powerpoint: brett suddell (3.5 mb)
TRANSCRIPT
The Current Situation and Future Outlook for Natural Fibres within the
Automotive Industry
Dr. Brett SuddellDr. Brett SuddellUniversity of Wales Swansea, IRCUniversity of Wales Swansea, IRC
(U.K.)(U.K.)
Joint Meeting of the 32nd session of the Intergovernmental group on Hard Fibres and the
34th session of the Intergovernmental group on Jute, Kenaf and Allied Fibres8 to 11th July 2003Salvador, Brazil
Presentation Format Short introduction to IRCShort introduction to IRC Background to surveyBackground to survey Intro to NF’s – Advantages/DisadvantagesIntro to NF’s – Advantages/Disadvantages Automotive SectorAutomotive Sector ApplicationsApplications European PerspectiveEuropean Perspective U.S. perspectiveU.S. perspective ConclusionsConclusions AcknowledgmentsAcknowledgments
University of Wales Swansea
Interdisciplinary Research CentreCentre of ExcellenceSchool of EngineeringUniversity of Wales
SwanseaSingleton ParkSwansea SA2 8PPSouth WalesUK
Tel:+44 1792 295286Fax:+44 1792 295693
[email protected] © Crown Copyright: Royal Commission on the ancient and historical monuments of Wales
Introduction to the IRC Established in 1989, 10 year funding via Established in 1989, 10 year funding via
EPSRCEPSRC £12m industrial funding over last decade£12m industrial funding over last decade Rolls Royce University Technology CentreRolls Royce University Technology Centre WDA Centre of ExpertiseWDA Centre of Expertise Materials CETIC Centre of ExcellenceMaterials CETIC Centre of Excellence Accredited by Rolls Royce plc for design Accredited by Rolls Royce plc for design
standard datastandard data
Activities
33rdrd Sustainable Composites Network seminar Sustainable Composites Network seminar (60+ people)(60+ people)
Work closely with Australian partnersWork closely with Australian partners Working with local SME’s and institutionsWorking with local SME’s and institutions Research with institution based in IndiaResearch with institution based in India Enquiries from Africa, Europe, Asia to work on Enquiries from Africa, Europe, Asia to work on
Natural Fibre composite research programmesNatural Fibre composite research programmes
Background to Survey
Welsh and Australian experts brought togetherWelsh and Australian experts brought together
New Wales in New South Wales technical New Wales in New South Wales technical programmeprogramme
IRC selected due to proven research track recordIRC selected due to proven research track record
Idea for this research borne out of this meetingIdea for this research borne out of this meeting
Background to Survey
Main Focus was the Automotive industry Main Focus was the Automotive industry
Identified fibres and respective applicationsIdentified fibres and respective applications
Identified Key Players in Academia and IndustryIdentified Key Players in Academia and Industry
Different Continents such as Europe; Australia; America Different Continents such as Europe; Australia; America (North and South); India; Africa and Asia (North and South); India; Africa and Asia
Conferences & Personal visits ““EcoComp” – London, September 2001EcoComp” – London, September 2001
““Bast Fibrous Plants..” – China September 2001Bast Fibrous Plants..” – China September 2001 LINK workshop – UMIST, Manchester October 2001LINK workshop – UMIST, Manchester October 2001 ““Global outlook for Natural Fibre reinforcements” – Orlando, USA Global outlook for Natural Fibre reinforcements” – Orlando, USA
December 2001December 2001 Central Science Laboratory focus meeting – London December 2001Central Science Laboratory focus meeting – London December 2001 ““The Industrial Application of Bioplastics 2002”, York, Feb 2002The Industrial Application of Bioplastics 2002”, York, Feb 2002 Composites Processing Association meeting, Birmingham Feb 2002Composites Processing Association meeting, Birmingham Feb 2002 ““High Performance Structures & Composites”, Seville, Spain. March 2002High Performance Structures & Composites”, Seville, Spain. March 2002 ““GreenTech”, Amsterdam April 2002GreenTech”, Amsterdam April 2002 ““Progress in woodfibre composites”, Toronto, Canada, May 2002Progress in woodfibre composites”, Toronto, Canada, May 2002 ECCM-10, Brugge, Belgium June 2002ECCM-10, Brugge, Belgium June 2002 Plant Fibres laboratory (Copenhagen)Plant Fibres laboratory (Copenhagen) BioComposites CentreBioComposites Centre Warwick Manufacturing GroupWarwick Manufacturing Group
Vegetable fibre classification
Bast F ibres- F lax
- Hem p- Kenaf
Leaf F ibres- S isa l
- C uraua- Banana
Seed F ibres- Cotton- Capok
Fruit F ibres - C oconut
W ood F ibres - P inew ood
Vegetable F ib res- C e llu losic fibres
Bast Fibres – Bast is Best? Natural task to stabilise plantNatural task to stabilise plant Composed of an inner woody core Composed of an inner woody core
surrounded by bundles of long hollow surrounded by bundles of long hollow fibres and an outer protective skin each fibres and an outer protective skin each containing individual fibre cells or containing individual fibre cells or filamentsfilaments
Filaments = cellulose & hemicellulose, Filaments = cellulose & hemicellulose, matrix lignin or pectinmatrix lignin or pectin
Good mechanical propertiesGood mechanical properties Low density BF have potential to be Low density BF have potential to be
outstanding reinforcements in outstanding reinforcements in lightweight composite partslightweight composite parts
Leaf Fibres
In general coarser than Bast fibresIn general coarser than Bast fibres Sisal most important – Agave PlantSisal most important – Agave Plant Often applied with Flax in hybrid matsOften applied with Flax in hybrid mats
Provides good permeability when mat Provides good permeability when mat impregnated with resinimpregnated with resin
Interior applications sisal preferred due to Interior applications sisal preferred due to low level of odourlow level of odour
Advantages
Environmental: Environmental: Plant fibres are a renewable resourcePlant fibres are a renewable resourceVery low Energy requirement in production Very low Energy requirement in production
(6,500BTU’s=2.2Kg Kenaf, (6,500BTU’s=2.2Kg Kenaf, 23,500BTU’s=2.2Kg of glass fibres)23,500BTU’s=2.2Kg of glass fibres)
Disposal can be by compostingDisposal can be by compostingCOCO2 2 neutralityneutrality
Advantages Biological:Biological:
Natural organic product Natural organic product No dermal or respiratory issues when compared to No dermal or respiratory issues when compared to
glass fibresglass fibresDo not pose a biohazard on disposalDo not pose a biohazard on disposal
Production:Production:Fibres are non-abrasive so extremely low wear Fibres are non-abrasive so extremely low wear
rates on toolingrates on toolingExcellent formability – deep mouldings can be Excellent formability – deep mouldings can be
producedproducedMoulding off cuts can Moulding off cuts can
be reusedbe reused
Advantages Component Weight:Component Weight:
Plant fibres have a max. density of Plant fibres have a max. density of 1.5g/cm1.5g/cm33 (that of Cellulose) (that of Cellulose)
Density flax=1.4g/cmDensity flax=1.4g/cm33
Density Glass fibres = 2.5g/cmDensity Glass fibres = 2.5g/cm33
Resulting in high specific strength and Resulting in high specific strength and stiffness = low component weightstiffness = low component weight
Injection moulded ABS 4 door panels = Injection moulded ABS 4 door panels = 9Kg, same panels utilising NF’s = 5Kg for 9Kg, same panels utilising NF’s = 5Kg for similar mechanical propertiessimilar mechanical properties
Advantages
Cost:Cost:Abundant resource in many nationsAbundant resource in many nationsBast fibres cost significantly less than Bast fibres cost significantly less than
glass fibresglass fibresNatural fibres 0.5-0.6 Euros/KgNatural fibres 0.5-0.6 Euros/KgGlass fibres 9.0 Euros/KgGlass fibres 9.0 Euros/Kg
In addition, weight critical applications In addition, weight critical applications usually incur lower costs with any weight usually incur lower costs with any weight savingssavings
Further Advantages
Readily available worldwideReadily available worldwide Exhibit a safer crash behaviour in tests i.e. no Exhibit a safer crash behaviour in tests i.e. no
splinteringsplintering Hollow tubular (cellular) structure also provides:Hollow tubular (cellular) structure also provides:
Good acoustic propertiesGood acoustic propertiesGood thermal insulating propertiesGood thermal insulating properties
Limitations Concerns over fibre consistency/qualityConcerns over fibre consistency/quality Low impact strength (high concentration of fibre Low impact strength (high concentration of fibre
defects)defects) Fibres are hydrophilic Fibres are hydrophilic Issues of bonding with polymersIssues of bonding with polymers Previous 2 issues largely overcome by development of Previous 2 issues largely overcome by development of
effective fibre surface treatments – MAPPeffective fibre surface treatments – MAPP Emission issues – fogging and odourEmission issues – fogging and odour Processing Temps – natural sugars caramelise Processing Temps – natural sugars caramelise
between 150-205between 150-205ºC must keep below this levelºC must keep below this level
History
3000 years ago first composite material made in ancient Egypt - clay/mud reinforced by straw to build walls
Development of other more durable construction materials such as metals, NF interest was lost
History
Early 1930’s, Henry Ford walked into his Company’s research lab with a bag of chicken bones, dumped them on a desk and said, “See what you can do with these!”
Tried cantaloupes, carrots, cornstalks, cabbages and onions
Soybean stalks. In 1940, Soybean oil could be used to make high quality
paint enamel and could be moulded into a fibre based plastic with 10 times the shock-resistance of steel
If the material had not required a long cure time and had associated moulding problems, we might be driving around in soybean fords today!!
History 1939-45 WWII – shortage of Aluminium in England, led to the use of 1939-45 WWII – shortage of Aluminium in England, led to the use of
flax fibres impregnated with phenolic resin to form fuselage skins of flax fibres impregnated with phenolic resin to form fuselage skins of spitfires – “Gordon-Aerolite”spitfires – “Gordon-Aerolite”
1942 Henry Ford – prototype hemp fibre composite car – did not 1942 Henry Ford – prototype hemp fibre composite car – did not enter production due to economic limitations at that timeenter production due to economic limitations at that time
Trabant (1950-90) first production car to be built from NF’sCotton within a Polyester matrix
Only in the last 15-20 years have NFC’s seen renewed interest
“The most environmentally friendly thing that you can do
for a car that burns gasoline is to make lighter bodies”
Henry FordHenry Ford
Structure of Automotive components market
Important elements of the automotive component industry relevant to natural fibre supply:
OEM’s (Original Equipment Manufacturers) – Car manufacturers Tier One Suppliers – suppliers of specialised interior systems for
assembly by OEM’s Substrate Suppliers – non-woven producers in textile industry &
plastics producers in case of new natural fibre granulate technology
Natural Fibre Suppliers – Hemp, Flax, Jute, Kenaf etc.
To influence specification and usage of natural fibres, suppliers must work with all components identified above.
The actual customers for natural fibres are the substrate/non-woven producers.
Automotive Market
To the natural fibre producer the To the natural fibre producer the automotive market is attractiveautomotive market is attractiveModel platform life is minimum 5 yearsModel platform life is minimum 5 years7-8 years7-8 years
Most important Processes Compression Most important Processes Compression Moulding and Injection mouldingMoulding and Injection moulding
Compression Moulding Most common use of bast fibres is in Most common use of bast fibres is in
compression moulding technologycompression moulding technology Medium-long fibres in non-woven mat or Medium-long fibres in non-woven mat or
feltfelt Mat produced by air laying or needle Mat produced by air laying or needle
punchingpunching Requires addition of polymers to act as Requires addition of polymers to act as
binders – blending prior to needling or binders – blending prior to needling or coating/impregnationcoating/impregnation
Injection Moulding Injection moulded composites reinforced Injection moulded composites reinforced
by short natural fibresby short natural fibres Short fibres (4-6mm) + PP in single/twin Short fibres (4-6mm) + PP in single/twin
extruder to produce granulate for injection extruder to produce granulate for injection mouldingmoulding
Examples Examples exterior apps – spoilers and fendersexterior apps – spoilers and fendersinterior apps – “hard” items - dash interior apps – “hard” items - dash
and instrument panelsand instrument panels
Miscanthus
Worlds largest GrassGrows up to 3mResembles sugar caneShort fibresBlended by handInjection mouldedStructural filler in plastic wheel trims
Applications
Mercedes-Benz ‘E’ClassMercedes-Benz ‘A’ Class
Audi A2 first mass produced vehicle with an all Al body,door panels reinforced with a flax/sisal mat
20% weight saving achieved with Flax/Sisal thermoset door panels
Natural fibres in automotive applications
Centre console trim
Various damping and insulation parts
C-pillar trim
Rear parcel shelf
Seat cushions
Door trim panels
Engine Shield
Bumper
Wheel arch
IENICA (ref. 1495) Summary ReportFibre Crops August 2000
Automotive Manufacturer
Model and Application
Audi A2,A3, A4, A4 Avant, A6, A8, Roadster, CoupeSeat backs, side and back door panel, boot lining, hat rack, spare tyre lining
BMW 3, 5 and 7 series and othersDoor panels, headliner panel, boot lining, seat backs
Daimler/Chrysler A, C, E and S-ClassDoor panels, windshield/dashboard, business table, pillar cover panel
Fiat Punto, Brava/Marea, Alfa Romeo 146, 156Ford Mondeo CD 162, Focus
Door panels, B-pillar, boot linerPeugeot New model 406Renault ClioRover Rover 2000 and others - Insulation, rear storage shelf/panelSaab Door panelsSEAT Door panels, seat backsOpel GM Astra, Vectra, Zafira
Headliner panel, door panels, pillar cover panel, instrument panel
Volkswagen Golf, Passat, BoraDoor panel, seat back, boot lid finish panel, boot liner
Volvo C70, V70
Plant fibre usage per vehicle
Front door liners: 1.2-1.8KgFront door liners: 1.2-1.8Kg Rear door liners: 0.8-1.5KgRear door liners: 0.8-1.5Kg Boot liners: 1.5-2.5KgBoot liners: 1.5-2.5Kg Parcel Shelves: <2KgParcel Shelves: <2Kg Seat Backs: 1.6-2.0KgSeat Backs: 1.6-2.0Kg Sunroof Interior Shields: <0.4KgSunroof Interior Shields: <0.4Kg Headrests: ~2.5KgHeadrests: ~2.5Kg
BMW 3, 5 and 7 Series3, 5 and 7 Series 20-24Kg of natural fibres20-24Kg of natural fibres ~16Kg coconut:sisal used as seat padding~16Kg coconut:sisal used as seat padding 80:20 flax:sisal blend for increased strength 80:20 flax:sisal blend for increased strength
and impact resistanceand impact resistance
Typical U.S. MaterialsApplicationApplication FibreFibre MatrixMatrix % %
FibreFibreDoor Door panel/insertspanel/inserts
Kenaf/Hemp, 50/50Kenaf/Hemp, 50/50Wood fibreWood fibre
PPPPPPPP
50505050
Rear parcel Rear parcel shelvesshelves
KenafKenafFlaxFlaxWoodWood
PPPPPPPPPPPP
505050508585
SeatbacksSeatbacks FlaxFlax PPPP 5050
Spare tyre Spare tyre coverscovers
FlaxFlaxWoodWood
PPPPPPPP
50505050
Other interior Other interior trimtrim
KenafKenafFlaxFlax
PPPPPPPP
50505050
Door PanelsInterior Door panels using Natural Fibres (manufactured by DLR Germany)
Chrysler Sebring convertible door panel – 25% Kenaf, 25% Hemp 50% PP
Ford Mondeo door insert
DaimlerChrysler
Exploring idea of replacing glass fibre with NF’s since 1991
Subsidiary Mercedes-Benz pioneered concept with “Belem project” in Sao Paulo, Brazil (Amazon delta)
Coconut fibres used in commercial vehicles for 9 years
DaimlerChrysler
2000 DC begins using NF in vehicle production in South Africa
Implemented transfer of technology from Germany to S.Africa for entire process chain
Sisal from local farmers to mat manufacturers to vehicle component supplies – none of these partners involved in sisal processing prior to this application
Spent $1.5bn on environmental initiatives in 2000 alone
Researchers in Germany using NF’s to reinforce EXTERIOR components
A truck with flax-based rather than glass-based exterior skirting panels now in production
Tests carried out at DC research centre, Ulm panels stood up to impact without shattering into splinters
DC have a global natural fibre initiative program that benefits 3rd world nations by developing products made from indigenous agricultural materials
DaimlerChrysler
Exterior Applications
Mercedes-Benz Travego Coach
‘Travego’ coach equipped with flax reinforced engine/transmission covers Exterior components must be able to withstand extreme conditions – wetness and chipping First use of NF’s for standard exterior components in a production vehicle Represents a milestone in materials technology Benefits:
Weight reduction of engine/transmission cover of 10%Cost reduction of 5%
U.K. Govt. Division DEFRA (MAFF)
Study commissioned in 1999 Market for NFC has grown from nothing to a
considerable industrial infrastructure during the last 5-10 years
58m vehicles produced globally Up to 20Kg of NF’s could be used per car Each new car model requires 1,000 to 3,000 tonnes of
NF’s p.a. 1999 in excess of 15,000t of flax fibre being used in
auto industry in Europe
Situation in 2000 European market for fibreglass European market for fibreglass
composites ~300,000,000 Kg (2000)composites ~300,000,000 Kg (2000) 1/3 in automotive applications1/3 in automotive applications Cost £5.50/Kg Cost £5.50/Kg Natural fibres cost 0.30-0.35p/KgNatural fibres cost 0.30-0.35p/Kg Significant cost reductions can be Significant cost reductions can be
achievedachieved
Germany occupies a totally dominant market position in terms of Germany occupies a totally dominant market position in terms of product innovation, research and commercial productsproduct innovation, research and commercial products
Germany is clearly the leading country in the consumption of Germany is clearly the leading country in the consumption of natural fibres in the European Automotive industry [2/3 of all natural fibres in the European Automotive industry [2/3 of all fibres]fibres]
Due to government subsidies in 80’s to stimulate the domestic Due to government subsidies in 80’s to stimulate the domestic growing of plants such as flax and hemp as industrial crops – did growing of plants such as flax and hemp as industrial crops – did not lead to new markets but raised the profile of NF’s not lead to new markets but raised the profile of NF’s considerablyconsiderably
UK & France fall behind GermanyUK & France fall behind Germany In Germany, car manufacturers are aiming to make EVERY In Germany, car manufacturers are aiming to make EVERY
component of their vehicles either recyclable or biodegradable*component of their vehicles either recyclable or biodegradable*
*S. Hill, “Cars that grow on Trees”, New Scientist, Feb. 1997, pp.36-39
Germany
1982-2002 EU >$60m in subsidies 1982-2002 EU >$60m in subsidies directed towards development of new flax directed towards development of new flax and hemp appsand hemp apps
In Germany alone >$104m invested in In Germany alone >$104m invested in R&D – new harvesting, fibre processing R&D – new harvesting, fibre processing and refining technologiesand refining technologies
>$89m further investment planned in >$89m further investment planned in GermanyGermany
M.Karus et al. “Study on Markets and Prices for Natural Fibres (Germany and EU)”Nova Institute, March 2000
European consumption of Natural fibres (tonnes)
Fibre 1996 1999
Germany Rest of Europe
Germany Rest of Europe
Flax 1800 na 11000 4900Jute 1800 300 2000 1400Hemp na na 1100 600Kenaf 400 na 900 naSisal na na 500 na
Totals 4000 300 15500 6900
Projections*2005 W-Europe 50-70,000t2010 W-Europe >100,000t
G.C. Ellinson, R,McNaught, “The use of natural fibres in nonwoven structures for applications as automotive component substrates”, MAFF UK Government report NF0309, Feb 2000
*D. Plackett, “The natural fibre-polymer composite industry in Europe – Technology and Markets”, Proc. Progress in woodfibre-plastic composites, Toronto, May 2002.
Values for 2000Germany 17140Rest of Europe 11,160Total 28,300
European Usage
0
2000000
4000000
6000000
8000000
10000000
12000000
14000000
16000000
Kg
Flax Jute Hemp Kenaf Sisal Total (Kg)
1996 Germany
1996 Rest of Europe
1999 Germany
1999 Rest of Europe
Western Europe
0 10000000 20000000 30000000 40000000 50000000 60000000 70000000 80000000 90000000 100000000
Total Demand (Kg)
1996
1999
2000
2005
2010
Year
European Potential World automobile production of 58m vehicles World automobile production of 58m vehicles
p.a.p.a. 30% is Western Europe30% is Western Europe Potential market of 18m vehiclesPotential market of 18m vehicles Equates to 175,000-350,000 tonnes p.a.Equates to 175,000-350,000 tonnes p.a. Europe is ahead of North America in its use of Europe is ahead of North America in its use of
natural fibre composite applications by ~8 yearsnatural fibre composite applications by ~8 years
Consuming Petroleum resources at an Consuming Petroleum resources at an ‘unsustainable’ rate‘unsustainable’ rate
100,000 times faster than nature can 100,000 times faster than nature can create itcreate it
Governments have established laws to Governments have established laws to encourage use of green or recycled encourage use of green or recycled productsproducts
EU legislation ELV directive [2000/53/EC]ELV directive [2000/53/EC] Came into force Oct 2000Came into force Oct 2000 All member states required to transpose All member states required to transpose
into law by April 2002into law by April 2002 Directive aims to:Directive aims to:
‘‘depollute’ all scrapped cars ~10m/yeardepollute’ all scrapped cars ~10m/yearAvoid hazardous wasteAvoid hazardous wasteReduce landfill to max 5%/car by 2015Reduce landfill to max 5%/car by 2015
Driving Force - Government Legislation
Recycling concerns being driven by EU regulations [EU directive Article 7 on end of life vehicle disposal]
Pressure on manufacturers to consider environmental impact of products at all stages of their life cycle including the ultimate disposal
RecoveryRecoveryWt %Wt %
RecyclingRecyclingWt %Wt %
Jan 1Jan 1stst 2005 2005 8585 8080
Jan 1Jan 1stst 2015 2015 9595 8585
Driving Forces
CostCost Weight reductionWeight reduction Crash worthinessCrash worthiness Sound insulationSound insulation Green productsGreen products RecyclingRecycling
European Research Automotive Industry e.g. SAAB and Research Automotive Industry e.g. SAAB and Research
Institutions collaborating on EU growth projectsInstitutions collaborating on EU growth projects ““EcoFina”EcoFina” Addresses the substitution of mineral fillers and Addresses the substitution of mineral fillers and
fibres made with organic matrices, by Polymeric fibres made with organic matrices, by Polymeric Matrix composites based on annually renewable Matrix composites based on annually renewable natural fibresnatural fibres
Allow for the production of vehicle components Allow for the production of vehicle components with potentially complete recyclabilitywith potentially complete recyclability
www.ecofina.orgwww.ecofina.orgD. Puglia, J. Biagiotti, J.M.Kenny, “ECOFINA: Ecoefficient Technologies and Products based on Natural Fibre Composites”, D. Puglia, J. Biagiotti, J.M.Kenny, “ECOFINA: Ecoefficient Technologies and Products based on Natural Fibre Composites”,
Proceedings of ECCM-10, June 3-7 2002, BruggeProceedings of ECCM-10, June 3-7 2002, Brugge
Total (All sectors) NF demand North Total (All sectors) NF demand North AmericaAmerica
1980 = 47.62M Kg1980 = 47.62M Kg1990 = 52.16M Kg1990 = 52.16M Kg
North America in 2000North America in 2000181m Kg of natural fibres used181m Kg of natural fibres used
3.5% (5.9-6.8m Kg) e.g. flax, hemp, 3.5% (5.9-6.8m Kg) e.g. flax, hemp, kenafkenaf
96.5% Wood flour and fibre96.5% Wood flour and fibre
0
50
100
150
200
Years
Kg
(Milli
ons)
1980 1990 2000
U.S. End Markets (2000)
75%
7%8%
10%
Building ProductsOther - Infrastructure, MarineAutomotiveIndustrial and Consumer
Forecast Growth outlook for natural fibres in automotive Growth outlook for natural fibres in automotive
products 2000-2005 50% per year*products 2000-2005 50% per year* $150M (2000) to $1.4bn (2005) North America $150M (2000) to $1.4bn (2005) North America
alone!! [54% annual growth rate]alone!! [54% annual growth rate] Market in Market in 20052005 will require will require 45.45M Kg45.45M Kg of of
natural fibresnatural fibres Processing and weight benefits compared to Processing and weight benefits compared to
glass fibres will particularly drive the growth of glass fibres will particularly drive the growth of NF’sNF’s
*Kline and Company Inc., report 2000
U.S. Companies Flexform Technologies LLCFlexform Technologies LLC
Blends Kenaf, Hemp and PPBlends Kenaf, Hemp and PPUses – door panels, dashboards, ceiling Uses – door panels, dashboards, ceiling
tiles, wall panels, z-truss structures for load tiles, wall panels, z-truss structures for load floors in RV’sfloors in RV’s
Demand is high among Tier 1 suppliers (2001) Demand is high among Tier 1 suppliers (2001) expected to double by end of 2003expected to double by end of 2003
Users include GM, Ford, Chrysler, International Users include GM, Ford, Chrysler, International Truck, Mack Truck, Volvo TruckTruck, Mack Truck, Volvo Truck
2003 dodge viper door panels and console 2003 dodge viper door panels and console made from flexform matsmade from flexform mats
U.S. Companies Kenaf industries of South TexasKenaf industries of South Texas
Produces wide range of kenaf productsProduces wide range of kenaf products Johnson Controls Tier 1 automotive supplierJohnson Controls Tier 1 automotive supplier
Began looking at nat.fibre composites for interior Began looking at nat.fibre composites for interior door panels 10 years agodoor panels 10 years ago
Developed EcoCor – 50:50 NF:PP 50% hemp, 50% Developed EcoCor – 50:50 NF:PP 50% hemp, 50% kenafkenafUsed in full door panel of 2001 Chrysler sebringUsed in full door panel of 2001 Chrysler sebring
Findlay Industries (tier 1)Findlay Industries (tier 1) Door package trays, trunk liners & hard trim Door package trays, trunk liners & hard trim
(kenaf/PP blends)(kenaf/PP blends)
Non-automotive research TeelGRTTeelGRT Based in Baraboo, WisconsinBased in Baraboo, Wisconsin Using Jute, Sisal, Wood, Coir, flax, straw, Using Jute, Sisal, Wood, Coir, flax, straw,
kenaf and denimkenaf and denim Plastic wood, tables, shipping pallets and Plastic wood, tables, shipping pallets and
piggy bankspiggy banks
Example of U.S. Research
Prof. Wool (Univ. of Delaware) recently Prof. Wool (Univ. of Delaware) recently awarded (2001) $11m (over 4 yrs) from US awarded (2001) $11m (over 4 yrs) from US department of Energy to develop department of Energy to develop ALLALL natural natural compositescomposites
One current project – development of a One current project – development of a monolithic, aerodynamically shaped roof for monolithic, aerodynamically shaped roof for hurricane resistant housing. Made from NF’s, hurricane resistant housing. Made from NF’s, natural foam insulation and soy-based resinsnatural foam insulation and soy-based resins
Interesting to note that 350,000,000 Kg of flax worth US$ 400m is converted to US$ 3bn worth of finished goods as value is added along the production chain
World Potential 58m vehicles produced p.a.58m vehicles produced p.a. Max natural fibre consumption 50:50 Max natural fibre consumption 50:50
natural:synthetic ~800,000 tonnes/yearnatural:synthetic ~800,000 tonnes/year If each vehicle used every possible If each vehicle used every possible
application of Nf’sapplication of Nf’s
Advantages to using Bast Fibres in the Auto Industry
Reduction in weight between 12-30% (primary importance)
Reduction in cost (secondary importance) Renewable and sustainable plant fibre
resources Recyclable Abundant supply, accessible to car
manufacture areas
Conclusions Natural fibres have enormous potential to be Natural fibres have enormous potential to be
used in composites for automotive industryused in composites for automotive industry Offer Offer cost savingscost savings, , environmental benefitsenvironmental benefits
and and reduced component weightreduced component weight Issues of toughness and variable properties Issues of toughness and variable properties
must be resolved in order that these must be resolved in order that these composites see more widespread usecomposites see more widespread use
NF products are NOT confined to the NF products are NOT confined to the automotive industryautomotive industry
…the future… “ “The car of the future could be moulded from The car of the future could be moulded from
cashew nut oil and hemp. And that’s not all. In cashew nut oil and hemp. And that’s not all. In the boot could be a set of golf clubs built the boot could be a set of golf clubs built around Jute fibres, nestling next to a tennis around Jute fibres, nestling next to a tennis racket stiffened with coconut hair. The bicycle racket stiffened with coconut hair. The bicycle frames strapped to the flax-based roof rack frames strapped to the flax-based roof rack may derive their strength from any one of the may derive their strength from any one of the 2000 other suitable plants. The truth is, natural 2000 other suitable plants. The truth is, natural fibres are undergoing a high tech revolution that fibres are undergoing a high tech revolution that could see them replace synthetic materials in could see them replace synthetic materials in many diverse applications”many diverse applications”
S. Hill, “Cars that grow on trees”, New Scientist, Feb 1997. pp.36-39
Partners & Publicity
Cartoon courtesy of Western Australian Newspaper [22/05/01]
Collaborative programme with University of New South Wales, Sydney (Australia)
Objective – to produce a lightweight natural composite car suitable for use as an inner city taxi
Future Work
Survey into other sectorsSurvey into other sectors Construction of item of sports Construction of item of sports
equipmentequipment NATURAL FIBERS, BIOPOLYMERS NATURAL FIBERS, BIOPOLYMERS
& THEIR BIOCOMPOSITES& THEIR BIOCOMPOSITES(Editors: A. K. Mohanty, M. Misra, L. (Editors: A. K. Mohanty, M. Misra, L. T. Drzal)T. Drzal)Publisher: CRC PressPublisher: CRC PressExpected Date December 2003Expected Date December 2003
Acknowledgements Engineering and Physical Sciences Engineering and Physical Sciences
Research Council (EPSRC) for Research Council (EPSRC) for funding the researchfunding the research
The many people who contributed The many people who contributed to the surveyto the survey
FAO, andFAO, and To your goodselves for listeningTo your goodselves for listening