European Good Practices in Eco-creativity, natural fibres & short value Eco creativity, natural fibres & short value
chainsLighter than light – Potential of blends from natural g g
fibres and recycled carbon fibres for lightweight applications
B d G li h/A G ß /R NBernd Gulich/Anna Große/Romy NaumannSaxon Textile Research Institute (STFI)/DE
5th RESET Seminar on“Eco-creativity, natural fibres & short value chains” y,Lodz (PL), 17th October 2017
Saxon Textile Research Institute (STFI)Saxon Textile Research Institute (STFI)Affiliated Institute of Chemnitz University of Technology
International Competence in Nonwovens – Textile Lightweight Engineering – Technical Textilesin Nonwovens – Textile Lightweight Engineering – Technical Textiles
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Saxon Textile Research Institute (STFI)
• Non-profit, founded in 1992
Affiliated Institute of Chemnitz University of Technology
Non profit, founded in 1992 • Since 2006 associated to
Chemnitz University of T h lTechnology
• About 150 employees (researchers, laboratory
The institute is located in Saxony
(researchers, laboratory assistants and technicians)
• More than 100 R&D projects on i l d ti l l l The institute is located in Saxony.regional, and national level are
carried out each year • 5 to 10 patent applications are submitted per year5 to 10 patent applications are submitted per year• Member of TEXTRANET, EDANA, European Technology Platform, Euro Textile
Region, standardisation working groups, etc.
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Profile of STFI – Competenciesp
Innovation Center of T h i l T til
Center of Excellence Center for Textile Li ht i ht E i i Technical Textiles
Technical Woven & Knitted Fabrics/Reinforcing Structures
Finishing/Coating/Lamination /
in Nonwovens Fibre nonwovens Extrusion nonwovens
Lightweight Engineering Processing of glass,
carbon, aramid, basalt Manufacturing of pre Finishing/Coating/Lamination /
Ecology Development of materials
and testing methods
Textile recycling Manufacturing of pre-forms and composites
carbon recycling
Transfer Center Services Communication and
process management International cooperation
Accredited Test Laboratory Certification Department
for PPE Certification Body
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Certification Body Geosynthetics
RESET – 5th Thematic Seminar
European Good Practices in Eco-creativity, natural fibres & short value Eco creativity, natural fibres & short value
chainsLighter than light – Potential of blends from natural g g
fibres and recycled carbon fibres for lightweight applications
B d G li h/A G ß /R NBernd Gulich/Anna Große/Romy NaumannSaxon Textile Research Institute (STFI)/DE
Bernd GulichE mail: bernd gulich@stfi deE-mail: [email protected] (PL), 17th October 2017
Background of the GP - StatisticsBackground of the GP Statistics
Use of natural fibres in the European Application of natural fibres in the European automotive 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% comparedto year 2005to year 2005
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Copyright: STFI
Background of the GP
Advantages of composites from natural fibres used in
Background of the GP
g pthe automotive industry- Low density, 10 to 30 % weight reductiony g- Good mechanical and acoustic properties - Good processability y- 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
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Copyright: STFI
Natural fibres in the automotive industryNatural fibres in the automotive industry
60 % hemp fibres 40 % PP fibres Fibre blend
NNonwoven
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Copyright: STFI
Natural fibres in the automotive industry
Nonwoven productionp
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Copyright: STFI
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 based on needle-punched nonwovens made from natural fibres-PP-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 g/m² reduction of mass per unit area from 2200 g/m² down to 1800...1600 g/m²Usual blends are 50% NF / 50% PP or 60% NF / 40% PP
Whi h ff t d f b fib ? Which effects do come from carbon fibres? Weight? Mechanical properties? Price?
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Copyright: STFI
Determination of the optimal blending ratioDetermination of the optimal blending ratio
First step: S i b i i f h fib b l i d b fib ( CF)Stepwise substitution of hemp fibres by reclaimed carbon fibres (rCF)Share of PP remains constant (40 %)Basic mass per unit area 1.600 g/m²
VariantBlend [Weight%] NF/rCF
absoluteVariant absolute[%]Hemp PP rCF
CFP 0 60 40 0 0CFP 0 60 40 0 0CFP 1 40 40 20 33.3CFP 2 30 40 30 50 0CFP 2 30 40 30 50.0CFP 3 20 40 40 66.6
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Copyright: STFI
Determination of the optimal blending ratio
Bl d NF / CF Tensile strength E-modulus Bending stress Flexural d l
Mechanical properties independence on the blending ratio
Blend(NF=hemp)
NF /rCFabs.
Tensile strengthDIN EN ISO
527-4: 1997-07
E modulusDIN EN ISO
527-4: 1997-07
Bending stressDIN EN ISO
14125: 2011-05
modulusDIN EN ISO
14125: 2011-05[%] MD CD MD CD MD CD MD CD[%]
NF PP rCF [%]MD
[MPa]CD
[MPa]MD
[GPa]CD
[GPa]MD
[MPa]CD
[MPa]MD
[GPa]CD
[GPa]60 40 0 0 25.15 24.41 2.47 2.47 49.82 49.83 2.87 3.0340 40 20 33.3 40.21 48.22 5.09 5.81 41.08 57.63 3.58 5.3430 40 30 50.0 50.34 71.21 5.89 8.24 50.99 49.93 4.46 4.7920 40 40 66.6 35.76 78.18 4.30 8.24 28.48 38.87 2.95 4.6120 40 40 66.6 35.76 78.18 4.30 8.24 28.48 38.87 2.95 4.61
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Copyright: STFI
Determination of the optimal blending ratioMechanical properties independence on the blending ratioDetermination of the optimal blending ratio
pa] E-modulus MD
mod
ulus [G E-modulus CD
Flexural modulus MD
Flexural modulus CD
s or Flexu
ral
E‐Mod
ulus
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Copyright: STFI
Determination of the optimal blending ratioMechanical properties in dependence on the blending ratioDetermination of the optimal blending ratio
Tensile strength MDMPa
]
Tensile strength CD
Bending stress MD
Bending stress CDding
stress [M
ngth or b
end
Tensile
stren
T
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Copyright: STFI
D t i ti f th t ti l f li ht i ht t tiSecond step:St i d ti f th it t t t bl di ti b d
Determination of the potential for lightweight construction
Stepwise reduction of the mass per unit area at constant blending ratio based on pre-trials
Blend [Weight%]Variant
Blend [Weight%]Mass per unit
area [g/m²]Hemp PP rCF [g ]CFP 0 60 40 0 1600
CFP 2-1 30 40 30 1600CFP 2 1 30 40 30 1600CFP 2-2 30 40 30 1400CFP 2-3 30 40 30 1200CFP 2 3 30 40 30 1200CFP 2-4 30 40 30 1000CFP 2 5 30 40 30 800
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Copyright: STFI
CFP 2-5 30 40 30 800
Mechanical properties in dependence on the mass per unit area
Determination of the potential for lightweight construction
Blend Mass per unit
Tensile strengthDIN EN ISO
E-modulus DIN EN ISO
Bending stressDIN EN ISO
Flexural modulus
Mechanical properties in dependence on the mass per unit area
(NF=hemp) per unit area
DIN EN ISO 527-4:1997-07
DIN EN ISO 527-4: 1997-07
DIN EN ISO 14125: 2011-05 DIN EN ISO
14125: 2011-05[%] [g/m²] MD CD MD CD MD CD MD CD[%]
NF PP rCF[g/m ] MD
[MPa]CD
[MPa]MD
[GPa]CD
[GPa]MD
[MPa]CD
[MPa]MD
[GPa]CD
[GPa]60 40 0 1600 25.15 24.41 2.49 2.47 49.82 49.83 2.87 3.0330 40 30 160030 40 30 1600 62.67 152.7 7.1 13.9 66.68 74.9 5.33 8.6430 40 30 1400 55.09 125.63 6.25 12.3 62.84 72.5 6.13 8.530 40 30 1200 53.92 91.76 6.32 9.88 57.77 58.98 4.79 6.153.92 91.76 6.32 9.88 57.77 58.98 4.79 6.130 40 30 1000 43.43 77.16 4.94 8.1 52.21 56.52 4.08 4.7930 40 30 800 36.61 73.1 3.99 7.72 49.71 54.99 2.91 6.28
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Copyright: STFI
D t i ti f th t ti l f li ht i ht t tiMechanical properties in dependence on the mass per unit areaDetermination of the potential for lightweight construction
E-modulus MD
]
E-modulus CD
Flexural modulus MD
Flexural modulus CD
odulus [G
par F
lexu
ral m
o‐M
odulus or
E‐
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Copyright: STFI
D t i ti f th t ti l f li ht i ht t tiDetermination of the potential for lightweight constructionMechanical properties in dependence on the mass per unit area
Tensile strength MD
Tensile strength CDMPa
]
Tensile strength CD
Bending stress MD
Bending stress CD
ing stress [M
ngth or b
end
Tensile
stren
T
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Copyright: STFI
Lighter than light – Potential of blends from natural fibres 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
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!same or better mechanical properties!
But: Are lightweight structures still payable then?
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Copyright: STFI
C i f i Comparison of prices
H fib Polypropylen Reclaimed Amount of Mass per unit area
Hemp fibres Polypropylen fibres
Reclaimedcarbon fibres
Amount of material
costs1.20 €/kg 2.00 €/kg 6.00 €/kg
1600 g/m²60 % 40 %
960 g/m² 640 g/m² -1 15 €/m² 1 28 €/m² 2 43 €/m²1.15 €/m² 1.28 €/m² - 2.43 €/m²
1600 g/m²30 % 40 % 30 %
480 g/m² 640 g/m² 480 g/m²1600 g/m 480 g/m 640 g/m 480 g/m0.57 €/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
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Copyright: STFI
Samples of moulded parts
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Copyright: STFI
Lighter than light – Potential of blends from natural fibres and recycled carbon fibres for lightweight applications
GP ContactName of person Bernd GulichName of organisation Sächsisches Textilforschungsinstitut e. V. (STFI)E-mail [email protected] +49 371 5274 204Website www.stfi.de
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Thank you! Thank you!
Project smedia