material characterization of natural fiber – acrylic ... · material characterization of natural...
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08/01/2011 1
Material Characterization of Natural Fiber – Acrylic Thermoset Composites
Andre BendoJeremy Funk, John Norton, Dr. Gero Nordmann & Dr. Michael KalbeBASF Corporation
08/01/2011 2
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 3
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 4
Key Trends / Drivers
CAFE Standards requiring improved fuel efficiency
35.5 mpg by end of 2016
Proposed increase to 54.5 mpg by 2025
Strategies to meet rising standards
– Vehicle energy efficiency
– Power train / propulsion
– Weight reduction
Reducing vehicle weight allows for extended driving distances for alternative engines (electric or hybrid)
Interconnected
08/01/2011 5
Key Trends / Drivers
Growing demand for environmentally – friendly materials
Interior air quality
– Emissions from resin & additives
– Reduction in VOCs
Green materials
– Bio-based resins (soy, corn)
– Natural fibers
08/01/2011 6
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 7
Chemistry Advantage
Acrylic-based thermoset binder provides opportunity to
Produce very-durable composites & nonwovens
Lower weight at comparable performance or
Increase performance at same wall thickness
Reduce or eliminate VOCs, Odor & Fogging
Address rising demand for “green” materials
08/01/2011 8
OH
XOHHO
OHOOHO
OOH
OOH
Acrylic-based solutions consist of two components, dissolved in water
...and a polyalcohol:
...a polycarboxylic acid: ...to form a polyester
O
XO
O
O O
OO
O
O
X
X OX
Both components react at temperatures above > 130°C
Chemistry Advantage - Solutions
08/01/2011 9
OHOOHO
OOH
OOH
OH
XOHHO
Latex
...to form a latex-modified polyester
O
XO
O
O O
OO
O
O
X
X OX
Latex
Acrylic-based dispersions consist of two components, dissolved in water
...a polycarboxylic acid, modifiedwith a latex component:
...and a polyalcohol:
Both components react at temperatures above > 130°C
Chemistry Advantage - Dispersions
08/01/2011 10
Chemistry Advantage
Combines properties of thermoplastics & thermosets
Before cure: thermoplastic behavior
– Provides low-viscosity & excellent wetout of a wide variety of particles & fibers
– Allows production of prepregs / semi-finished goods
After drying & curing (at elevated temperatures): thermoset behavior
– Forms lightweight, durable thermoset
– Possesses excellent thermal, mechanical, & chemical stability
– Reduces VOCs, shelf-life storage issues
08/01/2011 11
Uncured resin (left) softens ≈50ºC;
Cure (right) occurs between 120-200ºC
DMA Analysis
Chemistry Advantage
acrylic resin dispersion withflexible-tough latex Tg ≈25ºC
08/01/2011 12
Chemistry Advantage
Production & curing of thermoplastic films
Can be applied to reinforcement / substrate via
– Impregnation (bath)
– Dipping
– Spraying
– Rolling
– Blow-Line
Bath
Foam
Spraying
08/01/2011 13
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 14
Target Composite Applications
Substrates Wood fibers Seed fibers: Cotton Bast fibers: jute, hemp, kenaf, flax...
Main application areas Automotive (ca 5 – 10 kg natural fibers are used in
each car)
Main products Door trims Rear window shelves Sound isolation parts Seat shells...
Characteristics of natural fiber composites
08/01/2011 15
Target Composite Applications
15
08/01/2011 16
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 17
Mechanical Performance Comparison
Critical automotive interior specifications
Tensile properties – ASTM D638-10
Flexural properties – ASTM D790-10
Izod impact – ASTM D256-10
Water absorption (24 hrs)
08/01/2011 18
Mechanical Performance Comparison
Constants
Mat type – 1000 gsm, kenaf (85%) / PET (15%)
Binder loading level ~28%
Chemistry Effect on Mechanical Properties
Dispersion grade vs. Solution grade vs. Dispersion/Solution Blend
Processing Parameters on Mechanical Properties
Cure Temperature
Cure Time
08/01/2011 19
Chemistry EffectMechanical Performance Comparison
Tensile properties – ASTM D638-10
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
Dispersion (High Tg) Solution/DispersionBlend
Dispersion (Low Tg) Solution
Binder Type
Tens
ile S
treng
th (M
Pa)
MD Tensile Strength (Mpa) CD Tensile Strength (Mpa)
08/01/2011 20
Chemistry EffectMechanical Performance Comparison
Flexural properties – ASTM D790-10
0.0
10.0
20.0
30.0
40.0
50.0
60.0
Dispersion (High Tg) Solution/DispersionBlend
Dispersion (Low Tg) Solution
Binder Type
Flex
ural
Stre
ngth
(MPa
)
MD Flexural Strength (Mpa) CD Flexural Strength (Mpa)
08/01/2011 21
Chemistry EffectMechanical Performance Comparison
Izod impact – ASTM D256-10
0
5
10
15
20
25
Solution Solution/DispersionBlend
Dispersion (high Tg) Dispersion (low Tg)
Binder Type
Impa
ct S
treng
th (k
J/m
^2)
08/01/2011 22
Processing EffectMechanical Performance Comparison
Tensile properties – ASTM D638-10
0
5
10
15
20
25
30
170C/60sec 180C/60sec 190C/60sec 200C/60sec
Tens
ile S
treng
th (M
Pa)
MD Tens Strength (MPa) CD Tens Strength (MPa)
08/01/2011 23
Processing EffectMechanical Performance Comparison
Tensile properties – ASTM D638-10
0
5
10
15
20
25
30
200C/30sec 200C/60sec 200C/90sec
Tens
ile S
tren
gth
(MPa
)
MD Tens Strength (MPa) CD Tens Strength (MPa)
08/01/2011 24
Processing EffectMechanical Performance Comparison
Flexural properties – ASTM D790-10
0
10
20
30
40
50
60
170C/60sec 180C/60sec 190C/60sec 200C/60sec
Flex
ural
Stre
ngth
(MPa
)
MD Flex Strength (MPa) CD Flex Strength (MPa)
08/01/2011 25
Processing EffectMechanical Performance Comparison
Flexural properties – ASTM D790-10
0
10
20
30
40
50
60
200C/30sec 200C/60sec 200C/90sec
Flex
ural
Stre
ngth
(MPa
)
MD Flex Strength (MPa) CD Flex Strength (MPa)
08/01/2011 26
Processing EffectMechanical Performance Comparison
Flexural properties – ASTM D790-10
0
500
1000
1500
2000
2500
180C/60sec 190C/60sec 200C/60sec
Flex
ural
Mod
ulus
(MPa
)
MD Flex Modulus (MPa) CD Flex Modulus (MPa)
08/01/2011 27
Processing EffectMechanical Performance Comparison
Flexural properties – ASTM D790-10
0
500
1000
1500
2000
2500
3000
3500
200C/30sec 200C/60sec 200C/90sec
Flex
ural
Mod
ulus
(MPa
)
MD Flex Modulus (MPa) CD Flex Modulus (MPa)
08/01/2011 28
Processing EffectMechanical Performance Comparison
Izod impact – ASTM D256-10
90%
95%
100%
105%
110%
115%
120%
180C/60sec 190C/60sec 200C/60sec
Rela
tive
Impa
ct S
treng
th
08/01/2011 29
Processing EffectMechanical Performance Comparison
Izod impact – ASTM D256-10
80%
85%
90%
95%
100%
105%
200C/30sec 200C/60sec 200C/90sec
Rela
tive
Impa
ct S
treng
th
08/01/2011 30
Processing EffectMechanical Performance Comparison
Water absorption (24 hr)
0%
10%
20%
30%
40%
50%
60%
70%
170C @ 60sec 180C @ 60sec 190C @ 60sec 200C @ 60sec
Volu
me
Cha
nge
(%)
Soak Vol % of Initial Dry Vol % of Initial
08/01/2011 31
Processing EffectMechanical Performance Comparison
Water absorption (24 hr)
0%
5%
10%
15%
20%
25%
30%
35%
200C @ 30sec 200C @ 60sec 200C @ 90sec
Volu
me
Cha
nge
(%)
Soak Vol % of Initial Dry Vol % of Initial
08/01/2011 32
Presentation Overview
Key Trends / Drivers
Chemistry Advantage
Target Composite Applications
Mechanical Performance Comparison
Summary
08/01/2011 33
Summary
Composite usage in automotive is growing – addressing need for light weighting
Interest in renewable materials is growing – addressing need for “green”
New materials need to meet or exceed performance requirements
08/01/2011 34
Summary
New acrylic-based thermosets satisfy all trends
Can meet automotive interior specifications
Enable lighter, thinner parts
Allow high fiber content composites (reduce use of non-renewable materials)
Eliminate VOCs
08/01/2011 35
Thank You for Your Attention
Questions?