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Natural-Fiber-Reinforced Polymer
Composites in Automotive
Applications
James Holbery and Dan Houston
INTRODUCTION
The utilization of lightweight, lowcost natural fibers offers the potential to
replace a large segment of the glass and
mineral fillers in numerous automotive
interior and exterior parts. In the past
decade, natural-fiber composites with
thermoplastic and thermoset matrices
have been embraced by European car
manufacturers and suppliers for door
panels, seat backs, headliners, package
trays, dashboards, and interior parts.
Natural fibers such as kenaf, hemp, flax,
jute, and sisal are providing automobile
part reinforcement due to such drivers
as reductions in weight, cost, and CO2,
less reliance on foreign oil sources,
recyclability, and the added benefit that
these fiber sources are green or ecofriendly. While the United States has not
issued regulations concerning automo80
implemented.4
Recently, European companies have
taken the lead in natural-fiber composite
development, such as Dieffenbacher
(Germany), BASF (Germany), and
Rieter Automotive (Switzerland). Rieter
Automotive was awarded the top prize
at the 2005 JEC Composite Showcase
for its Acaba (banana) fiber continuousfiber processing development, where the
primary energy savings is estimated at
60% or more.5 In North America, Delphi
Interior Systems, Visteon Automotive,
Kafus Bio-Composites/Flexform Technology, and Cargill Ltd., to name but a
few, are actively involved in naturalfiber-composite development and
manufacture. With rapid advancements
in fully bio-based polymers that may be
processed with natural fibers, it is only
a matter of time before fully bio-based
composites are prevalent within the
automotive industry.
See the sidebar for details on naturalfiber selection and preparation.
THERMOPLASTICTHERMOSET POLYMERS
The manufacture of natural-fiber
composites includes the use of either a
thermoset or thermoplastic polymer
binder system combined with the naturalfiber preform or mat. In automotive
applications, the most common system
used today is thermoplastic polypropylene, particularly for nonstructural components. Polypropylene is favored due
to its low density, excellent process-
PP
3
Density (g/cm )
0.8990.920
Water Absorption
0.010.02
24 hours (%)
Tg (C)
10 to 23
Tm (C)
160176
Heat Deflection
5063
Temp (C)
Coefficient of
6.813.5
Thermal Expansion
(mm/mm/ C 105)
Tensile Strength
2641.4
(MPa)
Elastic Modulus
0.951.77
(GPa)
Elongation (%)
15700
Izod Impact
21.4267
Strength (J/m)
LDPE
HDPE
0.9100.925
<0.015
0.940.96
0.010.2
125
105116
3250
PS
Nylon 6
1.041.06 1.121.14
0.030.10
1.31.8
133 to 100
120140
110135
4360
Max. 220
Nylon 6,6
1.13-1.15
1.01.6
48
215
5680
80
250269
7590
10
1213
68
88.6
7.29
4078
14.538
2569
4379
12.494
0.0550.38
0.41.5
45
2.9
2.53.9
90800
>854
2.0130
26.71,068
12.5
1.1
20150
42.7160
35>300
16654
* Selected data obtained from Reference 11; LDPE = low-density polyethylene; HDPE = high-density polyethylene; PP = polypropylene;
PS = polystyrene.
Polyester Vinylester
Resin
Resin Epoxy
Density (g/cc)
1.21.5
Elastic
24.5
Modulus (GPa)
Tensile
4090
Strength (MPa)
Compressive
90250
Strength (MPa)
Elongation (%)
2
Cure Shrinkage
48
(%)
Water Absorption 0.10.3
(24 h @ 20C)
Izod Impact,
0.153.2
Notched (J/cm)
1.21.4
3.13.8
1.11.4
36
6983
35100
100
100200
47
16
12
0.1
0.10.4
2.5
0.3
Leaf
Seed
Fruit
Stalk
Wood Fibers
Sisal
Manila
Curaua
Banana
Palm
Cotton
Kapok
Coconut
Coir
Bamboo
Wheat
Rice
Grass
Barley
Corn
Hardwood
Softwood
(~10,000+
varieties)
fiber in order to soften and separate the fibers by partial rotting. This process can be
accomplished through several methods where moisture, microorganisms, or chemistry
break down the bark tissue that binds the fiber and nonfiber portions, making the fibers
easier to separate, during which time the retting process removes the hemicellulose and
lignin components. The following retting processes are the most prominent in use today,
and each has certain advantages.
Dew retting occurs when the stalks are left in the field so that rain, dew, or irrigation
is used to keep the stems moist. This may take up to five weeks and produces a coarse
fiber with a light brown color. Water retting occurs when stems are bundled and then
submerged in water so that bacteria break down the pectin. This takes seven to ten days
and produces a quality fiber. Warm-water retting occurs when bundles are soaked for
24 hours, after which the water is replaced. Heat is then applied to warm the batch for
the next two or three days. This results in a uniform, clean fiber. Green retting is an allmechanical process that separates the components and is used when the fiber is needed
for textiles, paper, or fiberboard products. Chemical retting occurs when chemicals are
used to dissolve the pectin, allowing the components to be separated. This shortens the
time to as little as 48 hours when the next process can then be instigated, and produces a
high-quality product.
Although the natural retting process is lengthy, the resulting fibers have many desirable
characteristics. The chemical retting process is quick but affects several properties,
including a loss in tenacity, color, and luster as compared to the bacterially retted fibers.
Natural reinforcing fibers can be modified by a variety of physical and chemical methods
to correct for fiber deficiencies; fibers can be treated to promote bonding and adhesion,
dimensional stability, and thermoplasticity. The physical methods for modifying natural
fibers such as calendaring, stretching, thermo-treatment, and weaving or integration
into yarns do not change the chemical composition of the fiber. Rather, these change
the structural and surface properties of the fiber and thereby influence the mechanical
bonding to polymers. Surface modification of natural fibers can be used to optimize
properties of the fiber-matrix interface.
Table B. Properties of Selected Natural and Manmade Fibers
Fiber
Density
(g/cm3)
Cotton
1.51.6
Jute
1.3
Flax
1.5
Hemp
1.47
Kenaf
1.45
Ramie
Sisal
1.5
Coir
1.2
Softwood Kraft Pulp
1.5
E-glass
2.5
S-glass
2.5
Aramid (Std.)
1.4
Carbon (Std. PAN-based)
1.4
Elongation
(%)
Tensile
Strength
(MPa)
Elastic
Modulus
(GPa)
Reference
7.08.0
1.51.8
2.73.2
24
1.6
3.63.8
2.02.5
30.0
4.4
0.5
2.8
3.33.7
1.41.8
400
393773
5001,500
690
930
400938
511635
593
1,000
2,0003,500
4,570
3,0003,150
4,000
5.512.6
26.5
27.6
70
53
61.4128
9.422
4.06.0
40.0
70.0
86.0
63.067.0
230240
6,7
6
4
4
4
8
8
9
9
9
9
9
9
Property
Flex Strength (MPa)
Flex Modulus (GPa)
Elongation at
Break (%)
Impact Strength
(kJ/mm2)
Density (g/cm3)
Glass
Fiber
(30 wt.%)
Natural
Fiber
(35 wt.%)
80
6.0
2.2
70
6.0
1.9
38
20
1.54
1.42
Material Used
Interior
Glove Box
Wood/cotton fibers
molded, flax/sisal
Door Panels
Flax/sisal with
thermoset resin
Seat Coverings
Leather/wool backing
Seat Surface/Backrest Coconut fiber/natural
rubber
Trunk Panel
Cotton fiber
Trunk Floor
Cotton with PP/PET
fibers
Insulation
Cotton fiber
Exterior
Floor Panels
Flax mat with
polypropylene
Figure 2. Flax, hemp, sisal, wool, and other natural fibers are used to make 50 MercedesBenz E-Class components.16
step further, identifying bio-based materials as one of the two key parts of its
plan to create a global sustainability
network. The second key part is the use
of renewable energies to replace conventional fuels, which are pursuing a biobased automotive supply chain that
includes a network, from the farmer to
the automotive distributor.16 Global
automotive suppliers such as Honda
embarked on using natural-fiber materials, such as wood-fiber parts in the floor
area of the Pilot sport utility vehicle
(SUV), a decision that was driven by
engineering considerations as well as
corporate philosophy. Overall, the variety of bio-based automotive parts currently in production is astonishing;
DaimlerChrysler is the biggest proponent
with up to 50 components in its European
vehicles being produced from bio-based
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