GPEC conference 2014

Innovative Plastics and Molding
SPE Environmental Division
A Division of the Society of Plastics Engineers
Utilizing
Thermoplastic
BioPolymers for light
weighting parts in
the Transportation
Industry
1
Presented by Robert Joyce
Founder and President of Innovative Plastics and Molding
March 14, 2014

Discussion Topics
• Innovative Plastics and Molding, Inc.
• Identify biopolymer markets / applications in the
transportation industry.
• Light weighting parts and challenges with thermoplastic
reinforced polyolefin’s.
• What makes a great cake.....Biopolymer requirements to
mold parts for applications.
• Summary
• Appendix. a, b, c, d, e,
• Questions
2

• A profitable bio polymer technology company with 3
employees located in Toledo, Ohio.
• Over 12 years in advanced biopolymer development
with 20 years of Plastics experience.
• Leader in Biopolymer development - patented products
and composition and patent pending applications in
biopolymers.
• License technology to companies that would like to
mold parts with FibreTuff and or compound FibreTuff.
•“ The company provides technical services and
solutions for molding FibreTuff.
• Assistance in distributor marketing and sales for
material conversion.
•“ FibreTuff” a wood, cellulose flour based PP alloy
composite.
• Injection molded, extruded for sheet, profile, blow
molded.
Innovative Plastics and Molding, Inc
3
Robert Joyce founder and President of
Innovative Plastics and Molding, Inc.

BioPolymer market in light weight
vehicles.......
4
• 24% x 378 lbs = 90.72
lbs
• 90.72 lbs x 15,000,000
vehicles = 1.36 billion
• 1.36 billion x .02% =
27,216,000 lbs..

Identified applications for BioPolymer
parts in transportation industry
5
• Trucks, Automobiles, Airplanes, Recreation vehicles, etc..
• Automobiles
• Under hood: potential for blow molded shapes; battery tray
enclosures; cold air canisters in air induction systems; brackets for
bottle/canister holders; radiator fan shroud assemblies
• Weather seal carriers (with TPE)
• Trunk area: inserts for spare tire hold-downs; spacers/bumper support
• Firewall: two shot grommets; housing for cable routing
• Interior: door bolster inserts; arm rest/consoles; headliner close-outs;
HVAC flapper door structures; replace ABS, glass-filled PP; speakers,
seat backs/frame components; knee bolsters; glovebox housings.

Light weighting transportation parts
having 3 dimensional complex shapes
6
• Parts designs are more complex and demanding.
• Combining parts with assemblies.
• Thinner wall stock - smaller ribs, gates, more features...sharper
radius, corners, etc..
• Good fastener and clip retention will be necessary.
• Weld ability - lower filler levels in reinforced thermoplastics.....
• Multiple interface - compatibility with other materials in the
same mold.

Challenge for light weighting transportation
parts.
7
• Dimensional changes and complex shapes will present
challenges to existing reinforced thermoplastic materials -
• Better flow.
• Minimize warp.
• CLTE - adequate fiber distribution.
• Better adhesion qualities are desirable.
• Anticipate cost adder.....
• Bulk density and part weight still an issue.
• Biopolymers can rise to occasion through alloy compositions.

Transportation industry requirements for
Thermoplastic Biopolymers include:
• Good cost equation
• Need consistent and reliable supply
• Global supply channels.
• Clean biomass resource.
• Recycle ability.
• Performance
• Same or equal to other fillers.
• Functionality
• No odor.
• Uniform quality in a continuous production
process.
• Low Moisture.
8
FibreTuff pellets

Ingredients for a successful thermoplastic
biopolymer composition...
• Biomass resource - wood, corn, rice
hulls, kenaf, hemp, sisal, coconut, PLA,
cellulose...
• Coupling - maleic anhydride, silane
• Polymer(s) - polyolfin’s - virgin/
recycle...
• Synergy between the ingredients.
• Polar and non polar activity.
9
Biomass filler

Biopolymer Pellet construction is important
• A low moisture pellet with superior
adhesion will provide:
• Improved heat resistance.
• No evidence of fines or fracturing.
• Very low drying time.
• Float when exposed to submersion in
water - low bulk density.
• Resistance to mold and or mildew
growth.
• Utilizes traditional pigment systems for
UV stabilization.
10
Biopolymer “FibreTuff” pellet
floating in water

Expectations for processing thermoplastic
biopolymer
• Drop in Replacement
• Flows well - hot runner trials, sequential gating,
direct or sub gating, foaming. etc..
• Extreme heat exposure - 15 min in barrel without
ignition or smoking.
• Cycle time reduction. 10-15%
• Less abrasion of screw and barrel versus traditional
fillers. Lower maintenance costs....
• Energy savings - lower heats can be utilized. 5 - 10%.
• Recycle ability -10% back into the process. More cost
reduction.
11

Molded Part Performance with
BioPolymers
• Lower Part Weight.
• Resistance to mold, fungus.
• Toughness - Good strength with impact.
• Good Elongation - no brittleness.
• Good Hardness.
• Good moisture resistance - No visible fibers at the surface.
• Color ability
12

• Parts are becoming more complex - thinner walls with clips and
fasteners, additional features requiring multiple injection units.
• Key motivators for Transportation industry to light weight parts.
• Cost
• Performance
• Functionality
• Successful thermoplastic biopolymer implementation requirements
for light weighting molded parts.
• Formulation
• Pellet construction
• Molder is all about “costs”
• Part Performance
• Biopolymers are available now for implementation to light weight
transportation products.
Summary
13

FibreTuff BioPolymer with >50% Recycle
• Key ingredients include: Polyolefin's that have
synergy with coupling, cellulose and another
polymer.
• A compressed low moisture pellet that has
excellent moisture resistance with superior
adhesion between natural fibers and polymer
matrix.
• Improved processing window with no bio odor.
• Molded parts show improved heat resistance
with consistency.
14
Class A surface molded
with FibreTuff
Appendix:

15
FibreTuff 2.1 Data
Typical Properties
FibreTuff 2.1 DataFibreTuff 2.1 DataFibreTuff 2.1 DataFibreTuff 2.1 DataFibreTuff 2.1 Data
ISO Method ASTM Method Unit
IPM FibreTuff
2.1 >50% PP
recycle
content
40% Talc filled
Black
Filler content
Melt flow
Specific Gravity
Tensile Stress @ yield 50mm/min
Elongation @ break
Elongation @ yield
Flexural Modulus 1.3mm/min, 50 mm
Tensile Modulus 1mm/min
Izod Impact, notched 23C
Izod Impact, notched -40C
HDT 0.45 MPa (64psi)
Water absorption, 24 hrs
**Tear Strength w Multibase MF A 6221 CUV
**Maximum load (N)Multibase MF A 6221 CUV
*Injection pressure
*Drying Time
*Test bar sample data. Processing best practices. **Parts
tested with cohesive failure.
>20 Cellulose 40% talc
ASTM D 1238 g/10 min 3.33 10
ASTM D792 g/cc 1.05 1.25
ISO 527 ASTM D638 MPa 30.2 30
ASTM D638 % 7.0 NA
ISO 527 ASTM D638 % 6.0 NA
ASTM D790 MPa 1820 3650
ISO 527 ASTM D638 MPa 1520 NA
ASTM D256 J/m2 25.7 15.8
ASTM D256 J/m2 26.4 NA
ISO 75/Be ASTM D648 C 106 127
ISO 62 ASTM D 570 % 0.21 NA
Additional dataAdditional dataAdditional dataAdditional dataAdditional data
ISO 34 kN/m 19.503 NA
ISO 34 N/mm 455.754 NA
Psi 1600 400-1500
3 hrs @ 200F 1-2 hrs.@ 219F

Recycle PP benefits with FibreTuff
2.1 versus other traditional fillers
• Lower weights versus glass filled and
talc filled PP
• Good cost equation.
• Weight savings +10%
• Less wear on screw and barrels.
• Energy savings.
• Performance
• Less warp
• Good Hot stamp performance...no adhesion
promoter required.
• Good TPE bond strength ...
16
Auto part molded with FibreTuff 2.1

Specialty Development with FibreTuff 2.1
• Automotive Under hood
• Target markets: Injection molded 30% talc
filled PP...
• Applications: Battery boxes, Fan Shrouds...
• Advantages...Strength to weight ratio,
improved heat deflection temps...
•Automotive Exterior
• Target markets: Injection molded 20% talc
filled TPO, 40% Talc filled PP..
• Applications: Substrates, trunk area..
• Advantages...good weld ability, improved
heat deflection temps...
17
Fan shroud molded with
FibreTuff 2.0 cellulose pellet
FibreTuff 2.1 cellulose pellet

Extrusion blow molding development
with FibreTuff cellulose composite
• Loudspeakers / Resonators
• Improved acoustics and insulation
compared to traditional plastics or
laminates or fiber boards
• Offer a high quality satin-like surface for
modern and attractive design.
18
Extruded tube with FibreTuff cellulose pellet

Automotive Specialty Development
with FibreTuff 2.1
• Automotive Electrical
• Target markets: Injection molded
applications that need high strength with
lower weights versus glass reinforced and
talc filled PP for clips / fasteners.
• Applications: Fuse holders, IP Consoles..
• Advantages: Toughness - living hinge,
Lower weights, Energy Savings, less warp,
and improved cycle times..
19
Fuse holder with FibreTuff cellulose pellet

• Utilize existing Chemical and Physical foaming agents.
• Require 8 to 10% or more weight reduction to offset costs.
• Drop in replacement.
• Reduce warp.
• Increase melt flow.
• Maintain Good Strength is a challenge.
• Gas assist injection molding.
• Pressure will help compress fibers.
• Minimize loss in strength.
• Reduce residence time.
• Help eliminate weld lines.
Processing methods to promote further light
weighting BioPolymer
20

FibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with Mucell
Method Solid
Reduction
5%
Reduction
10%
Injection
Pressure
12,000 psi 9,975 psi 9,630 psi
Shot Size “ per
stoke
2.2 2.02 1.88
Specific Gravity
g/cc
ASTM D792 1.05 0.973 0.938
Tensile Strength
at Break (MPa)
ISO 527 30 23.3 21.2
Flexural Modulus
(MPa)
ISO 178 1800 1980 1810
Impact Strength
(KJ/M²)
ISO 180 3.2 2.25 2.23
21
• Weight reduction at 11%
• Maintain or increase Flexural Modulus by 10%
• Decrease strength by 25 to 30%

Questions
More information
www.woodcompositesandmolding.com
Thank You
22

GPEC conference 2014

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to GPEC conference 2014

Similar to GPEC conference 2014 (20)

Recently uploaded

Recently uploaded (20)

GPEC conference 2014