Injection mouldable biomaterials for recyclable furniture

Injection mouldable biomaterials for
recyclable furniture
BIOMATERIALS – Towards Industrial Applications
22.5.2013 Startup Sauna, Otaniemi
Heidi Peltola
VTT Technical Research Centre of Finland
23/05/2013
Contents
 Drivers for biopolymers and fibre composites
 Definitions
 Biocomposite research at VTT
 Biopolymer research
 Cellulosic fibre research
 Processing and process development
 Commercial biocomposite compounds for
injection moulding
 Case Ekokeittiö – Puustelli Miinus
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Drivers for biopolymers and fibre composites
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Alternative for non-renewable based polymers and composites
Closed CO2-cycle
New environmental laws and regulations, European strategic research
programs
Price increase in petrochemical based polymers (-> need for cheap fillers
and renewable or bio-based polymers)
Increasing demand and customer interest of bio-based materials
→ increasing production -> decreasing price
Research activity of WPC and bio-based composites is increasing
→ property development towards engineering materials, new grades of
materials
Image, ‘natural’ look and feeling
Biodegradable and non-biodegradable
Increasing help and interest in industry by creating new recycling
possibilities for bio-based materials helps to adapt these materials in use
Packaging industry is moving from cost cutting towards renewable materials
Safer and lower weight materials (smaller fuel consumption) for
transportation
About 20% yearly increase in market (NFC&WPC)
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Green Composites
Injection mouldable…
Bio-based composites
NRPC Naturally Reinforced Plastic Composites
Biocomposites
NFC Natural Fibre Composites
Natural Composites
WPC Wood Plastic Composites
= Natural/renewable fibre +
N
o
n
b
i
o
d
e
g
r
a
d
a
b
l
e
Renewable polymers
Renewable PE
Renewable PET
Renewable PA
Renewable PU…
PLA, PHA (PHB)
Lignin
Starch, cellulose and
protein derivatives
Petrochemical based polymers
PE, PP
PS, PVC
PET, PA, PC…
PCL
PVA
PBS…
B
i
o
d
e
g
r
a
d
a
b
l
e
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Biocomposite research at VTT
Development of
Polymers
Natural fibres
Different fibre types and shapes:
wood, flax, hemp, cotton etc.
 Industrial minor flows
 Nanofibres
 Fibre treatments
business operations
Processing
& Process
Development
Additives
 Commercial additives
 Nanoparticles
 Additives developed
by research centers
and companies
 Commercial polymers:
PE, PP, PLA, PCL, PHB etc.
Biopolymer blends
Biopolymers developed by
research centers and companies
and value chains
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Biopolymer research at VTT
Polymers from biomass
Synthesized from
biobased
monomers
Tall / Vegetable oil based
PGA
Polymers from C2-C6
PLA applications
New co-polymers
Chemically synthesized
bio/degradable polymers
Cellulose derivatives
Starch derivatives
Lignin derivatives
Hemicellulose derivatives
Protein derivatives
Polyesters
(succinates, lactones..)
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Cellulosic fibre research for biocomposites
Pelletising
Physical
treatments
Chemical
treatments
Plasticising
Enzymatic
treatments
Fibre
fractionation
Chemoenzymatic
treatments
Additives
Cellulosic fibres
as reinforcement
Better
fibre/matrix
adhesion
Improved
compatibility
Optimised
fibre aspect
ratio
Better fibre
dispersion
Better
processability
Improved material properties for composites
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Processing and process development
Fibre dimensions, dispersion and distribution:
Determined by process parameters, methods, melt viscosity and pre-processing
Parameter combination >15
 Screw geometry
 Processing steps
and methods
 Viscosity & shear
 Orientation
8
6
on
ten
t (%
0
)
4
5
10
15
20
25
2
0
0.10
0.20
Fibe
30
0.30
r we
ight
Pla
sti
ciz
er
c
m
Young's
Pa)
odulus (G
10
fract
0.40
ion
0.50
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Correlation between
composite strength,
fibre content, and
plastisizer content
Nättinen et al. Mech. of Time-Depend Mat, 16, 2012,
47-70.
Peltola et al. Plastics, Rubber and Composites:
Macromol, 40 (2011) 86-92
Peltola et al. Journal of Materials Science and
Engineering. Vol. 1 (2011) No: 2 , 190-198
Nättinen et al. Journal of Composite
Materials Vol. 45 (2011) No: 20, 2119-2131
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Commercial biocomposite compounds for injection moulding
 UPM ForMi – cellulose fibre reinforced plastic
composite with high (up to 50%) renewable material
content, specially designed for injection moulding
applications
 Kareline® - natural fibre reinforced composite
granulates available based on PP, ABS, PS, POM
and PLA matrix, excellent for injection moulding and
extrusion
 Tecnaro Arboform® - made from 100% renewable
materials (lignin, natural fibres and additives) and is
mainly used for injection moulded wood applications
 Beologic – Recyclable, ready-to-use compounds
filled with 25 up to 85% of wood fibres in PVC, PP,
HDPE or PLA matrix
 Among others!
ISKU Prima chair, seat
made from WPC
http://www.iskuinterior.fi
23/05/2013
Case Ekokeittiö – Puustelli Miinus
New biocomposite based materials and solution for kitchen
furnitures launched in 2013 by Puustelli Company
Impact:
 Reduction of waste material using injection moulding instead of
carpenter work
 New production method and material allows totally new frame structures
and lower weight furnitures, lower weight components
 30-45% Reduction to carbon footprint compared to current materials
(MDF or fibre boards)
 Reduced VOC emissions in new materials
 Possibility to use domestic industry in component manufacturing
 Biocomposites allows new joining techniques
 Developed by Puustelli Group Oy and Desigence Oy, with industrial
designer, Professor Juhani Salovaara as the lead designer. UPM, VTT
and the Wood Chemistry Laboratory of Aalto University, as well as a
number of top specialist companies in the field, also made a large
contribution to the technological design process.
Additional information: Lisa Wikström or Kirsi Immonen
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VTT creates business from technology
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