2014 SPE TPO conference / FibreTuff

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BioPolymers Light weighting parts in the Transportation Industry

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2014 SPE TPO conference / FibreTuff

  1. 1. Innovative Plastics and Molding Utilizing Thermoplastic BioPolymers for light weighting parts in the Transportation Industry 1 Presented by Robert Joyce Founder and President of Innovative Plastics and Molding
  2. 2. Innovative Plastics and Molding 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
  3. 3. Innovative Plastics and Molding • A profitable bio polymer technology company with 3 employees located in Toledo, Ohio. • Over 12 years in advanced biopolymer development with patented technology and 20 years of Plastics experience. • License technology to companies that would like to mold parts with FibreTuff and or compound FibreTuff. •“ FibreTuff” a wood, cellulose flour based PP alloy composite. Innovative Plastics and Molding, Inc 3 Cosmetic FibreTuff a “platform” technology Consumer product Food Medical
  4. 4. Innovative Plastics and Molding 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..
  5. 5. Innovative Plastics and Molding 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.
  6. 6. Innovative Plastics and Molding 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. Auto part for interior molded with FibreTuff 2.1
  7. 7. Innovative Plastics and Molding 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. • Bulk density and part weight still an issue. • Biopolymers can rise to occasion through alloy compositions.
  8. 8. Innovative Plastics and Molding 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
  9. 9. Innovative Plastics and Molding 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
  10. 10. Innovative Plastics and Molding 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
  11. 11. Innovative Plastics and Molding Expectations for processing thermoplastic biopolymer • In most cases - Need 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. 11 Auto part molded with FibreTuff
  12. 12. Innovative Plastics and Molding • 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 12
  13. 13. Innovative Plastics and Molding 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. 13 Class A surface molded with FibreTuff Appendix:
  14. 14. Innovative Plastics and Molding 14 FibreTuff 2.1 Test Melt flow Rate Cellulose Filler Content Density Tensile Strength at Yield Elongation at Yield Tensile Modulus Flexural Modulus Heat Deflection Temperature Flammability Mold Shrinkage Coefficient of Linear Thermal Expansion (per condition) (CLTE) Water Absorption Impact Strength Notched Charpy 23°C 0 °C -40 °C Recycled Content Test Method FT 2.1 2nd Production (ISO) ISO 1133, 230°C, 2.16 kg 3.6 g/10 min. Report method used, sample size and value >20% ISO 1183, Method A 1.07 g/cm3 ISO 527-1 & ISO 527-2, Specimen A, 50 mm/ minute test speed, Strength 33 MPa ISO 527-1 & ISO 527-2, Specimen A, 50 mm/ minute test speed 5.3% ISO 527-1 & ISO 527-2, Specimen A,1 mm/ min test speed 2170 MPa ISO 178, Specimen D, 64 mm support span, 2 mm/min test speed 1930 MPa ISO 75-1 & ISO 75-2 Specimen D, flatwise, 0.34 +/- 0.1 mm deflection. 264 psi 63 °C ISO 3795/SAE J369 Specimen B smooth surface 32.2 mm/min Report method used, sample size and value) After 48 h at 23 +/- 2 °C Flow (F), Cross Flow (CF) F .90% CF .99% (ISO 11359-2, -30 +/- 2 to 100 +/- 2 °C) Flow and Cross Flow  F 62.6 um/m/C CF 186 um/m/C ISO 62, 24 h immersion, Specimen H 0.21% ISO 180/1A, Specimen D, At 23 +/- 2 °C, -40 +/- 2 °C, and 0 +/- 2 °C 2.68 J/m2 2.28 J/m2 1.54 J/m2 >50%
  15. 15. Innovative Plastics and Molding 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 ... 15 Auto part molded with FibreTuff 2.1 Auto part for interior molded with FibreTuff 2.1
  16. 16. Innovative Plastics and Molding 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... 16 Fan shroud molded with FibreTuff 2.0 cellulose pellet FibreTuff 2.1 cellulose pellet
  17. 17. Innovative Plastics and Molding 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. 17 Extruded tube with FibreTuff cellulose pellet
  18. 18. Innovative Plastics and Molding 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.. 18 Fuse holder with FibreTuff cellulose pellet
  19. 19. Innovative Plastics and Molding • Utilize existing Physical foaming agents and Chemical 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. • Very good increase in stiffness. Processing methods to promote further light weighting BioPolymer 19
  20. 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 Innovative Plastics and Molding 20 • Weight reduction at 11% • Maintain or increase Flexural Modulus by 10% • Decrease strength by 25 to 30%
  21. 21. Innovative Plastics and Molding 21 FibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFA Sample Water Bath Density (g/cc) % Reduction 2% Control 0.85 - 2% PN40E NO 0.76 11% 2% RIC50FP YES 0.66 22% Results: In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. In the extrusion process, the control sample as well as PN40E was not run through a water bath. RIC50FP was sent through a water bath to yield a 22% density reduction. FibreTuff 2.1 with RIC50FP 0 0.225 0.450 0.675 0.900 2% Controlled 2% PN40E 2% RIC50FP 0.66 0.76 0.85 Density(g/cc)
  22. 22. Innovative Plastics and Molding 22 FibreTuff 2.1 3mm thickness 450um bubbles FibreTuff 2.1 6mm thickness 200 um bubbles
  23. 23. Innovative Plastics and Molding Questions More information www.woodcompositesandmolding.com Thank You 23

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