Material Characterization of Natural Fiber Acrylic Thermoset Composites Andre Bendo Jeremy Funk, John Norton, Dr. Gero Nordmann & Dr. Michael Kalbe BASF Corporation 08/01/2011 1
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 2
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 3
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 Interconnected Reducing vehicle weight allows for extended driving distances for alternative engines (electric or hybrid) 08/01/2011 4
Key Trends / Drivers Growing demand for environmentally friendly materials Interior air quality Emissions from resin & additives Reduction in VCs Green materials Bio-based resins (soy, corn) Natural fibers 08/01/2011 5
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 6
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 VCs, dor & Fogging Address rising demand for green materials 08/01/2011 7
Chemistry Advantage - Solutions Acrylic-based solutions consist of two components, dissolved in water...a polycarboxylic acid:...to form a polyester H H H X H H...and a polyalcohol: H Both components react at temperatures above > 130 C X X X X H 08/01/2011 8
Chemistry Advantage - Dispersions Acrylic-based dispersions consist of two components, dissolved in water...a polycarboxylic acid, modified with a latex component: H H H H H X Latex...and a polyalcohol: H Both components react at temperatures above > 130 C...to form a latex-modified polyester X X Latex X X H 08/01/2011 9
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 VCs, shelf-life storage issues 08/01/2011 10
Chemistry Advantage DMA Analysis Uncured resin (left) softens 50ºC; Cure (right) occurs between 120-200ºC acrylic resin dispersion with flexible-tough latex T g 25ºC 08/01/2011 11
Chemistry Advantage Production & curing of thermoplastic films Can be applied to reinforcement / substrate via Impregnation (bath) Dipping Spraying Rolling Bath Foam Blow-Line Spraying 08/01/2011 12
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 13
Target Composite Applications Characteristics of natural fiber composites 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... 08/01/2011 14
Target Composite Applications 08/01/2011 15 15
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 16
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 17
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 18
Chemistry Effect Mechanical Performance Comparison Tensile properties ASTM D638-10 MD Tensile Strength (Mpa) CD Tensile Strength (Mpa) 40.0 35.0 Tensile Strength (MPa) 30.0 25.0 20.0 15.0 10.0 5.0 0.0 Dispersion (High Tg) Solution/Dispersion Blend Dispersion (Low Tg) Solution Binder Type 08/01/2011 19
Chemistry Effect Mechanical Performance Comparison Flexural properties ASTM D790-10 MD Flexural Strength (Mpa) CD Flexural Strength (Mpa) 60.0 Flexural Strength (MPa) 50.0 40.0 30.0 20.0 10.0 0.0 Dispersion (High Tg) Solution/Dispersion Blend Dispersion (Low Tg) Solution Binder Type 08/01/2011 20
Chemistry Effect Mechanical Performance Comparison Izod impact ASTM D256-10 25 Impact Strength (kj/m^2) 20 15 10 5 0 Solution Solution/Dispersion Blend Dispersion (high Tg) Dispersion (low Tg) Binder Type 08/01/2011 21
Processing Effect Mechanical Performance Comparison Tensile properties ASTM D638-10 30 MD Tens Strength (MPa) CD Tens Strength (MPa) 25 Tensile Strength (MPa) 20 15 10 5 0 170C/60sec 180C/60sec 190C/60sec 200C/60sec 08/01/2011 22
Processing Effect Mechanical Performance Comparison Tensile properties ASTM D638-10 30 MD Tens Strength (MPa) CD Tens Strength (MPa) 25 Tensile Strength (MPa) 20 15 10 5 0 200C/30sec 200C/60sec 200C/90sec 08/01/2011 23
Processing Effect Mechanical Performance Comparison Flexural properties ASTM D790-10 60 MD Flex Strength (MPa) CD Flex Strength (MPa) 50 Flexural Strength (MPa) 40 30 20 10 0 170C/60sec 180C/60sec 190C/60sec 200C/60sec 08/01/2011 24
Processing Effect Mechanical Performance Comparison Flexural properties ASTM D790-10 60 MD Flex Strength (MPa) CD Flex Strength (MPa) 50 Flexural Strength (MPa) 40 30 20 10 0 200C/30sec 200C/60sec 200C/90sec 08/01/2011 25
Processing Effect Mechanical Performance Comparison Flexural properties ASTM D790-10 2500 MD Flex Modulus (MPa) CD Flex Modulus (MPa) 2000 Flexural Modulus (MPa) 1500 1000 500 0 180C/60sec 190C/60sec 200C/60sec 08/01/2011 26
Processing Effect Mechanical Performance Comparison Flexural properties ASTM D790-10 3500 MD Flex Modulus (MPa) CD Flex Modulus (MPa) 3000 Flexural Modulus (MPa) 2500 2000 1500 1000 500 0 200C/30sec 200C/60sec 200C/90sec 08/01/2011 27
Processing Effect Mechanical Performance Comparison Izod impact ASTM D256-10 120% 115% Relative Impact Strength 110% 105% 100% 95% 90% 180C/60sec 190C/60sec 200C/60sec 08/01/2011 28
Processing Effect Mechanical Performance Comparison Izod impact ASTM D256-10 105% 100% Relative Impact Strength 95% 90% 85% 80% 200C/30sec 200C/60sec 200C/90sec 08/01/2011 29
Processing Effect Mechanical Performance Comparison Water absorption (24 hr) 70% Soak Vol % of Initial Dry Vol % of Initial 60% Volume Change (%) 50% 40% 30% 20% 10% 0% 170C @ 60sec 180C @ 60sec 190C @ 60sec 200C @ 60sec 08/01/2011 30
Processing Effect Mechanical Performance Comparison Water absorption (24 hr) 35% Soak Vol % of Initial Dry Vol % of Initial 30% Volume Change (%) 25% 20% 15% 10% 5% 0% 200C @ 30sec 200C @ 60sec 200C @ 90sec 08/01/2011 31
Presentation verview Key Trends / Drivers Chemistry Advantage Target Composite Applications Mechanical Performance Comparison Summary 08/01/2011 32
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 33
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 VCs 08/01/2011 34
Thank You for Your Attention Questions? 08/01/2011 35