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: bernd.gulich@stfi.deLodz (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 bernd.gulich@stfi.dePhone +49 371 5274 204Website www.stfi.de

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Thank you! Thank you!

Project smedia