Presentation Naturalfiber

7/24/2019 Presentation Naturalfiber

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Development of Composites

Based on Natural FibersM.T. Ton-That & J. Denault

Industrial Materials Institute

The Institute of Textile ScienceOttawa, ON

April 13, 2007


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Presentation outline

Opportunities with natural fibres

Challenges of natural fibre composites

Canadian Natural Fibre Initiative on

Flax and hemp fibre biocomposites

Conclusions


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Polymer Composites

Polymer Composites = Reinforced Plastics

Reinforcing phase

Reinforcement usually has much greater mechanical properties andserves as the principal load-carrying members.

Reinforcing effect determined by interface, aspect ratio, distributionand orientation

The matrix Plays a role of a binder to keep the fibers in a desired location and

orientation.

Transfers load to the fiber through the fiber-matrix interface.

Protects fiber from environmental damage.

The fiber-matrix interface plays a decided role on the transformationof load from the matrix to the fiber.

Composites are more favourable than plastics


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Eco-Composites:

Composites of The Future

Eco-Composites:

Composites of The Future

Respond to the needs of materials in the 21st century

To cope with limitation of petroleum supply

To cope with environmental pollution concern

Economically favourable composites made of

Sustainable crop-derived plastics

Inexpensive crop-derived fibres as reinforcement Case of success

Natural fibers: wood, hemp, flax, kenaf

Bio-based polymer: PLA from corn and sweet potato

Respond to the needs of materials in the 21st century

To cope with limitation of petroleum supply

To cope with environmental pollution concern

Economically favourable composites made of

Sustainable crop-derived plastics

Inexpensive crop-derived fibres as reinforcement

Case of success

Natural fibers: wood, hemp, flax, kenaf

Bio-based polymer: PLA from corn and sweet potato

Attention: bio-based

products are not always

sustainable


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Natural Fibres vs

Synthetic Fibres

Natural

fibres

Bast Fibres: Flax, Hemp, Kenaf,Abaca, Banana,Bamboo, Jute, Totora

Leaf Fibres: Sisal, Curaua, Fique, Phormium, Palm

trees, Caroa, Kurowa, Pineapple Seed Fibres: Cotton, Capok

Fruit Fibres: Coir,African palm

Wood Fibres: soft & hard wood

0

20

40

60

80

100

Price

(cent/lb)

Fiber

glass

Natural

fibers

CaCO3

Wood

fiber


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NF Composites in

North American

The market for NF composites in NorthAmerica: mainly for construction

2000 = 200,000 tonnes

2005 = 3X

NF composites market

050

100

150

200

250

300

350400

1980 1990 2000

Million lb

Other natural

fibersWood fiber

Driving force:purely economic


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Construction

applications

Play ground

Deck

Toronto Broad walk

Mighty Mount Rusmore


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ConstructionapplicationsSiding and soffit products

Marina

Pool


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NF composites in EuropeConsummation in tone of natural fibres in

automotive industry in Europe

Driving force: Government Legislation

Recycling concerns being driven by EU regulations end of lifevehicle disposal: Jan 1st, 2005: 80 wt%; Jan 1st, 2015: 85 wt%

GHG emission limit and tax incentive


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Volkswagen: back of seats,door panels, trunk panels(Golf, Passat, Variant, Bora, Fox, Polo)

Audi: back of seats, side panels, trunk covering,speakers holders (A2, A4, Avant, A6, A6 Avant, A8) BMW: door panels, headliners, trunk floor panel (Serie

3, 5 and 7) Daimler Chrysler: door panels, business tables,

padding-pillars reinforcing, dashboard parts (Class A,

C, E and S) Opel: headliners, door panels, dashboard parts (Astra,

Vectra, Zafira) Peugeot: back of seats, trunk coverings (406-607) Renault: rear shelf (Clio, Twingo)

Mercedes Benz trucks: front sections for the trucks. HSK LS 1938, internal engine cover, insulation for the

engine, sun-blades, interior insulation and bumper. HPN L 1622 -internal insulation;

wheel box; roof; and back cover.

Automotive Parts Made

of NF Composites


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Automotive Parts Made

of NF Composites


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Advantages of NaturalFibre Reinforcement

Renewable source of raw material

Biodegradable Sustainable? Excellent specific strength and high modulus

High flexural and tensile modulus -up to 5base resin, high

notched impact strength -up to 2base resin Reduced density of products Lower cost Reduced tool wear

Safe manufacturing processes No airborne glass particles, relief from occupational hazards. Reduced dermal and respiratory irritation and no emission of toxic

fumes when subjected to heat and incineration


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Challenges of Natural

Fibre Reinforcement

Challenges Concerns over fibre consistency/quality

Low impact strength (high concentration of fibre defects) Problem of stocking raw material for extended time

Possibility of degradation, biological attack of fungi and mildew Foul odor development

Fibres are hydrophilic

Issues of compatibility with polymers: fibre-matrix interface and fibredispersion challenges Sensitive to humidity

UV resistance not better than plastics Fibre degradation during processing Fibre orientation and distribution

Solutions Fibre treatments Compatibilization Textile technologies: mat and fabric structures


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Composite EvolutionComposite Evolution

Industrial

Sectors

Structural composites

Thermosets

Platform

Technologies

and materials

Structural Composites

Biocomposites

Nanocomposites

Biobased polymers

1950 1980-2000 2005Thermoplastics

Nanocomposites

Microelectronics

Ground transportation

Aerospace

BiomedicalTransportationConstructionEnergySportEnvironment

AerospacePackaging


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Natural Fibres in Canada

National level: federal government: sustainable economy Bio-fibres to produce value-added products: chemicals, textile, composites, etc

Agriculture and Agri-food Canada: 145 M$ funding for this year alone: multi-disciplinary research (soil, genetic modification, refinery, extraction, processing) Canadian biomass innovative network (CBIN)

Carbonhydrate: starch (wheet, corn, etc)

Oil: canola

Cellulose: flaxseed fibres and hemp

Present acttraction: triticale corp in Western Canada (carbonhydrate and cellulose)

Local level: AB: BioAlberta, AVAC

NB: BioAtlantech

SK: Flax Canada 2015

ON: Bioproducts Business Network, AUTO 21, Ontario Agri-Food Technologies (OAFT), QC: Centre qubcoise de valorisation des biotechnologies

BC: BioProducts BC

BIOCAP


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Feedstock

Producer

Processing of

FibersTwo methods:

1 Enzymatic2 Green

Mechanical/Chemical

Two Primary Tracks1 - For Fibre

2 - For Biochemicals

BioMaterials

BioChemicals such as ferulic acid

Harvest +Post-

Harvest

Preparation of

Feedstock

BioEnergy/ BioFuel

GHGReduction

Kemestrie

Biolin

John Baker

(Stone Hedge

Hemp)

AAFCSaskflax

NRC-PBI

Module 4

NRC-BRI

Seed Oils

Process Heat

Biocomposites

Biopolymers

Ferulic Acid

PlatformModule 3

NRC-IMI

NRC-BRI

NRC-ICPET

Related

CBIN

Threads

Module 1

NRC-IBS

NRC-BRI

NRC-IMI

NRC-ICPET

NRC-BRI

End Users (Private Sector)

Composite Innovation

Centre (Links to Boeing,

Dow BioProducts andothers), Biolin, Hemptown

Biolin

Saskflax

Module 5

NRC-IMI

NRC-ICPET

TRACK 1

TRACK 2

Module 2

AAFC

NRC-IBS

Black boxes Industry

Research Contributions

Red boxes ProjectModules

Natural Fibres Initiative for

Biochemicals and Biomaterials


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Biocomposites

Objectives

Development flax (hemp) fiber composites andapplications based on synthetic (PP) and biobased(PLA) polymers

Improvement of processability Improvement in mechanical properties, humidity resistance

and flammability resistance

Evaluation of the performance of value-addedproducts coming from recycling sources Use of recycled plastics


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Flaxcomposite

compound

Dried blendof f lax,

polymer andadditives

Processing

Extrusion: short fibre

Injection moulding: short fibre

Compression moulding: short, long, continuous,matt, fabric

Mat or fabric construction

Compression moulding

Thermo-forming


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NF Composites

IMI Patented technology licensed to

Formulation based CaO additive

Licensed technology applied to transportation andconstruction sectors

0

1000

2000

3000

4000

5000

Recycled PP Wood

composite

IMI 's

composite

Flexuralm

odulus(MPa)

35

45

55

65

75

Flexurals

tress(MPa)

Modulus

Stress

Increase ofmaterial cost

(%)

Improvement in flexuralperformance

(%)

3.6 28

* Compared with commercial system


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Roles of CaO

CaO

Absorbs humidity in woodNeutralizes acidity in wood

minimize degradation during processing

Reacts with maleic anhydride group of coupling agent

Improve interface between wood and PP matrix

Increase molecular weight of coupling agent

Limit a loss in toughness and impact


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Thermal andflammability resistance

Improvement of the thermal resistance

Slow down the burning process of the composites sincethe burning rate of the sample with CaO at 1 min (L1)and 5min (L5) is smaller than that of the REF.

No L1

(mm)

L5

(mm)

No CaO 12 65

10% CaO 7 36

No

T10%

(oC)

T20%

(oC)

Weight lossat 500

oC

(wt%)

No CaO 334 364 91

10% CaO 346 398 73


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Recycling

Wood-PP composites (with maleic anhydride couplingagent and CaO) can be reground, extruded andinjection moulded 3 times without important loss ofperformance

24

26

28

30

32

1st process 2nd process 3rd process

Tensilestrength(MPa)

4500

5000

5500

6000

6500

Tensi

lemodulus(MPa)

Strength

Modulus

70

80

90

100

110

1st process 2nd process 3rd process

Unotched

Izodimpactstren

gth

(kJ/m2)


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Flax Fiber CompositesCompression moulding

Modulus and strength of the composites improve significantly with thepresence of coupling agent

Type of coupling agent also plays an important role

The presence of CaO provide a great increase in modulus

25

30

35

40

45

PP

30%

FLA

X

30

%FLA

X+PB

3150

30

%FLA

X+EP

3015

30%

FLA

X+E4

3

30%

FLA

X+E4

3+CaO

Tensilestrength(MPa)

1000

2500

4000

5500

7000

Ten

silemodulus(MPa)

Strength

Modulus


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Interface

No coupling agent

Very poor interaction between the fiber and the matrix


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Interface

With coupling agent and CaO

Good interface


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Mechanical properties Injection moulding

Flax fibres improved significantly the performance of PP, but theproperties can be further improved Fibre retting and the fibre isolation process is not optimized Flax composite processes are not optimized

It should be interesting to work with flax fabric as reinforcement

20.00

25.00

30.00

35.00

40.00

PP 30% FLAX +E43

+CaO

Ten

silestrength(M

Pa)

1000

2000

3000

4000

5000

Tensilemodulus(M

Pa)

Strength

Modulus

6.00

9.00

12.00

15.00

18.00

PP 30% FLAX

+E43 +CaO

Izodimpactstrength(

kJ/m

2)


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Conclusions

Natural fibres like wood, ricehusk and flax can improvesignificantly the polymer performance

The composite properties are determined by many differentfactor: fibre source, formulation, processing equipment andprocessing parameters

The incorporation of some selective mineral fillers can greatly

improves the thermal and the flammability resistance, thestiffness and the impact properties without sacrifying thestrength.

Forms as continuous fibres and fabric should be of great

interest for producing high performance composites!


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Opportunity of textile

industry in composites

Mass productions Transformation of NFs into different forms of reinforcement for

composites, such as unidirectional NFs, NF fabrics, NF matt, co-mingle of NFs and synthetic polymer fibres, at low cost and low energyconsumption

Hybrid of NFs or NF and synthetic fibres

Fibre treatment to improve performance and overcome limitation

Special applications Functionality: surface coating (thermally and electrically conductive)

Recycling of fibres???

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Presentation Naturalfiber