Hybrid yarns and fabrics of PLA & Thermoformable self ...

Co-funded by the European Union

Hybrid yarns and fabrics of PLA & Thermoformable self-reinforced PLA compositesCOMFIL Hans Knudsen

Firenze 2019

▪ About COMFIL

▪ Development of PLA hybrid yarns

▪ Fabric of PLA and sheets

▪ Sheets (Organo sheets) of self-reinforce PLA

▪ Forming on sheets and fabrics

▪ Conclusions

Outline

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Who is Comfil

▪ A production and development company, who

manufactures and develops materials to the

thermoplastic fibre composite industry

▪ Started in 1991 within Trevira Neckelmann in

Silkeborg (Belonged to Hoechst)

▪ MBO 1/10-2001

▪ Production in Romania

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Who is Comfil

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What is Comfil®

▪ A thermoplastic composite yarn (based on continues

fibres, both reinforcement and matrixes)

▪ A fabric made from the Comfil ® yarn

▪ Consolidated plates (Organo sheets).

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What is Comfil®

▪ An air-texturized yarn

▪ A texturized yarn by air, can have different textures as

overfeed can vary.

▪ Can be made with different polymers

▪ Yarn count???

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What is Comfil®

▪ A steam texturized yarn

▪ A texturizing method, where the tenacity is kept, even with

high bulk.

1100 dtex HT-PET →

Same Steam tex →

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▪ Reinforcement fibres

Reinforcement fibres and

Polymers/ Matrix materials

▪ HT-PET (High

tenacity

polyester) Sr-PET

▪ Other HT fibres

▪ Glass

▪ Aramid

▪ Carbon

▪ Basalt

Polymers/ Matrix materials

PEPPPolyesters (PET, PBT, PEN,L-PET + more)POMPA (6, 66, 46, 11 + more)PPSPEEKPEIPVDF

PLAOther polymers up to customer needs

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Comfils manufacturing processes

▪ A) Spinning of polymerfibres

▪ B) Texturizing and Co-mingling of fibres (matrix) and

reinforcement fibres

▪ C) manufacturing of fabrics, some within house

▪ D) Consolidation (plates continuous otherwise

vacuum consolidation)

▪ E) Pultrusion of profiles and tapes, chips

Co-funded by theEuropean Union

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Development of hybrid yarns


Equipment used at ITA

▪ Lab scale air texturising machine

▪ Components from SSM Schärer Schweiter Mettler AG

Horgen, Switzerland

Investigated parameters

▪ Production speed

▪ 100 – 200 m/min

▪ Over feeding rates

▪ 0,5 – 2 %

▪ Air pressure

▪ 5 – 7 bar

Take-off godet

Delivery

godets*

Commingled yarn

Mixing box

Matrix fibres

Reinforcing fibres

Commingled

yarn

Spreading bars

40 cm

Air jet nozzle

*Heating possible

Dir

ectio

n o

f p

rod

uctio

n


Materials used for Commingling

▪ 50:50 wt.-% ratio of fibres

▪ Yarn count of 200 tex

Materials

Low T PLAm High T PLAm

SRPC phase Matrix phase Reinforcing phase

PLA manufacturer Nature Works

211,87 ± 110,22 ± 2125 - 135AMIBM

CorbionYarn count T [dtex]

t248,52 ± 1

30,09 ± 3176,99

Tensile strength σ [cN/tex]t

Melting temperature T [°C]m

Filaments provided by Centexbel

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Hybrid yarns have been produced successfully

▪ Colouring is good to determine

the intermingling of the fibres

▪ No intermingling at low 5 bar

▪ High ondulation at 7 bar

Manufacturing parameters and material properties of hybrid yarns

A B C

Pressure p [bar] 6 6 6

Manufacturing speed v [m/min] 150 200 200

Difference of overfeeding rate between fibres ΔOR [%]

rf/mf

0,5 0,5 2

Yarn count T [dtex]t

2070,71 ± 13 2070,10 ± 9 2079,81 ± 12

Tensile strength σ [cN/tex]t

12,83 ± 0,97 12,33 ± 1,30 11,92 ± 1,38

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UD wound textiles have been consolidated using heat pressing

▪ Consolidation temperature 140 °C

Temperature Pressure

Pre

ssu

re p

[b

ar]

T

To

ol t

em

pe

ratu

re T

[°C

]T

Time t [min]

T = Ti C

TR

TD

HoldingHeating CoolingMould Oil heating

15 cm

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Examination of cross sections of UD composites show good fibre distribution

Reinforcing PLA fibres

PLA matrix

Epoxy resin (sample preparation)

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Tests of UD composites indicate the potential of biobased SRPCs

F

PLA:PLA hybrid yarn basedUD composite comparedto industrial benchmark(data from literarure)

Tensile strength

Tensile Modulus0

1000

2000

3000

4000

5000

6000

0

20

40

60

80

100

120

140

A B C Curv®

Te

ns

ile

M

od

ulu

s E

[M

Pa

]

Te

ns

ile

S

tre

ng

th

s

[Mp

a]

M

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Hybrid yarns have been produced successfully at COMFIL

▪ Best results on lab scale

▪ 150 m/min

▪ 1.5 % overfeed for reinforcing fibres

▪ 2 % overfeed for matrix fibres

▪ 6 bar

▪ Lab scale results have been transferred to

industrial scale

▪ Industrial scale manufacturing is possible

Industrial scale manufactured

hybridy yarns are available for fabric development

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Development of woven fabrics


Weavability tests in weft direction ▪ The weavability of commingled hybrid yarns and monofil-tapes was tested at ITA

using industrial-scale (broad) weaving machines and inserting the PLA yarns in

weft direction

Rapier weaving machine Dornier PTS4/SOC10

Weaving parameters

Yarn count T [dtex]t2000

Width [mm] 1920

Warp density [yarns/cm] 2.5

Weft density [yarns/cm] 2.5

Weave design Plain weave

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Weavability tests in weft direction successful

▪ Commingled yarns were tested with speeds up to 200 picks/min. ▪ Higher speeds up to 350 picks/min were tested on an air jet weaving machine

▪ Hybrid yarn materials showed no difficulties during weaving

Hybrid yarns

(weft direction)

20 mm

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Development of weave designs for SRPCs

▪ A needle based narrow fabric weaving machine of type Jakob Müller NFJK2 was used to produce fabrics with 60 mm width.

▪ Two different weave designs were chosen to evaluate different yarn floatation / orientation of the yarn in the fabric (low/high ondulation)

and different mechanical properties

Weaving parameters

Yarn count T [dtex]t 2000

Width [mm] 60

Warp density [yarns/cm] 10

Weft density [yarns/cm] 10

Weave design

---

Plain weaveSatin 4-1Twill 2/2

Narrow fabric weavingmachine Jakob Müller NFJK2

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Weaving in of fabrics successful at ITA

▪ Results: ▪ The commingling reference yarn material was used to establish a stable

weaving process with high density.

▪ Successful production of narrow fabrics for mechanical testing

Warp

d

irecti

on

Weft direction

Plain weave Satin 4-1

10 mm10 mm

Weft direction

Warp

d

irecti

on


Forming tests at ITA hot press▪ to check the feasibility of standard weave designs

(for e.g. misalignments of fibres through forming, …)

▪ Simplistic consolidation of 1 and 3 layers complete

▪ No misalignments visible

▪ All standard weave designs feasible

3 cm 3 cm 3 cmPlain weave Satin 4/1 Twill 2/2

125 mm

Dome geometry formingtool for lab-scale hot press

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Weaving in industrial scale successful at COMFIL

▪ Material used

▪ 50/50 wt.-%

▪ 410 tex

▪ Fabric produced

▪ Twill 2/2,

▪ 680 g/m2

Fabric has been used to produce a first

demonstratorWeaving from creel system at COMFIL

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Conclusion & Outlook 1

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Conclusion & Outlook

▪ Processing parameters have been identified for

▪ Hybrid yarns

▪ Woven fabrics▪ Industrial scale production of composite intermediates for self-reinforced PLA

is possible▪ Use of hybrid yarns results in well distributed reinforcing fibres within the

composite

▪ Hybrid yarn based fabrics show good drapeability

▪ Currently on-going

▪ Increase of manufacturing speeds▪ Investigations into other uses of the intermediate products

Sustainable materials are available for

the next production processes

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Fabric of PLA

and sheets

COMFIL

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Fabric of PLA

▪ A) Spinning of PLA fibres

▪ B) Co-mingling of PLA fibres

▪ C) manufacturing of fabrics

▪ The yarns are “normal” textile yarns.

▪ The yarns can be used in most textile processes to

manufacture fabrics.

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Self rein-forced PLA (sr-PLA)

Production of self-reinforced PLA composite▪ To define of the optimal processing conditions for self

reinforced PLA composite

Tm,1 < Tprocess < Tm,2

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THERMOFORMING AND

COMPRESSION MOULDING

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Production of UD Tapes via woven fabric

·

OK Temperatures

Too high Temperatures

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Composite intermediates

Consolidated SR-PLA plates for thermoforming

·

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Organo sheets

Consolidated SR-PLA plates for thermoforming

·

• Manufactured from fabrics• Thickness: from 0.3 mm to app. 5 mm• Length?• Width? Depending of quantity, • For now up to 650mm

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Composite intermediates

Consolidated SR-PLA plate for thermoforming

·

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THERMOFORMING AND

COMPRESSION MOULDING

▪ PLA SHEETS IS VERY EASY TO THERMOFORM AND

COMPRESSION MOULD.

▪ A PROCES WERE IT IS POSSIBLE TO PROCESS A 2mm

THICK ITEM IN LESS THAN A MINUTTE IS available.

▪ OVERVIEW IN NEXT SLIDES

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Manufacturing processes

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Thermoformed sport shoe reinforcement

made of self-reinforced PLA

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Thermoformed automotive underbody part

made of self-reinforced material

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Thermoformed car seat shell made of self-reinforced PLA

Acknowledgement to MoPaHyb projectfor use of the mold for the seat structure

Self-reinforced PLA seat structure produced on a modular production plant for high perfomance compononents

Scheme of the fully automated modular production plant concept

Source: KIT-wbk

Sou

rce:

Fra

un

ho

fer

ICT

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Self reinforced material

·

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Take home message!

▪ PLA/PLA yarns and fabrics will be

available this year

▪ PLA/PLA organo sheets will be

available this year

▪ PLA/PLA organo sheets are easy to

thermoform or compression mould

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Acknowledgement

▪ This project has received funding from

the European Union’s Horizon 2020

research and innovation programme

under Grant Agreement No 685614

Firenze 2019

BIO4SELF – contact

▪ Contact: Hans Knudsen| [email protected]

▪ Website: www.bio4self.eu

mailto:[email protected]

http://www.bio4self.eu/

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