Processes for nanocellulose composite manufacturing

Purpose and goal

The purpose of the project was to develop new green composite materials from the forest sector and use environmentally friendly water-based production methods without harmful chemicals. It will in turn provide new business opportunities for industry and more resource-efficient utilization of raw materials and energy. The main goals were to first and foremost increase bending stiffness by at least 50% and tensile stiffness should amount to 5 GPa.

Expected results and effects

A demand from industry was that the rigidity would amount to 5 GPa to be competitive with glass fiber reinforced composites. After several attempts, levels up to 4,5-5 GPa were achieved, which could be approved. For rigid packaging, the requirement that bend stiffness was increased would be increased by at least 50%, however, the outcome was 135% higher. The project also performed advanced injection molding into foam composites of polypropylene and nanocellulose. The result for the test sample was satisfactory and comparable to what is commercially available.

Planned approach and implementation

In order to make it possible to work on a pilot scale level, a prerequisite for creating sufficient material for the project, the so-called Wet Web comingling process and the DEVO process were modified to fit for nanocellulose composites. The two processes were initially developed for pulp fiber composites. To make it possible to work with very small plastic granules, the previously developed Kyoto process was modified. When analyzing mechanical test results, it could be confirmed that all three processes are in line with glass fiber reinforced plastics.