Natural Fiber Reinforced Foams Based on Renewable Resources for Automotive Interior Applications

Abstract

A fiber reinforced rigid foam system based on plant polyols has been developed and successfully tested. Interior car trims made with Elastoflex(r) E3517 and reinforced with natural fibers contain approx. 80% materials from renewable resources. The properties of the polyurethane system are comparable to polyether-based standard systems. The polyols are made by ring-opening addition from epoxidized soya, rapeseed or sunflower oil and ethylene glycol by our project partner HOBUM Fettchemie. The polyols show excellent compatibility with aromatic isocyanates. Fleeces of flax, sisal and jute fibers are used. About 60 weight-% of the panels are based on fibers, 40 weight-% are based on the polyurethane system. The system is self-releasing and does not contain heavy metals. Together with our second project partner EMPE-Findlay, car door panels with good mechanical properties have been produced. Due to the high content of renewable resources, these parts can be recycled with minimum damage to the environment. Several processes for the production of natural fiber reinforced interior car trims and the properties of the parts are discussed in the paper. The joint project by HOBUM Fettchemie, EMPE-Findlay Industries and BASF AG has been funded by the German Ministry of Agriculture (Fachagentur fur nachwachsende Rohstoffe e.V)