Demonstrating the unique properties of new nanocellulose composite for automotive applications

Project Information

AquaComp

Grant agreement ID: 697675

DOI

10.3030/697675

Project closed

EC signature date 4 September 2015

Start date 1 October 2015

End date 30 September 2017

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 243 125,00

EU contribution

€ 870 187,50

Coordinated by

ELASTOPOLI OY
Finland

Periodic Reporting for period 2 - AquaComp (Demonstrating the unique properties of new nanocellulose composite for automotive applications)

Reporting period: 2016-10-01 to 2017-09-30

Summary of the context and overall objectives of the project

Elastopoli has developed nanocellulose composite (AquaComp) with superior (>30% better) mechanical, acoustic and haptic properties and is targeting to replace the existing non-renewable polymer composites in markets such as automotive. home electronics and others. In vehicles, the weight-to-performance ratio of mineral- and glass-filled composites is substantially improved with AquaComp composite. In addition, the ability to control the dampening frequencies of the AquaComp material will help to reduce or tune the noise inside a passenger car to desired levels by tuning the resonance frequencies of the produced parts alongside the improved mechanical properties and lowered weight. In speakers, our materials are more akin to wood than plastics. The main innovation of Elastopoli is the unique manufacturing method of the nanocomposites. The technology is based on wet mixing of polymers and nanocellulose. This is the only known method capable of introducing high amounts of nanocellulose as reinforcing fibres in the polymer matrix. The wet mixing technology solves the two main problems related to conventional dry mixing technologies. First, drying of nanocellulose is difficult and expensive leading to high composite prices. Second, when nanocellulose is dried during mixing, it loses most of its theoretical strengthening capability.

The overall objectives were for the existing technology to be scaled-up for industrial scale production and detailed investment calculations, business model and market introduction strategy prepared. The qualification of new materials in the automotive sector has a long sales cycle, and it was aimed to get Elastopoli materials into the approvals process at several European and Asian OEM and Tier 1 automotive companies. This is necessary to get (any) new composites to market upon new vehicle launch in a few years time.

Demonstration in several automotive applications was targeted. This was supported because of large enough quantities were available through the planned scale-up. For the automotive industry to manufacture the products/parts in industrial scale with injection moulding, and to perform its application testing and thus approve the material in its production, it was necessary to digitise the composite materials in industry standard software. This is an important tool for reducing the time-to-market of new materials and designs for all the plastics manufacturing industry.

Europe has set a policy target of achieving a 60 % reduction of CO2 by 2050 compared to 1990 levels (European Union 2013). Very important in reaching this target is the reduction of emissions in passenger cars. One straightforward way is to reduce the weight of the vehicles which has direct impact on the fuel consumption and thus emissions. Lightweight materials have been identified as one key area to achieve the emission reduction targets. Lighter and stronger materials also contribute towards passenger safety which has also been identified as one key aspect in Smart, Green and Integrated Transport (European Union 2013). The third important aspect is making transportation quieter and reduce noise and vibration.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the project Elastopoli has delivered samples to both automotive and household appliances applications, where the properties have been compared mainly against glass-fiber and/or mineral filled composites. AquaComp composites have shown in these material replacements competing properties with lighter weight, thus offering weight saving in these applications especially through redesign.

This project succeeded to perform market replication of AquaComp composite, into speakers, HVAC systems, other industrial goods as well as the much larger automotive market. During the SME Instrument, Elastopoli was able to reach out to new and existing customers in Europe and Asia by attending exhibitions and trade fairs, organising workshops as well as direct customer visits. Acoustic, haptic and visual properties have come up in the discussions with the potential customers and very often the designers appreciate even more these properties compared to light-weighting possibilities. To support initial discussions, Elastopoli has built a special mould, where several different sample surfaces can be produced, giving to the designers real feeling of these features. This was very valuable in the beginning, though these test pieces were soon superseded by real injection moulded pieces from customer applications. Simulation data measurements have been done for several grades and simulations have been performed for technically demanding parts and the data has been evaluated and calibrated.

This approach generated a healthy sales pipeline.

Business models and business plans have been developed to expand production capacity over the next five years to satisfy anticipated European and Asian demand. The investment requirements for these plants have also been identified from the knowledge created during the SME Instrument.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Elastopoli’s wet mixing technology has unique properties being the only known technology to achieve a homogenous mix of (nano)cellulose and various polymers and realize part of the potential that (nano)cellulose has to offer as a reinforcing material.
• High strength and modulus, yet low density leading to 30% superior properties compared to MF polymers largely used in the transportation sector.
• Isotropic structure – same properties in all 3D directions. Same shrinkage and mechanical properties in both flow and transversal directions leading to superior design possibilities compared to GF reinforced polymers largely used in the transportation sector.
• Good flowability in thin walled products – lightweight solutions (<< 1 mm, allowing also the use in 3D printing) due to the small size of reinforcing nanocellulose fibrils leading to design freedom and lighter constructions.
• Unique tailorability of haptics, acoustics and visual surface look give freedom to tailor the user experience in for example car cockpits and musical instruments.

Most importantly, the digitisation of the materials has provided for commercial industry standard software to be utilised in the entire manufacturing process, which gives a distinct competitive advantage against competing materials.

Commercial trends are increasingly eco-conscious today. At the same time, regulatory requirements are steering production in the direction where energy consumption, waste generation and transportation costs are minimised. A good example of regulatory drivers is EU’s end of life vehicle directive. The directive requires 95% recoverability and 85% recyclability on automotive production in Europe. In addition, the existing requirement to decrease CO2 emissions is in high importance to car manufacturers.

Serviced by the exisiting and planned manufacturing plants, market introduction, which commenced at small scale in the musical instrument sector, have advanced to commercial speakers (with the multi-national LG) during the lifetime of the project. The sales pipeline, developed during the project anticipates sales in the home electronics sector to continue, followed by new markets in HVAC and, upon new vehicle introduction, the automotive sector at the start of the next decade.

1st and 2nd generation production processes