Thermosetting Bio Composites

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1 Thermosetting Bio Composites M.Sc. O. Hansen Fibre reinforced plastics Bio2AN Rotorua - Scion IfBB Institute for Bioplastics and Biocomposites

2 Agenda 1 Thermosetting 2 Composites 3 Sustainable aviation 4 Sustainable automotive 2

3 What are thermosetting polymers? Thermosets are polymers that are produced by curing from a pre-polymer commonly called resin The reaction with hardeners and temperature create extensive cross-linked materials with covalent bonding Some main differences to thermoplastics : after cross-linked not fusible anymore High tensile strength High stiffness Low to no creeping Thermally stable Recycling Use of the finely ground material as filler Domininghaus, Hans; Elsner, Peter; Eyerer, Peter; Hirth, Thomas (2012): Kunststoffe. Berlin, Heidelberg: Springer Berlin Heidelberg. 3

4 Thermosetting biopolymers Basically thermosets have a lower share in market Special applications Development of thermoset biopolymers has not progressed so far Approximately 85% of biobased polymers are thermoplastics 4

5 Thermosetting biopolymers Thermosets need a reactive system Not many substances in nature difficult to create new thermosetting biopolymers Pre-molecules can be produced partly on the basis of renewable raw materials Most of the thermoset biopolymers available on the market are drop in solutions 5

6 Application of thermosetting (bio)polymers Among the most important products made of engineering resins Insulation materials Derived timber products Decorative laminates Electro laminates Composites Varnish

7 Composites fibre reinforced plastics Combination of thermoset an natural fibres to create a bio composite Fibre reinforced plastic Matrix Reinforcement Thermoplastic Thermoset Natural fibre Synthetic fibre Textile/fabric Single fibre all Pictures Fraunhofer WKI 7

8 InteReSt Functionally integrated and resource-saving lightweight structures for aviation Aim: Significant increase in the share of sustainable materials in aircraft construction Approach Use of bio-based hybrid material Considering of components from a functional point of view as well as their contribution to the empty weight Structural mechanical design and optimization according to bionic principles 8

9 Challenges in the project Several requirements to material and construction Weight of component in aerospace Stiffness and strength along load paths Vibration due the engine at connecting points Fire behaviour Recycling edm aerotec GmbH Door as function demonstrator TU München 9

10 Fire behaviour and outlook Natural fibres are flammable Primary fire behaviour depends on matrix Modification of bio-based resin with flame retardant Fire protection classification Aircraft Materials Fire Test Handbook Fraunhofer WKI Bio based hybrid composite Fraunhofer WKI 10

11 Sustainable lightweight design for a trendsetting mobility Aim: Evaluation of material based on renewable resources for exterior automotive applications Approach Development of selected components as NFRP for a Porsche Cayman GT 4 On-road test of components while various races Conversion in a industrial series production 11

12 Course of the project Four Motors Four Motors 12

13 Challenges and outlook Material - Grammage, texture - Mechanical properties - Draping Process - Production processes - Curing conditions - Pretreatment of fibers Component - Assembly and live performance - Gap sizes, thickness, weight e.g. RTM Fraunhofer WKI Fraunhofer WKI e.g. DIN EN ISO 527 Fraunhofer WKI Could NFRP comply the requirements of official approval and homologation for road service? 13

14 Thanks for your attention Results: Ole Hansen M.Sc. Scientific coworker Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institut Application centre HOFZET Heisterbergallee 10A Hannover, Germany Fon: +49 (0)