High performance biobased self-reinforced composites from polylactid acid

1. Co-funded by the
European Union
BIO4SELF: High performance biobased self-
reinforced composites from polylactid acid
Plastindustrien event Denmark
June 4, 2019 Copenhagen

2. Outline
 Why PLA ?
 Why selfreinforced ?
 BIO4SELF approach ?
 Some key results
 Further info

3. Why PLA ?

4. Some terminology:
A bioplastic is biobased and/or biodegradable
Source: European Bioplastics
 A bioplastic can be fossil based
 A bioplastic can be NOT biodegradable

5. PLA is one of the most used
biobased biodegradable bioplastics
Source: ‘Biopolymers facts and statistics’, IfBB (2017)

6. Why selfreinforced ?

7. SRPC: selfreinforced polymer composite
 Production of these composites via combination of:
a low melting PLA grade
a high stiffness, high melting PLA reinforcing fibre
SRPCs consist of polymeric reinforcing fibres
embedded in a matrix of the same polymer type
1
2

8.  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
SRPCs offer a wide range of advantages

9. (Biobased) SRPCs high potential for a
variety of applications
 Automotive
 Door panels
 Underbody panels
 Industrial equipment
 Protection shrouds
 Machine cover
 Sporting
 Body armour
 Canoes
 Military
 Body armour
Current commercial SRPCs are fossil-based, typically
polypropylene e.g. Curv®, Pure®; also polyester (COMFIL)

10.  Renewable materials are used, instead of fossil-based
 Recyclability: mono material, thermoplastic
 Contribution to Sustainable Development Goals (SDG)
defined by United Nations:
 #9 - building resilient infrastructure
 #12 - dedicated to sustainable consumption
 Invited for 1000 Solutions Initiative (SolarImpulse)
BIO4SELF as sustainable solution

11. JEC Innovation Award for ‘Sustainability’
Thermoformed seat shell structure from selfreinforced PLA
Acknowledgement to MoPaHyb project
for use of the mold for the seat structure

12. TechTextil Innovation Award for ‘Sustainability’
High stiffness PLA yarn & resulting selfreinforced composites

13. BIO4SELF approach ?

14. Methodology:
from raw material to composites
 Compounds
 Hydrolysis stabilised compounds
 Fibre materials
 High stiffness reinforcement yarns
 Low melting matrix yarns
 Textile intermediates
 Hybrid yarns via comingling
 Composite manufacturing & Prototyping
 Filament winding
 Press consolidation
 Environmental & EoL aspects
By who ?

15. Multidisciplinary consortium
16 partners from within Europe:
5 SMEs, 5 large enterprises, 3 research centres, 3 univs
 covering complete value chain

16. BIO4SELF - Acknowledgement
 Funding
 Funded within H2020 (NMBP call)
 Total project budget: € 8.05 mio, grant: € 6.77 mio.
 Coordinator: Centexbel
 Start: March 1st 2016
 Duration: 40 months
This project has received funding from the European Union’s
Horizon 2020 research and innovation programme under Grant
Agreement No 685614

17. Some key results…

18. Methodology:
from raw material to composites
 Compounds
 Hydrolysis stabilised compounds
 Fibre materials
 High stiffness reinforcement yarns
 Low melting matrix yarns
 Textile intermediates
 Hybrid yarns via comingling
 Composite manufacturing & Prototyping
 Filament winding
 Press consolidation
 Environmental & EoL aspects

19. Compound level:
large increase in hydrolytical stability
 Hydrolytical stabilisation needed for applications with long lifetime:
 Various additives evaluated, some successful at ca. 1wt%
 Test ‘accelerated hydrolysis’: 70°C and 80 % relative humidity
 Key parameter: molecular weight (g/mol)
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
0 24 48 72 96 120 144 168 192 216 240
Mw (g/mol)
Hydrolysis time (hours)
Stable during extended test interval
Immediate degradation
pure PLA
Hydrolytically
stabilised
PLA compounds
(1wt% additive)

20. Lifetime prediction: several years to failure
for moderate temperature and humidity
0
10
20
30
40
50
60
20 25 30 35 40 45
Timetofailure(years)
Temperature (oC)
30 % RH
40 % RH
50 % RH
60 % RH
70% RH
𝑡𝑓𝑎𝑖𝑙 =
ex p( 𝐸 𝑎
𝑒𝑓𝑓
𝑅𝑇
𝐴 ∙ 𝑅𝐻
 ‘Failure’ defined as 20% performance loss

21. Manufacturing and testing of prototypes
 Biobased injection moulded prototypes
for automotive and white goods
 Example tumble dryer:
Process fanBottom baseboard

22. Prototyping – Dryer Process Fan
Dryer process fan produced: left PLA-based material and right PP-GF30 (benchmark material)

23. BIO4SELF- Arcelik’s Motivation
 Marketing potential of use of
renewable bio-materials
 Green-Premium line

24. Further info

25. BIO4SELF – Newsletter

26. BIO4SELF – Further info
 Contact:
 Guy Buyle (+32 9 243 82 53 | guy.buyle@centexbel.be )
 Website: www.bio4self.eu