Manufacturing of bio‐based thermoplastic composites using industrial process for high‐volume applications

• Published in: Polymer composites 2021-11, Vol.42 (11), p.6146-6159
• Main Authors: Khoun, Loleï, Bravo, Victor L., Champagne, Michel F.
• Format: Article
• Language: English
• Subjects: Automotive fuels; Automotive parts; biopolyamide; Cellulose; cellulose fiber; Composite materials; Cycle time; Fiber composites; Fiber reinforced polymers; Glass fiber reinforced plastics; Greenhouse gases; Industrial applications; Long fibers; Manufacturing; molding compounds; Performance evaluation; physical properties; Polyamide resins; Polymer matrix composites; Tensile properties; thermoplastic resin; Transportation industry; Weight reduction
• ISSN: 0272-8397; 1548-0569
• DOI: 10.1002/pc.26292

The use of high strength‐to‐weight ratio materials in automotive component is a solution to reduce fuel consumption and decrease greenhouse gases emissions. Fiber reinforced composite materials are believed to enable weight saving that cannot be achieved with metals while meeting component mechanical requirements. Moreover, the use of renewable bio‐based composites is seen as a key aspect to further address the reduction of greenhouse gases emission. However, composite manufacturing process must meet short cycle time, performance, and cost targeted by the transportation industry in order to be considered as replacement materials. This article investigates the use of an industrial compression—direct long fiber thermoplastic (D‐LFT) process line to manufacture cellulose reinforced bio‐based polyamide parts in order to increase the penetration of sustainable materials in the transportation sectors. Process evaluation and composite performance were first carried out on a simple 2D geometry. Then the use of 100% bio‐sourced materials with the high‐throughput D‐LFT process was validated with the manufacturing of an automotive composite seat pan demonstrator. Bio‐based composite parts were successfully manufactured. Tensile properties in the range of glass fiber reinforced polypropylene composites traditionally used with the D‐LFT process were measured, validating the potential of cellulose–biopolyamide composite materials for industrial applications. High‐throughput process is used to manufacture 100% renewable bio‐based composite components with equivalent properties to glass fiber reinforced polypropylene component while having lower environmental impacts.