ExtruCO2

Development of a low-temperature processing method for the production of natural long-fibre filled polypropylene sheet for automotive applications.

The use of natural fibres as reinforcing fillers in polypropylene sheet for automotive applications is becoming increasingly popular within the European Union. This has been driven by environmental concerns, increased recyclability & a move towards more sustainable products & processes. The growth rates for natural fibres in automotive applications are predicted to increase by 4% over the next 7 years. However, due to the relatively low thermal degradation temperature of natural fibres, they degrade under 'normal' processing temperatures, resulting in odours, loss of mechanical properties & discoloration. This has prevented even greater up-take of natural fibres for sheet applications.

ExtruCO2 aims to develop the necessary extrusion & mixing technologies to allow for the low-temperature processing of natural fibre filled polypropylene (using liquid CO2 as a processing aid) to produce a non-woven polypropylene sheet suitable for thermoforming automotive applications.

The main objectives are:

• To produce a sheet material based on renewable resources with better mechanical & thermal properties & recyclability than those currently on the market.
• To develop innovative technologies for low-damage sheet production.
• To remove the need for expensive & environmentally harmful fibre chemical treatment.

This project enabled the SME participants to obtain a technological edge leading to increased competitiveness. In line with the objectives of the EU & Framework 6, the products & processes developed have helped contribute to sustainable manufacturing.

Start date: 01/02/2004
Completion date: 31/01/2006