Technology Overview: Biocomposites

Composites Engineering Show, 4th Nov 2015, 15.00-16.00

A Biocomposites Industry for the Future

Chris HareTechnology ManagerNetComposites

Increasing the Performance of Natural Fibre Reinforced Plastics

Dr Brendon WeagerTechnical DirectorComposites Evolution

Biocomposites in the prepreg industry

Alix SaugetR and D EngineerSHD Composite Materials

A Biocomposites Industry for the

Future

Chris Hare Technology Manager

NetComposites

4th November 2015

Composites Engineering Show

info@netcomposites.com

Biocomposites

Why bother?

How do I join the revolution?

Who has beaten me to it?

Why Bother?

Why bother?

Yes, let’s save the planet:

• Reduce CO2

• Reduce embodied energy

• Reduce reliance on finite resources

• Move towards sustainable societies

• Increased recycling opportunities (even incineration)

Why bother?

Commercial advantages:

• Light-weighting

– E.g., replace glass fibres with natural

fibres

• Noise and vibration reduction

– E.g., inter-laminar layers

• An aesthetically beneficial product

– E.g., natural fibres can lend a unique

look and proclaim their greener origins

Image courtesy Alpaca Guitars US

Why bother?

But we can’t do that without:

• A cost competitive product

• An equivalent performance product

• A processing method that is feasible

• A supply chain

Why bother?

But we can’t do that without:

• A cost competitive product

• An equivalent performance product

• A processing method that is feasible

• A supply chain

Source: Technology Overview of Biocomposites, Materials KTN/NetComposites March 2014

Why bother?

But we can’t do that without:

• A cost competitive product

• An equivalent performance product

• A processing method that is feasible

• A supply chain

Comparison of fibre properties.Source: Technology Overview of Biocomposites, Materials KTN/NetComposites March 2014

100% bioresin/glass prepreg. Equivalent to phenolic in fire and mechanical propertiesSource: Composites Evolution Ecopreg

Why bother?

But we can’t do that without:

• A cost competitive product

• An equivalent performance product

• A processing method that is feasible

• A supply chain

Why bother?

But we can’t do that without:

• A cost competitive product

• An equivalent performance product

• A processing method that is feasible

• A supply chain

Door module courtesy Jaguar Land Rover

Why bother?

The future is LCA!

Use with caution

Product MJ/kg Density Specific

Glass fibre 44.43 2.5 111

Flax yarns 55.21 1.4 77

Jute yarns 29.32 1.4 41

Cellulose fibres 7.14 1.5 11

Cotton yarn 152 1.5 228

Embodied energy data for natural fibres

Data courtesy of TNO and mostly derived from Ecoinvent database

How do I join the revolution?

How do I join the revolution?

Primary routes to market (fibres):

Wood plastic composites/wood fillers

• Large volumes of low cost extrusion

• Low performance

Intermediate non-woven sheet materials

• NF with thermoplastic binders

• Compression moulded low cost, mid performance parts Image courtesy

flaxcomposites.com

How do I join the revolution?

More recent developments

Nano cellulose fibres (microfibrillated cellulose, MFC or nanofibrillated cellulose, NFC)

• Previously very energy intensive, that problem is largely solved

• 1-2 micrometres microfibrils 5-20 nm in diameter

Woven intermediate sheets

• Technical fibres combining matrix and reinforcement

• Better performance, quick cycle time

Image courtesy of Innventia

Image courtesy of Sheffield Hallam University/NetComposites

How do I join the revolution?

More recent developments

Natural fibre long fibre

thermoplastics (NF-LFT)

• Longer fibres, higher

performance

• Direct swop for glass LFT

• Lower tool wear

Image: NetComposites

How do I join the revolution?

More recent developments

Regenerated cellulose fibres

• Continuous, consistent

• Relatively low performance, but potential for much higher

(ionic liquid based systems)

Biopolymer fibres

• Continuous, consistent

• Generally low performance (compared to glass or carbon)

• Flexible – mats, woven, commingled yarns

Image: BioMid Fibre

How do I join the revolution?

More recent developments

Natural Fibre UD tapes

• Lightweight

• Highly aligned fibres

• Can give high performance

from discontinuous fibres

• Avoids weaving processes

• Hybrid opportunities Image: NetComposites

How do I join the revolution?

Primary routes to market (matrix materials):

100% Biorez PFA resin Trans Furans Chemicals. Phenolic replacement

55% renewably sourced vinylester DSM PalapregIn use for automotive SMC style moulding

37 to 54% (21 to 30% with hardener) bio content Entropy resins Super Sap. Resin-infusable.

30% bio content PlantBottle for Coca Cola. Derived from sugar cane molasses.

20 to 0% Envirez US Polyester range from Ashland USA.

How do I join the revolution?

Current biobased thermoplastic matrix materials

• Biobased PBS and PHA. Biosourced and degradable

• Biobased HDPE and Nylon 11. Biosourced and not degradable

• PTT (Corterra), PET, Nylon 5,6. Partially biosourced and not

degradable

Future thermoplastic matrix materials

• PEF, 100% biobased, similar to PET

• 100% biobased, PET, PBT, PP, LLDPE, Nylon 6, 6.6, TPU

Who has beaten me to it?

Image: ecotecnilin

Ceiling panel

Ready to launch

Class 1 fire/smoke performance

83% acoustic performance

Sandwich panel

100% bio-sourced

Jaguar, Qashquai, Peugeot

claimed

Not too many. This is an emerging market and you can

capitalise.

Who has beaten me to it?

Flax-epoxy prepreg body

system (C-Tech

Composites/SHD/Biotex)

Vac bag/autoclave moulding

Lightweight

Flexible/resilient

Lower cost than carbon fibre

Paul Bird MotoGP Fairing

Who has beaten me to it?

Injection moulded wood-reinforced

productsCourtesy Tecnaro (Coza plastics, AudioQuest)

Concept furnitureCourtesy Lingrove

WPC decking products – many varieties

Who has beaten me to it?

Composites Evolution

• Biotex products

– Commingled textiles flax/jute + PP/PLA

– Intermediate sheets for stamp forming

– Developing hybrid sandwich structures

and more

– Developing improved interfaces

– Hybrid NF/CF

Image Courtesy BIC Sport

Image Courtesy Carbio Project

Who has beaten me to it?

Hemp Eyewear

Hemp fibre and PLA sunglasses

Thank you for listening

Chris Hare Technology Manager

NetComposites Ltd

4A Broom Business Park

Bridge Way

Chesterfield

S41 9QG, UK

Tel: +44 (0)1246 266244

Web: netcomposites.com

Email: info@netcomposites.com