novel structural materials with multi-scale fibre...
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD
Novel structural materials withmulti-scale fibre components(NoMa)
Katariina Torvinen, Research Manager VTTDesignMuseo 13.06.2017
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• Budget of project ~1.3 M€• Duration 01.6.2015 - 30.11.2017• Research partners: VTT and LAMK• Funding partners:
TEKES, VTT, companies and LAMK
NoMa consortium
SMALL ENTERPRISES
3D Formtech Oy
3DTech Oy
Ahosen Taimisto Oy
Brainwood Oy
Co. Panu Isokangas Oy
Earthpac Oy
Novarbo Oy
Epira Oy
Hikinoro Oy
Swanheart Design Oy
FL-Pipe Oy
LARGE ENTERPRISES
Metsä Board
Metsä Fibre
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Novel fibre foams and biocompositesapplications
DESIGN
LEARNINGTOGETHER
NEWAPPLICATIONS
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Goal of the study
Multi-scale fibres (from centimeters to nanoscale,various aspect ratios) for stronger materialstructures
• Optimal combination of fines, long fibers,nanocelluloses, polymers and additives to obtaingood adhesion in biocomposites and bondingin fibre foam structures
• Novel bio based products for SMEs throughinnovative raw material combinations (hempfractions, hydrophobins, lignocellulosic fines,nanocelluloses, wood wool, side streams) andtechnologies combined with design approach
Gap
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Fibre composites according to fibre content
Increased fibre/cellulose content
Printing paper,Coated paper,Sized paper
Non-woven
MFC, NFC,containing plastic
films
Injection mouldedproducts with cellulosic
fibres
Extrusion moulded profiles with cellulosicfibres
Thermosetting mouldedfibre composites
All cellulosecomposites
Foam formed materials
Materials for 3D-printing
Classic WoodComposites
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Fiber foams
• Fiber suspension +air– Typical air content 40
- 70%– Foam stability can be
controlled– Typical bubble
diameter ~100 µm
• No fiber flocculation– Small bubbles fill the
free space
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Foam forming of low density structures• Foaming of water-fiber-surfactant mixture to reach air content 50
- 60%• Foam is poured into a foam forming mould, size 42 x 42 cm2
• Drainage of liquid using gravity or low vacuum level, no wetpressing
• Drying in oven 60 - 70°C, ~24 h, drying time depends on pulptype
Foamingvessel
Forming mouldwith fibre foam
In-plane dried structures ofdifferent thicknesses in
oven
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Application: Light weight inner packages§ Light and soft fibrous cushioning element that protects the product
from impacts§ Product shape made in manufacturing phase§ Replacement of non-biodegradable EPS based inner packages
(Europe: 1.6 million tons of EPS waste in 2010)
Kiiskinen H., Torniainen E., Kinnunen K., Method of forming a fibrous product, WO 2015/036659 A1
Foam formedinner package
Cellulose fibre material to replace plastic bubblewrapDesign: Kaisa Jäntti, LAMKMaterials and foam forming: VTTPhotos: Kaisa Jäntti, LAMK and JuhaHakulinen, VTT
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Application: Designed decorativesound absorber panels
§Foam forming and design-driven aspect lead todesigned porous structureswith special 3D form andsound absorption property
§Cellulose pulp used as rawmaterial instead of highlyprocessed and disposablematerials
Kaarna wall panels designed by Hannakaisa Pekkala LAMKExhibition of ”Designed Cellulose For Future II” in May 2016, Helsinki
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Multi-scale material experiments:Hemp, refined bark and wood wool fractionswith cellulose pulp
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3D printed biocomposite decorative hydrogelsPatent pending
Exhibition of”DesignedCellulose ForFuture II” in May2016, HelsinkiAalto Arts
3D printed bio-based hydrogels for decorative applicationsDesign Susanna Kettunen LAMK3D printing and material development: VTTPhoto: Juha Hakulinen VTT
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Moldable pure cellulose pulp sheetsDesign: Tomi Laukkanen LAMKMaterials: Metsä GroupPhotos: Juha Hakulinen VTT
Pure 100% cellulose pulp sheetsmoldable materials
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Exhibition of”Designed CelluloseFor Future II” in May2016, Helsinki
3D printed toys for animalsDesign: Kristoffer Heikkinen LAMK3D printing: 3DTechCommercial materialsPhotos by Juha Hakulinen VTT
3D printed wood sawdust and biopolymerstimulus toys for production animals