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
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: [email protected]