Process
to Manufacture High Impact Natural Fibre Composites
ABSTRACT
The use
of natural fibers as reinforcing filler in thermoplastics is a relatively new
innovation and has great potential to replace glass fiber products in building,
consumer goods, furniture and automotive industry. Our published results
demonstrated that laying natural fiber mat and polymer film in a definite
pattern and orientation can enhance mechanical strength. In this invention, a
unique process has been developed to manufacture high impact strength composite
that contains loose natural fiber and/or a combination of loose natural fiber
and natural fiber mat to develop green composites outstanding impact strength
and other mechanical properties. Loose fibers used in this process can be
obtained from agro-plant and wood. Mats, if used, can be obtained from similar
sources. Polymer those are used include thermoplastic polyolefins (TPOs), acrylic and
polyester films. This invention is especially useful for natural composites
with natural fiber content above 40% by weight up to 93 wt% fiber. Film
stacking and fiber spraying methods were used to construct sheet, laminates and
thermoforming and compression molding were used to design a product. A range of
impact strength was obtained which varies from 100 J/m to as high as 250 J/m
with a significant increase in flexural and tensile strengths. Products having
uniform density profiles yield maximum enhancement in impact properties.
