Lien Van der Schueren Centexbel October 19, 2017

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1 Lien Van der Schueren Centexbel October 19, 2017

2 Centexbel Collective research and technical centre in Belgium On textiles & plastics Driven by the industry Activities R&D Testing Services Staff 160 skilled and highly educated men and women

3 Centexbel R&D Fields Functional thermoplastic textiles Melt processing of polymers in textiles and composites Textile functionalisation and surface modification Coating, finishing and surface modification for new and superior functional performances Health, safety and security Textile products for health, safety and security purposes Plastics Processing of plastics Functionalisation of plastics and surface technology Energy consumption

4 Cornet project BIO-SRPC Biobased self-reinforced polymer composites April 2013 April 2015 Project partners Centexbel (BE) Coordinator Institut für Textil (ITA) RWTH Aachen (DE) FKT (DE) Association Sirris SLC-Lab (BE)

5 Self-reinforced polymer composites Known as SRPC Composites A matrix reinforced by highly oriented strong fibres Self-reinforced Reinforcing fibres & matrix: same material class Fossil-based SRPCs already on the market 1 e.g. CURV (PP based): used in Samsonite suitcases

6 Self-reinforced polymer composites Single polymer grade (e.g. CURV) very tight processing window Two polymer grades: high melting, high modulus grade + lower melting grade broader processing window T m, 1 < T process < T m, 2

7 SRPCs: a wide range of advantages Lightweight: high specific stiffness and strength High impact resistance Excellent fibre-matrix adhesion Inherent thermoformability Environmentally benign material due to high recyclability of mono material composite

8 SRPCs: used in variety of applications Automotive Door and underbody panels Consumer goods: Household appliances Industrial equipment Protection shrouds Machine cover Sporting Body armour Canoes Military Body armour

9 BIO-SRPC main goal: bio-based SRPC PLA (polylactic acid) is an ideal candidate Currently most often used bio-based thermoplastic Available in different melting points (ranging from 130 C to 170 C)

10 Production chain for PLA SRPC In BIO-SRPC we developed: High tenacity PLA fibres Reinforcement fibres Matrix fibres Low melting PLA fibres Hybrid textiles Consolidation process of SRPC Thermoforming process Hybrid textile Consolidated plate Formed part

11 Production chain for PLA SRPC In BIO-SRPC we developed: High tenacity PLA fibres Reinforcement fibres Matrix fibres Low melting PLA fibres Hybrid textiles Consolidation process of SRPC Thermoforming process Hybrid textile Consolidated plate Formed part

12 Development of PLA fibres Low melting PLA fibres Low mechanical requirements (molten during consolidation process) High melting PLA fibres Form the reinforcement of the composite High tenacity & modulus required received main focus

13 Optimisation of high melting fibre Evaluation of optimal high melting PLA grade Best tenacity & stiffness for PLA low to medium MVR (Melt Volume Rate ~ viscosity) low PDLA content in PLLA

14 Optimisation of high melting fibre Optimisation of processing conditions Multifilament extrusion 1 step process (extrusion & drawing in 1 step) 2 step process (separate drawing step) results in higher properties

15 Production chain for PLA SRPC In BIO-SRPC we developed: High tenacity PLA fibres Reinforcement fibres Matrix fibres Low melting PLA fibres Hybrid textiles Consolidation process of SRPC Thermoforming process Hybrid textile Consolidated plate Formed part

16 Hybrid textiles Textiles containing well distributed low melting and high melting PLA fibres Different types developed Hybrid yarns Woven fabrics Low melting PLA High melting PLA Non-wovens

17 Hybrid textile Production of non-wovens consisting of low and high melting PLA fibres (via airlaying & needle punching) Flexible and fast production Good processability and drapability HM PLA Filaments HM PLA Fibres 30 cm Hybrid PLA Airlay nonwovens Needle punched nonwoven LM PLA Filaments LM PLA Fibres

18 Production chain for PLA SRPC In BIO-SRPC we developed: High tenacity PLA fibres Reinforcement fibres Matrix fibres Low melting PLA fibres Hybrid textiles Consolidation process of SRPC Thermoforming process Hybrid textile Consolidated plate Formed part

19 Composite Production Consolidation Processing parameters: pressure, temperature, time Thermoformability to final part consolidation thermoforming

20 Consolidation process Unidirectional bending stiffness Significantly higher compared to neat PLA (3,5 GPa) modulus can be more than doubled Through process optimisation: 4,6 GPa 8,1 GPa bending stiffness (GPa) UD1 UD2 UD3 UD4

21 Thermoforming process Starting from woven fabric Good thermoformability Resulting properties competitive to SRPC based on PP (petro-based)

22 General project conclusions Strong & stiff PLA filaments can be produced Selection of optimal PLA grade Optimisation of processing conditions Textile Structures Hybrid yarns and weaves out of low and high melting PLA fibres successfully produced Nonwovens: flexible and fast production SR-PLA Composites Increases toughness and mechanical properties of PLA Have properties that are competitive with Curv Have interesting processability due to two melting temperatures Have a high impact potential Potential applications: semi-structural applications

23 Collaboration issues Each partner in BIO-SRPC represents specific part of production chain: Filament extrusion (Centexbel) Hybrid textile production (ITA) Composite production and forming (SLC) Positive: available expertise But potential issues: Risk of slowing down project progress due to high dependency of partners High material need for certain processes in production chain

24 Collaboration issues General difficulty in composite research: effect only to be shown by making a composite Tried to tackle by Evaluation at small scale, without having to complete the whole loop (e.g. UD composites obtained by filament winding) Larger scale production at company of the User Committee

25 Dissemination actions First dissemination via the User Committee 6 monthly user committee meetings (5 in total); leading to numerous feedbacks & suggestions Predicting composite properties via modelling Less focus on chemical recycling of PLA Evaluation of impact resistance & use impact modifiers Involvement of the UC group by e.g. Use of materials (e.g. PLA grades, additives, ) Industrial trials at member company (e.g. filament extrusion at larger scale) Individual visits to member companies at project end

26 Dissemination actions Speeches at various (inter)national conferences: Oct 2013: 1 st European Textile Flagship Conference, Brussels Oct 2014: 22 nd annual meeting of the Bio-Environmental Polymer Society, Kansas City Nov 2014: Hofer Vliesstofftage, Germany March 2015: International Conference on Biobased Textiles and Plastics, Elewijt May 2015: 18 th International Techtextil-Symposium, Frankfurt Sep 2015: 54 th Dornbirn Man-Made Fibers Congress, Dornbirn Oct 2015: The European Forum for Industrial Biotechnology, Brussels Dec 2015: The 2015 European Biopolymer Summit, London

27 Further valorisation of project results Follow-up research via H2020 project BIO4SELF BIO4SELF: Biobased self-functionalised self-reinforced composite materials based on high performance nanofibrillar PLA fibres Member of BIO-SRPC user committee is project partner (as end user) in BIO4SELF project Website: Horizon 2020 European Union Funding for Research & Innovation

28 BIO-SRPC serving needs of companies Development of SRPCs requires innovations in all steps of process chain impossible for individual (SME) companies Thanks to project, awareness created for companies active over complete value chain Possibility of performing PLA filament extrusion on standard extrusion lines Optimal processing for obtaining high tenacity PLA yarns Possibility of making textile intermediates using standard textile processing equipment Demonstrating potential of PLA in composite sector Only possible via close cooperation between RTD partners ánd companies

29 Acknowledges & Contact Thanks to CORNET and the funding agencies Contact Lien Van der Schueren lien.vanderschueren@centexbel.be