New product concept
Natural Fibers for Low Density Composites
ClosedInquiries no longer accepted
Type of Solution sought
- A Material
- A Technology
Description of Desired Solution
Enable composite fabricators who use infusion or resin transfer molding (RTM) to fabricate low density, fiber-reinforced composites that contain greater than 50% biorenewable content and have a density between 1.0 and 1.5 gm/cc.
Background
Fiber-reinforced composites that use unsaturated polyester (UPE) resins as the polymer matrix find widespread application in the transportation and building & construction markets. In transportation, fiberglass-reinforced UPE resins are used to manufacture truck hoods and boat hulls. On the building and construction side, fiber-reinforced UPE resins are used in architectural panels, building facades and tub/shower applications.
The most commonly used reinforcement material in polymer matrix composites has been glass fibers. These fibers typically have a density near 2.5 gm/cc, and composites made with glass fibers typically have densities well above 1.5 gm/cc. Many natural fibers on the other hand have a density closer to 1.0 gm/cc. Replacing glass fibers with natural fibers can result in a significant decrease in density, enabling the fabrication of lightweight composites with densities much closer to 1.0 gm/cc. This decrease in density is very attractive in both transportation and building and construction applications.
The use of natural fibers also is attractive from a green perspective, which is very important in today´s marketplace. The use of products that contain bio-based raw materials has been encouraged by programs such as the USDA BioPreferredTM program, and building products made with rapidly renewable raw materials can help architects and building designers obtain LEED credits. Many companies also have internal initiatives to reduce their carbon footprint through the use of bio-based raw materials in place of petroleum-based feedstocks.
Composites are fabricated by many different fabrication processes, ranging from hand and spray layup to infusion and resin transfer molding to compression molding to pultrusion. This RFP is interested in natural fiber technology that can be used to fabricate composites made by infusion and resin transfer molding.
The most commonly used reinforcement material in polymer matrix composites has been glass fibers. These fibers typically have a density near 2.5 gm/cc, and composites made with glass fibers typically have densities well above 1.5 gm/cc. Many natural fibers on the other hand have a density closer to 1.0 gm/cc. Replacing glass fibers with natural fibers can result in a significant decrease in density, enabling the fabrication of lightweight composites with densities much closer to 1.0 gm/cc. This decrease in density is very attractive in both transportation and building and construction applications.
The use of natural fibers also is attractive from a green perspective, which is very important in today´s marketplace. The use of products that contain bio-based raw materials has been encouraged by programs such as the USDA BioPreferredTM program, and building products made with rapidly renewable raw materials can help architects and building designers obtain LEED credits. Many companies also have internal initiatives to reduce their carbon footprint through the use of bio-based raw materials in place of petroleum-based feedstocks.
Composites are fabricated by many different fabrication processes, ranging from hand and spray layup to infusion and resin transfer molding to compression molding to pultrusion. This RFP is interested in natural fiber technology that can be used to fabricate composites made by infusion and resin transfer molding.
Detailed Solution Description
- A nonwoven, chopped strand, natural fiber mat that is:
- Readily penetrated by UPE resins that have a viscosity of 250 cp or less at room temperature
- Low (
- Already available at the pilot scale or at commercial scale
- Cost-effective, less than $3.00 per square yard or 2.5 Euros per square meter.
- Microstructural evidence of exceptionally good bonding between the fibers and the resin matrix
Possible Routes To Investigate
- Kenaf
- Jute
- Hemp
- Sisal
- Flax
- Wood
Solution that are not of interest
- Fibers that have not been or are not easily processed into a mat
- Lab scale processes
Anticipated Next Steps with Respondents
We would like to introduce the first products within the next year.
Other Comments / Important Considerations
- Wettability of the fiber mat by UPE formulations that contain styrene. Certain fiber treatments may enhance fiber-matrix interactions
- Cost per square yard or square meter
- Low water uptake and release
- Batch-to-batch consistency
Type of Outcome expected
- Ready To Use Solutions
Company Demographics
- Business Type: Specialty Chemicals
- Annual Revenue: Multiple Billions
- Years in Business: >75
- Headquarters Location: USA
Business considered
- Mutually-beneficial partnership: Resin supplier + Fiber mat supplier
- Joint development of technology for producing low density composites