Description
MAIER is a company specializing in manufacturing of external and internal vehicle parts, using innovative technologies that provide unique finishes. The use of plastic materials consumes about 7% of global production of fossil fuel. As plastic is a product of non-renewable fossil fuel, the development of green polymers from renewable natural resources will play an ever-increasing role for future generations and the transformation towards a sustainable society. Due to these concerns, there is significant research going on with the aim of developing synthetic polymeric materials.MAIER has initiated this project to investigate and develop new thermoplastic materials for its external and internal vehicle parts that are more sustainable, has a lower environmental impact and with features and qualities suitable for manufacturing automotive decorative plastic inside and outside car components, allowing the replacement of certain thermoplastic materials currently used.
Summary of project results
The objective of the project has been to develop new plastic materials from renewable sources with a low environmental impact, that are more sustainable, and contains adequate characteristics and qualities for the manufacture of decorative plastic parts of the interior and exterior of cars, which will enable replacement of certain plastic materials currently used by industry, reducing petrol dependency and environmental problems. The project has developed polymeric compounds with a content of the material coming from renewable sources, in particular: - Reinforced polypropylene (PP) with cellulose fibers, replacing PP-talc; - Polyamide synthesized from castor oil and reinforced with fibers, replacing PP-fiberglass; - Mixtures of Acrylonitrile Butadiene Styrene (ABS) with poly lactic acid (PLA) to replace ABS / Polycarbonate (PC) blends. The project has studied and developed the formulations of the plastic compounds in order to obtain a set of properties that achieve the requirements of parts that have been marked as prototype (air intake grilles, uprights, and panels of instrumentation, respectively). Using these materials we optimized the formulations to meet specific requirements: PP with 20% of cellulose fiber and PA from renewable resources with 30% fiberglass. The blends of ABS/PLA failed to meet the set requirements. The project also confirmed the processability of the materials selected (included blends of ABS/PLA) through the manufacturing of prototypes. Calculations performed on the new materials show a reduced carbon footprint. During the final validation tests, the vent made of PP with 20% cellulose fiber met all the requirements. In the case of the post/upright made of PA6.1 with 30% glass fiber, met the functional requirements but not the aesthetic ones. Finally, the fronts made of ABS/PLA, didn't meet the established functional requirements
Summary of bilateral results
SINTEF worked on the second milestone phase of the project to contribute with its extensive knowledge in dispersion of cellulose fibers in a plastic matrix. Specifically, SINTEF participated in the task dedicated to the preparation of new formulations and characterization. This specific task was dedicated to the analysis of the influence of cellulose fiber content in PP matrix in the mechanical properties of the new developed materials.