Sustainable Automotive Composites Using Surface-Modified Cellulose Fibers

Advanced materials are needed to decarbonize the transportation sector and to improve the feasibility of non-petroleum-based vehicles. A key to this goal is to develop new, lightweight materials using sustainable feedstocks. In the proposed effort, TDA Research, Inc. (TDA) will design a lightweight, strong, and sustainable composite material to replace the conventional petroleum-derived plastics used in automotive manufacturing. The composite will combine surface-modified natural fibers with bio-derived polymer matrices to produce a material that has a lower carbon footprint than existing automotive materials and reduces the weight of the vehicle to provide better fuel economy (for reduced energy use and emissions). One challenge in developing these materials is ensuring the natural fibers are well dispersed in the polymer matrix to provide improved interphase strength in the final composite. TDA will develop a surface functionalization strategy that addresses this issue and compatibilizes the fiber surface for improved interaction with the polymer matrix, thus yielding better dispersion and making the composite stronger. We will optimize the functionalization and loading of natural fibers in bio-derived polymers to produce improved and sustainable automotive components, and perform preliminary mechanical and environmental testing of the composite materials to validate their conformance to specifications of parts currently used in automotive manufacture. In Phase I we will optimize the functionalization and loading of natural fibers in bio-derived polymers to prepare green, sustainable composites for the manufacture of automotive components. We will perform a series of preliminary mechanical and environmental tests on the composite materials to validate their conformance to specifications of parts currently used in automotive manufacture. We will then scale-up their production, carry-out recycling studies, and perform economic and lifecycle evaluations. In Phase II we will further engineer the composite production process to improve the composites material’s strength. We will also scale-up the manufacture of our composite material to support initial semi-pilot manufacturing during a post Phase II commercialization effort. To accomplish these tasks, we will work with a major U.S. manufacturer of green composite materials.