecast production in 2012
30 Source: bioplastics MAGAZINE [03/14] Vol. 9