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Potential of blends from natural fibres and recycled carbon fibres for lightweight applications
Published on 23 August 2018
Germany
Chemnitz
This is the good practice's implementation level. It can be national, regional or local.
About this good practice
Motivation of the project idea was to use the knowledge in plant fibre processing and carbon fibre recycling existing at STFI for the application of reclaimed carbon fibres in newly developed products at attractive price ranges. The focus of the project was on a significant weight reduction of fibre reinforced moulded parts for the automotive industry (such as pressed needle-punched nonwovens) while improving or at least keeping at the same time selected mechanical properties. The effect of partial substitution of natural fibres used as reinforcing material by reclaimed carbon fibres was investigated for textile basis materials (nonwovens) from blends of natural and thermoplastic matrix used so far. A technically and economically acceptable optimum to replace natural fibres by carbon fibres should be found exploiting the up to 13 times better specific E-modulus of carbon fibres and where weight reductions of up to 20% compared to currently used systems can be achieved. Objective of the project was furthermore, to achieve a homogeneous blend of the fibre materials despite their different properties and processing behaviour to ensure an easy processing. Advantages of composites from natural fibres used in the automotive industry are: low density (10 to 30 % weight reduction), good mechanical and acoustic properties, good processability, good behaviour in case of accidents (high stability, no splintering), better ecological balance (production, driving).
Resources needed
To build up a recycling and processing concept for carbon fibre materials requires investment for machinery and equipment. For upgrading an already existing machinery about 0.5 to 1.0 mn € are necessary, a complete new construction with all needed machinery components will be total in ca. 5.0 mn €.
Evidence of success
The main success factors can be seen in the application of natural fibres (like hemp) which is a regrowing material and therefore having a good availability throughout Europe. Furthermore, high-quality recycling material (carbon fibres) is used, leading to cost reduction compared to the use of “new” carbon fibre material. The carbon waste material is brought back into the production process which can safe material costs. Thus, sustainability aspects are covered by the used material components.
Potential for learning or transfer
With this Good Practice in the field of lightweight construction, fibre reinforced plastics and composites addressed companies are enabled to improve their product range and further strengthen their sustainable approach. Eco-friendly textile goods and technologies that minimize power consumption, CO2 emissions and the volume of waste generated at every manufacturing stage, are a priority for the T&C sector, stimulating the development of modern technologies in European regions. The GP contributes to these priorities with strategies to recycle and reuse materials like carbon fibres that are produced under high energy and material consumption in new production chains by simultaneously saving of raw materials.
The innovative character of the developed technology could bring thus benefits to other partners or regions. From a technological point of view, the described Good Practice is transferable to other regions provided that the requested investment for machinery is available.
The innovative character of the developed technology could bring thus benefits to other partners or regions. From a technological point of view, the described Good Practice is transferable to other regions provided that the requested investment for machinery is available.
Further information
Website
Good practice owner
Organisation
Saxon Textile Research Institute
Germany
Chemnitz
Contact
Scientific staff