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Biocomposites from Crop Fibres and Resins 66 2007 Iger Innovations

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Biocomposites from Crop Fibres and Resins 66 2007 Iger Innovations 2007 IGER INNOVATIONS Biocomposites from crop fibres B I O and resins C O M P Paul A Fowler, J Mark Hughes and Robert M Elias O BioComposites Centre, University of Wales, Bangor S I T www.bc.bangor.ac.uk E S F R O M C hat is a composite? In general, fibres with higher cellulose content, R O higher degrees of polymerisation and a lower P F CWomposites result from the combination of two or microfibril angle exhibit higher tensile strengths. I B R more distinct constituents or phases - a reinforced The selection of which fibres are suitable for a E S phase of stiff, strong material, often fibrous in particular biocomposite is determined by the degree A N nature, embedded within a continuous matrix phase of stiffness and tensile strength required in the final D R which is usually weaker and more compliant. This product. E S I combination produces a material with enhanced N S structural or insulation properties ; entirely different The biocomposite matrix phase from those of the individual components . Although manufacture of a true biocomposite would demand a matrix phase sourced largely from What are biocomposites? renewable resources, the current state of biopolymer Biocomposites have one or more of their phases technology usually dictates that synthetic derived from biological origins , e.g., plant fibres thermoplastics or thermosetting materials, such as from crops such as cotton, flax or hemp, or from polyethylene and polypropylene, are used in recycled wood, waste paper , crop processing by- commercial biocomposite production. There is still a products or regenerated cellulose fibres such as considerable need for the development of viscose/rayon . The matrix phase within a thermosetting materials from renewable resources. biocomposite may often take the form of a natural Recent examples of such developments include the polymer, possibly derived from vegetable oils or use of vegetable oils to build thermosetting resins, starches. More commonly, however, synthetic fossil- which can then be modified to form cross-linkable derived polymers (e.g., ‘virgin’ or recycled molecules such as epoxides, maleates, aldehydes and thermoplastics ) act as the matrices . isocyanates. The biocomposite reinforcement phase Factors influencing the performance of Microscopically, plant fibres can be viewed as biocomposites miniature composites themselves, made up of The geometry of plant fibres is ultimately controlled millions of microfibrils arranged in lamellae within by the morphology of the natural tissues and the way the cell wall. They are largely composed of three in which they are extracted. The ‘aspect ratio ’ is a main classes of cell wall polymers: cellulose, lignin measure of fibre length compared to diameter. Fibres and matrix polysaccharides, the latter including both with high aspect ratio are long and thin, whereas pectins and hemicelluloses . These are often those with low aspect ratio (e.g., softwood fibres) are combined with non-structural cell wall components, more short and chunky. The usual aim is to retain as such as waxes, inorganic salts and nitrogenous much fibre length as possible, since higher aspect substances, broadly referred to as extractives. ratios give rise to greater reinforcement. In practice, 66 2007 IGER INNOVATIONS moulding . A major limitation of this extrusion process, however, is that only relatively short fibres can be successfully utilised, resulting in limited reinforcement. S N Alternative techniques are required to successfully I S incorporate longer fibres. In the automotive industry, E R for example, long fibres from flax, hemp, kenaf and D N cotton are mingled with fibres of thermoplastic A S polymers acting as reinforcement to form a non- E R B I woven ‘fleece’. This combination is subsequently F hot pressed to melt the thermoplastic fibre and form P O R the biocomposite. The improved thermal insulation C achievable with biocomposites produced in this M O R manner could also be of considerable value in the F S building trade as part of the drive for carbon efficient E T I housing. S O P Fig. 1. Processing agri-fibres to prepare a biocomposite M Potential improvements O reinforcement phase. C O Mechanical improvements to existing biocomposites I through the introduction of new fibre types and B however, maintaining a high fibre aspect ratio additives may result in more diverse products. throughout the manufacturing process is difficult, Research programmes are currently looking to and in several finished products, the fibre length is develop solvent spinning of liquid crystalline frequently short and serves only as filler , doing little cellulose , which holds promise for producing new to impart true reinforcement to the composite. high-strength fibres. The use of reclaimed fibre from MDF (medium density fibreboard) or from waste Research is currently looking at breaking down streams in the pulp/paper industries is being natural fibres to form ‘cellulose nanofibres’, investigated to produce whereby the microscopic defects that cause local composites which are more stress deformations to develop within the matrix can cost and environmentally be eliminated. Biocomposite performance can also effective. There are also be improved by better alignment of the reinforcing opportunities for using fibres within the matrix. bioresins and bioplastics as adhesives in place of current Manufacture in practice fossil-based sources. Most biocomposites in current production are based The greatest potential for on thermoplastic polymer matrices such as reducing environmental polypropylene and polyethylene, with the standard impact has been shown to method of processing involving sheet compounding focus around the polymer followed by extrusion. In the compounding process, matrix and it is partly for this the polymer is heated to a molten state before the reason that there is significant fibre is added as a ‘flour’, together with any interest being directed additives required. Once mixing has been towards the development of Fig. 2. Blending matrix and completed, the biocomposite can often be extruded reinforcement phases to make a bio-based thermosetting and biocomposite panel. directly as the final product, or alternatively made thermoplastic resins. For into pellets prior to further extrusion or injection 67 2007 IGER INNOVATIONS instance, bio-technological methods are being is not sustainable, more laws are being enacted to investigated to try to improve both the quality and encourage the use of renewables. Manufacturers are yield of crop triglycerides to use as feedstocks for being financially encouraged to develop forward producing such matrix resins. These would not only plans for the whole life-cycle of their products B I be inexpensive compared to today’s resins but, if beyond their immediate usage, such as with the EC’s O C suitably modified, could also be biodegradable. Waste Electrical and Electronic Equipment Directive O M (WEEE). Such policies will not only stimulate the P O Interest in the uptake of thermosetting biopolymers uptake of recyclable biocomposites, but also create S I T for biocomposite production is inhibited by the high opportunities for all biodegradable materials. The E S curing temperatures required for their processing. At very stability of classical fibre-reinforced F R O temperatures in excess of 150ºC, the potential components, such as used in the computing and M combination and shaping options are much phone industries, often causes considerable C R O restricted, as most natural fibres are unable to problems in terms of reuse, and technically viable P withstand prolonged periods at such temperatures biocomposite alternatives could provide a F I B without significant deformation Therefore R considerable competitive advantage for E S significant effort is underway to derive new low- manufacturers as life cycle assessment (LCA) A N temperature, thermosetting bioresins, the current becomes the business norm. D lack of which is the only significant technical barrier R E S to uptake of this promising manufacturing route . Conclusion I N S Non-food crops and bio-renewable resources offer Future growth of the market an almost unlimited supply of potential fibre and The majority of biocomposites are currently used in resin feedstocks as sustainable raw materials for the automotive, construction, furniture and biocomposites. The burgeoning initial market for packaging industries, where increasing biocomposites is providing a major driver for the environmental awareness and the depletion of fossil development of new applications. If these factors fuel resources are providing the drivers for can be integrated with an extensive range of development of new more renewable products. processing options, this will help to ensure that the Waste reduction is a particularly effective driver for optimum combinations of natural fibres and matrices research and experimentation. With the growing can be brought together at financially viable prices. imposition of ‘producer pays’ policies for waste In such circumstances, the biocomposites industry is disposal across the developed world as countries likely to see a period of sustained growth. realise that the ever-increasing expansion of landfill Whilst there is thus ample opportunity for biocomposites to enter new markets and find new applications, it is essential that the benefits in terms of the environment and cost saving continue to be highlighted, emphasising the strong commercial case for these materials. Promoting biocomposite materials through widespread training and education will also be required if the industry is to establish sustainable commercial viability. Finally, of course, enlightened investment in research and development will be essential to maintain a constant flow of new products and ideas. Fig. 3. Biocomposite panel manufactured from a bioderived matrix resin. [email protected] 68.
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