European Good Practices in Eco-creativity, creativity, natural fibres & short value chains Lighter than light Potential of blends from natural fibres and recycled carbon fibres for lightweight applications Bernd Gulich/Anna Große/Romy Naumann Saxon Textile Research Institute (STFI)/DE 5 th RESET Seminar on Eco-creativity, natural fibres & short value chains Lodz (PL), 17 th October 2017
Saxon Textile Research Institute (STFI) Affiliated Institute of Chemnitz University of Technology International Competence in Nonwovens Textile Lightweight Engineering Technical Textiles 2
Saxon Textile Research Institute (STFI) Affiliated Institute of Chemnitz University of Technology Non-profit, founded in 1992 Since 2006 associated to Chemnitz University of Technology About 150 employees (researchers, laboratory assistants and technicians) More than 100 R&D projects on regional, and national level l are The institute is located in Saxony. carried out each year 5 to 10 patent applications are submitted per year Member of TEXTRANET, EDANA, European Technology Platform, Euro Textile Region, standardisation working groups, etc. 3
Profile of STFI Competencies Center of Excellence in Nonwovens Fibre nonwovens Extrusion nonwovens Textile recycling Center for Textile Innovation Center of Lightweight i Engineering i Technical Textiles Processing of glass, carbon, aramid, basalt Technical Woven & Knitted Fabrics/Reinforcing Structures Manufacturing of pre- Finishing/Coating/Lamination / forms and composites Ecology carbon recycling Development of materials and testing methods Services Accredited Test Laboratory Certification Department for PPE Certification Body Geosynthetics Transfer Center Communication and process management International cooperation 4
RESET 5 th Thematic Seminar European Good Practices in Eco-creativity, creativity, natural fibres & short value chains Lighter than light Potential of blends from natural fibres and recycled carbon fibres for lightweight applications Bernd Gulich/Anna Große/Romy Naumann Saxon Textile Research Institute (STFI)/DE Bernd Gulich E-mail: bernd.gulich@stfi.de de Lodz (PL), 17 th October 2017
Background of the GP - Statistics Use of natural fibres in the European automobile industry (2012) Application of natural fibres in the European automotive industry (2012) 31200 t increase of 60% compared to year 2005 6
Background of the GP Advantages of composites from natural fibres used in the automotive industry - Low density, 10 to 30 % weight reduction - Good mechanical and acoustic properties - Good processability - Good behaviour in case of accidents (high stability, no splintering) - Better ecological balance (production, driving) - Processability analogue to GMT (glass mat thermoplastic) process and assembly without (glass)dust formation 7
Natural fibres in the automotive industry 60 % hemp fibres 40 % PP fibres Fibre blend Nonwoven 8
Natural fibres in the automotive industry Nonwoven production 9
Lighter than light Potential of blends from natural fibres and recycled carbon fibres for lightweight applications Objective of the project: Exploitation of the potential for lightweight construction of moulded parts based on needle-punched nonwovens made from natural fibres-pp-blends blends through partial substitution of natural fibres by reclaimed carbon fibres (rcf) Initial situation: Natural fibres replaced the textile glass fibres in car interior reduction of mass per unit area from 2200 g/m² down to 1800...1600 1600 g/m² Usual blends are 50% NF / 50% PP or 60% NF / 40% PP Which h effects do come from carbon fibres? Weight? Mechanical properties? Price? 10
Determination of the optimal blending ratio First step: Stepwise substitution i of hemp fibres by reclaimed carbon fibres (rcf) Share of PP remains constant (40 %) Basic mass per unit area 1.600 g/m² Blend [Weight%] NF/rCF Variant absolute Hemp PP rcf [%] CFP 0 60 40 0 0 CFP 1 40 40 20 33.3 CFP 2 30 40 30 50.00 CFP 3 20 40 40 66.6 11
Determination of the optimal blending ratio Mechanical properties independence on the blending ratio E-modulus Flexural Blend NF /rcf Tensile strength Bending stress modulus DIN EN ISO DIN EN ISO DIN EN ISO (NF=hemp) abs. DIN EN ISO 527-4: 1997-07 527-4: 1997-07 14125: 2011-05 14125: 2011-05 [%] MD CD MD CD MD CD MD CD NF PP rcf [%] [MPa] [MPa] [GPa] [GPa] [MPa] [MPa] [GPa] [GPa] 60 40 0 0 25.15 24.41 2.47 2.47 49.82 49.83 2.87 3.03 40 40 20 33.3 40.21 48.22 5.09 5.81 41.08 57.63 3.58 5.34 30 40 30 50.0 50.34 71.21 5.89 8.24 50.99 49.93 4.46 4.79 20 40 40 66.6 35.76 78.18 4.30 8.24 28.48 38.87 2.95 4.61 12
Determination of the optimal blending ratio Mechanical properties independence on the blending ratio pa] modulus [G E-modulus MD E-modulus CD Flexural modulus MD Flexural modulus CD s or Flexural E Modulus 13
Determination of the optimal blending ratio Mechanical properties in dependence on the blending ratio Tensile stren ngth or bend ding stress [M MPa] Tensile strength MD Tensile strength CD Bending stress MD Bending stress CD 14
Determination ti of the potential ti for lightweight i construction ti Second step: Stepwise reduction of the mass per unit area at constant t blending ratio based on pre-trials Blend [Weight%] Variant Mass per unit Hemp PP rcf area [g/m²] CFP 0 60 40 0 1600 CFP 2-1 30 40 30 1600 CFP 2-2 30 40 30 1400 CFP 2-3 30 40 30 1200 CFP 2-4 30 40 30 1000 CFP 2-5 30 40 30 800 15
Determination of the potential for lightweight construction Mechanical properties in dependence on the mass per unit area Blend (NF=hemp) Mass per unit area Tensile strength DIN EN ISO 527-4:1997-07 E-modulus DIN EN ISO 527-4: 1997-07 Bending stress DIN EN ISO 14125: 2011-05 Flexural modulus DIN EN ISO 14125: 2011-05 [%] [g/m²] MD CD MD CD MD CD MD CD NF PP rcf [MPa] [MPa] [GPa] [GPa] [MPa] [MPa] [GPa] [GPa] 60 40 0 1600 25.15 24.41 2.49 2.47 49.82 49.83 2.87 3.03 30 40 30 1600 62.67 152.7 7.1 13.9 66.68 74.9 5.33 8.64 30 40 30 1400 55.09 125.63 6.25 12.3 62.84 72.5 6.13 8.5 30 40 30 1200 53.92 91.76 6.32 9.88 57.77 58.98 4.79 6.1 30 40 30 1000 43.43 77.16 4.94 8.1 52.21 56.52 4.08 4.79 30 40 30 800 36.61 73.1 3.99 7.72 49.71 54.99 2.91 6.28 16
Determination ti of the potential ti for lightweight i construction ti Mechanical properties in dependence on the mass per unit area E-modulus MD ] odulus [Gpa r Flexural mo Modulus or E E-modulus CD Flexural modulus MD Flexural modulus CD 17
Determination ti of the potential ti for lightweight i construction ti Mechanical properties in dependence on the mass per unit area Tensile stren ngth or bending stress [M MPa] Tensile strength MD Tensile strength CD Bending stress MD Bending stress CD 18
Lighter than light Potential of blends from natural fibres and recycled carbon fibres for lightweight applications Project results The substitution of 50 % of hemp fibres by reclaimed carbon fibres allows the weight reduction up to by up to 50 % at same or better mechanical properties! But: Are lightweight structures still payable then? 19
Comparison of prices Mass per unit area Polypropylen Reclaimed Hemp fibres Amount of fibres carbon fibres material 1.20 /kg 2.00 /kg 6.00 /kg costs 60 % 40 % 1600 g/m² 960 g/m² 640 g/m² - 1.1515 /m² 1.28 /m² - 2.43 /m² 30 % 40 % 30 % 1600 g/m² 480 g/m² 640 g/m² 480 g/m² 0.57 /m² 1.28 /m² 2.88 /m² 4.73 /m² 30 % 40 % 30 % 800 g/m² 240 g/m² 320 g/m² 240 g/m² 0.29 /m² 0.64 /m² 1.44 /m² 2.37 /m² 20
Samples of moulded parts 21
Lighter than light Potential of blends from natural fibres and recycled carbon fibres for lightweight applications GP Contact Name of person Bernd Gulich Name of organisation Sächsisches Textilforschungsinstitut e. V. (STFI) E-mail bernd.gulich@stfi.de Phone +49 371 5274 204 Website www.stfi.de 22
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