1. BIO-FIBRE REINFORCED COMPOSITES
Tadeusz Majewski
Department of Industrial and Mechanical Engineering

2. Every year end-of life vehicles in the Community generate between 8 and 9 million tonnes of waste, which must be managed correctly.
DERICITIVE 2000/53/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL
on end-of life vehicles
This Directive should cover vehicles and end-of live vehicles, including their components and materials, as well as spare and replacement parts, without prejudice to safe standards, air emission and noise control.
12. The recycling of all plastics from end-of life vehicles should be continuously improved. The Commission is currently examining the environmental impacts of PVC. The Commission will, on the basis of this work, make proposals as appropriate as to the use of PVC including considerations for vehicles.

3. The legislation provides for the creation of collection schemes where consumers return their used e-waste free of charge.
The objective of these schemes is to increase the recycling and/or re-use of such products.
It also requires heavy metals such as lead, mercury, cadmium, and hexavalent chromium and flame retardants such as polybrominated biphenyls (PBB) or polybrominated diphenyl ethers (PBDE) to be substituted by safer alternatives.

4. Article L0053-EN
Reuse and recovery
2(a) no later than 1 January 2006, for all end-of life vehicles, the reuse and recovery shall be increased to a minimum of 85 % by an average weight per vehicle and year. Within the same time limit the reuse and recycling shall be increased to a minimum of 80 % by an average weight per vehicle and year;
for vehicles produced before 1 January 1980, Member States may lay down lower targets, but not lower than 75 % for reuse and recovery and not lower than 70 % for reuse and recycling.
2(b) no later than 1 January 2015, for all end-of life vehicles, the reuse and recovery shall be increased to a minimum of 95 % by an average weight per vehicle and year. Within the same time limit, the re-use and recycling shall be increased to a minimum of 85 % by an average weight per vehicle and year.

5. Publications Wood and Natural Fibre Composites
Universität Kassel
Institut für Werkstofftechnik Kunststoff- und Recyclingtechnik
Prof. Dr.-Ing. Andrzej K. Bledzki
Publications Wood and Natural Fibre Composites
(1996 – 2010 altogether > 60 publications)
*650 citations till 2010 (only in 2009: 121 citations, IF 16,818) Composites reinforced with cellulose based fibers Progress in Polymer Science 24 (1999) 2, , A.K. Bledzki, J. Gassan *263 citations till 2010 (IF 1,187) Properties and modification methods for vegetable fibers for natural fiber composites Journal of Applied Polymer Science 59 (1996) A.K. Bledzki, S. Reihmane, J. Gassan *143 citations till 2010 (IF 1,951) The influence of fiber surface treatment on the mechanical properties
of jute-polypropylene-composites Composites 28 A (1997) J. Gassan, A.K. Bledzki

6. Raw materials as cellulose fibers (abaca, jute, hemp, sisal, kenaf, cotton), soft or hard wood fibers are widely used in an industry.
They have very interesting field of applications because of their promising properties.
These materials need further investigation to improve their properties and increase their applications. Some of their drawbacks can be improved in further research.
The parts from the composite materials are produced by injection moulding or extrusion.
Automotive industry is interested in new materials, because according to new regulations cars should be partially decomposable or recyclable.

7. Domestic application of WPC

8. Automotive applications
Mercedes-Benz Class S with environmental certificate
Components made from different bio fibre reinforced composites

9. Under floor protection trim of Mercedes A class made from banana fibre reinforced composites (Source: DaimlerChrysler Awarded for Banana Fibre Use in Mercedes A Class
Automotive interior components made from wood fibre reinforced composites (Source: Bledzki et al., Cars from Bio-Fibres, Macromolecular Materials and Engineering, 2006, 291, )

10. Front side
Back side with air bag sheet
Automotive instrumental panel with integrated airbag flap made from bio-fibre reinforced composites (Source: Bledzki et al., Cars from Bio-Fibres, Macromolecular Materials and Engineering, 2006, 291, )

11. PROPERTIES OF PARTS MADE OF WPC: Small weight,
Wood Plastic Composites (WPC) is widely used in automotive and domestic industry. With addition of natural fibers the composite materials obtain better properties, they are cheaper and friendly for the environment.
Cellulose fibers - abaca, jute, hemp, sisal, kenaf, cotton, soft or hard wood fibers
The parts from the composite materials are produced by injection moulding or extrusion.
Natural fibers, thanks to their lightweight, the strength and the low cost may replace artificial/mineral (glass or coal) fillers in many parts.
Nomenclature
WPC- Woof Fiber Composite
PP575 – Polypropylen
PAN – Polyacrylnitril
PET - Polyethylenterephthalat
W - Softwood
Cordenka – Man made cellulose fiber
%wt –percentage weight of fiber
PROPERTIES OF PARTS MADE OF WPC:
Small weight,
Small use of energy during production,
Good mechanical properties,
Good acoustic isolation,
Renewable materials.
Abaca [aabaca]-konopie, Manila (hemp)– konopie manilskie (cáñamo), shell of rice –cáscara, jute [dzilt]-juta, hemp [hemp]-cáñamo, sisal [sisal]-sizal, kenaf [kenaf]-

12. Compression molding in a tempered mold,
Mat compression moulding:: Fibrowood (Johnson Controls)
Wood fibre mat with resin
Substrate ready for
covering process
Compression molding in a tempered mold,
demolding

13. Bast Fibres with Thermosetting Binder
Mat compression moulding:
NF-EP
Natural fibre
mat
Sliding of the
EP resin
Mat with resin
Substrate
Compression molding
Drying
Deflector
Mixing pipe
Cutting
Process steps
In-Line covering of NF-mat with Epoxy Resin
NF-mat is pressed in the final shape in a Hot pressing tool
Part is cut in its final shape

14. Bast Fibres with Thermosetting Binder
Carrier vacuum covered with Foam-Foil
Carrier
Complete Door Panel

15. Under-floor cover A-Class
Exterior Applications: 1st Exterior Natural Fibre Application A-Class Under-floor (DaimlerChrysler/Rieter)
economy
ecology
technology
Under-floor cover A-Class
Functional safeguard

16. Extrusion

17. WPC Profiles

18. Mechanical properties
Laboratory scale testing device for measuring E

19. Elastic modulus for WPC and its changing with temperature
WPC- Woof Fiber Composite
PP575 – Polypropylen
PAN – Polyacrylnitril
PET - Polyethylenterephthalat
W - Softwood
Cordenka – Man made cellulose fiber
%wt –percentage weight of fiber
Elastic modulus for different specimens

20. Comparison E from different methods
WPC- Woof Fiber Composite
PAN – Polyacrylnitril
The difference between the results obtained from my laboratory scale testing device for the same type of material were no greater than 5 %
Comparison E from different methods
First bar – tension,
second bar – bending,
third bar – DMA (Dynamic Measurement Analyzer )
fourth bar –testing device

21. Shear modulus - G Testing device My testing device:1 2 3 4
My testing device:
The relative error of the storage modulus about 5%

22. Laboratory stands for measuring the shear modulus G

23. Development of Bioplastics Market

25. Thank you for your attention Agradecemos su participación y asistencia
Danke schön
Tadeusz Majewski, UDLAP
Foro de Innovación 2011
INNOVATIONFORUM11

27. The directive of European Parliament and of the Council of 18 September 20007 organized
EUROPEAN COMMISSION
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Formato de archivo: PDF/Adobe Acrobat - Vista rápida adopted by the European Parliament and the Council on 18 September 2000, also ... The reuse, recovery and recycling of end-of-life vehicles is encouraged ... are allowed to transpose some of its soft-law provisions by means of agreements ...