ECOPLAST

Research in new biomass-based composites from renewable resources with improved properties for vehicle parts moulding

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 Obiettivo del progetto (Objective)

'The main objective of the project is the development of new biomass-based composites validated for the automotive industry by means of the adaptation of base biopolymers and the generation of new ones, using innovative treatments for fibre reinforcements and the additivation of the base polymer with novel fillers and nanofillers. The principal research line will be focused on the adaptation of available biopolymers (PLA, PHB) and the creation of a new protein-based biopolymer (SELP) for its use as the base matrix to be able to meet automotive standard requirements. To achieve that advance, it is indispensable to improve the thermal characteristics of these polymers, the hydrolysis resistance, the dimensional stability and the volatile emission. Therefore, this project will develop several new reinforcements and novel additives like nanofillers, mineral fillers and treated natural fibres (nanocellulose) to be compounded with these base polymers in order to create new biocomposites. Accordingly, it will be used: a. Nanofillers to increase the thermal resistance. b. Natural fibres and nanocellulose to enhance the dimensional stability and the mechanical resistance. c. Mineral fillers to reduce the moisture absorbency. Another important goal in this project is the adaptation of conventional processing techniques (polymers compounding, injection moulding and thermoforming), widely used in the automotive industry, and the design of new ones tailored to these biocomposites. The challenge here will be to overcome the problem of degradation because of the extreme thermal conditions and the moisture absorbency.'

Introduzione (Teaser)

The automobile industry is focused on lowering its environmental footprint. Novel sustainable materials based on biopolymers and natural additives together with adaptations to conventional processing technology promise to help meet those goals.

Descrizione progetto (Article)

The food packaging and biomedical sectors have had promising success substituting biodegradable polymers for conventional ones and utilising conventional processing methods and equipment. However, more research is required on injection moulding and thermoforming to ensure that these materials can be validated for the more demanding transport environment.

Under the EU-funded http://www.ecoplastproject.com/alfresco/faces/public/index.jsp (ECOPLAST) project, scientists developed new thermoplastic, biomass-based composites and improved processing technologies used in the automobile industry to better handle the new materials. The team focused on adding natural fibres, nanofillers and other materials to conventional polylactic acid (PLA) and polyhydroxybutyrate (PHB). Researchers also developed new biomass-based thermoplastic composites through the synthesis of novel protein-based polymers.

Among the numerous accomplishments, scientists identified the components in PHB that lead to fogging and volatile emissions. They replaced them and delivered a new patented formulation for car interiors, which can be processed using conventional methods. They also developed a long-fibre PHB composite by exploiting a flax fabric, filling an important gap as only short-fibre renewable thermoplastics were available.

Researchers overcame difficulties of combining hydrophilic wood fibres with hydrophobic thermoplastic matrices by functionalising the surfaces of wood-based fibres. Novel reinforcements for PLA based on nanocellulose and organoclays were also quite promising.

Finally, four novel protein-based biopolymers were synthesised and production was scaled up to pilot scale. This brings commercialisation of these novel biopolymers one step closer to realisation.

Among the technological advancements are an improvement to extrusion that reduces volatile compounds and thus odour and fogging of PHB. The team also developed a programmable pulse generator that will be quite useful for pneumatic, electric, durability and ageing tests.

ECOPLAST efforts produced a variety of materials and processing technologies compatible with automotive requirements and capable of reducing the industry's overall ecological impact. Results were showcased in numerous television and radio interviews, press releases and publications. The efforts are expected to lead to patents and an increase in market share for companies in the consortium.