BioPolymers Light weighting parts in the Transportation Industry

1. Innovative Plastics and Molding
Utilizing
Thermoplastic
BioPolymers for light
weighting parts in
the Transportation
Industry
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Presented by Robert Joyce
Founder and President of Innovative Plastics and Molding

2. Innovative Plastics and Molding
Discussion Topics
• Innovative Plastics and Molding, Inc.
• Identify biopolymer markets / applications in the
transportation industry.
• Light weighting parts and challenges with thermoplastic
reinforced polyolefin’s.
• What makes a great cake.....Biopolymer requirements to
mold parts for applications.
• Summary
• Appendix. a, b, c, d, e,
• Questions
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3. Innovative Plastics and Molding
• A profitable bio polymer technology company with 3 employees located in Toledo,
Ohio.
• Over 12 years in advanced biopolymer development with patented technology and 20
years of Plastics experience.
• License technology to companies that would like to mold parts with FibreTuff and or
compound FibreTuff.
•“ FibreTuff” a wood, cellulose flour based PP alloy composite.
Innovative Plastics and Molding, Inc
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Cosmetic
FibreTuff a “platform” technology
Consumer product Food Medical

4. Innovative Plastics and Molding
BioPolymer market in light weight
vehicles.......
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• 24% x 378 lbs = 90.72
lbs
• 90.72 lbs x 15,000,000
vehicles = 1.36 billion
• 1.36 billion x .02% =
27,216,000 lbs..

5. Innovative Plastics and Molding
Identified applications for BioPolymer
parts in transportation industry
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• Trucks, Automobiles, Airplanes, Recreation vehicles, etc..
• Automobiles
• Under hood: potential for blow molded shapes; battery tray
enclosures; cold air canisters in air induction systems; brackets for
bottle/canister holders; radiator fan shroud assemblies
• Weather seal carriers (with TPE)
• Trunk area: inserts for spare tire hold-downs; spacers/bumper support
• Firewall: two shot grommets; housing for cable routing
• Interior: door bolster inserts; arm rest/consoles; headliner close-outs;
HVAC flapper door structures; replace ABS, glass-filled PP; speakers,
seat backs/frame components; knee bolsters; glovebox housings.

6. Innovative Plastics and Molding
Light weighting transportation parts
having 3 dimensional complex shapes
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• Parts designs are more complex and demanding.
• Combining parts with assemblies.
• Thinner wall stock - smaller ribs, gates, more features...sharper
radius, corners, etc..
• Good fastener and clip retention will be necessary.
• Weld ability - lower filler levels in reinforced thermoplastics.....
• Multiple interface - compatibility with other materials in the
same mold.
Auto part for interior molded with FibreTuff 2.1

7. Innovative Plastics and Molding
Challenge for light weighting transportation
parts.
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• Dimensional changes and complex shapes will present
challenges to existing reinforced thermoplastic materials -
• Better flow.
• Minimize warp.
• CLTE - adequate fiber distribution.
• Better adhesion qualities are desirable.
• Bulk density and part weight still an issue.
• Biopolymers can rise to occasion through alloy compositions.

8. Innovative Plastics and Molding
Transportation industry requirements for
Thermoplastic Biopolymers include:
• Good cost equation
• Need consistent and reliable supply
• Global supply channels.
• Clean biomass resource.
• Recycle ability.
• Performance
• Same or equal to other fillers.
• Functionality
• No odor.
• Uniform quality in a continuous production
process.
• Low Moisture.
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FibreTuff pellets

9. Innovative Plastics and Molding
Ingredients for a successful thermoplastic
biopolymer composition...
• Biomass resource - wood, corn, rice
hulls, kenaf, hemp, sisal, coconut, PLA,
cellulose...
• Coupling - maleic anhydride, silane
• Polymer(s) - polyolfin’s - virgin/
recycle...
• Synergy between the ingredients.
• Polar and non polar activity.
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Biomass filler

10. Innovative Plastics and Molding
Biopolymer Pellet construction is important
• A low moisture pellet with superior
adhesion will provide:
• Improved heat resistance.
• No evidence of fines or fracturing.
• Very low drying time.
• Float when exposed to submersion
in water - low bulk density.
• Resistance to mold and or mildew
growth.
• Utilizes traditional pigment systems
for UV stabilization.
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Biopolymer “FibreTuff” pellet floating in
water

11. Innovative Plastics and Molding
Expectations for processing thermoplastic
biopolymer
• In most cases - Need drop in Replacement
• Flows well - hot runner trials, sequential
gating, direct or sub gating, foaming. etc..
• Extreme heat exposure - 15 min in barrel
without ignition or smoking.
• Cycle time reduction. 10-15%
• Less abrasion of screw and barrel versus
traditional fillers. Lower maintenance costs....
• Energy savings - lower heats can be utilized.
5 - 10%.
• Recycle ability -10% back into the process.
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Auto part molded with FibreTuff

12. Innovative Plastics and Molding
• Parts are becoming more complex - thinner walls with clips and
fasteners, additional features requiring multiple injection units.
• Key motivators for Transportation industry to light weight parts.
• Cost
• Performance
• Functionality
• Successful thermoplastic biopolymer implementation requirements
for light weighting molded parts.
• Formulation
• Pellet construction
• Molder is all about “costs”
• Part Performance
• Biopolymers are available now for implementation to light weight
transportation products.
Summary
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13. Innovative Plastics and Molding
FibreTuff BioPolymer with >50% Recycle
• Key ingredients include: Polyolefin's that have
synergy with coupling, cellulose and another
polymer.
• A compressed low moisture pellet that has
excellent moisture resistance with superior
adhesion between natural fibers and polymer
matrix.
• Improved processing window with no bio odor.
• Molded parts show improved heat resistance
with consistency.
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Class A surface molded
with FibreTuff
Appendix:

14. Innovative Plastics and Molding
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FibreTuff 2.1
Test
Melt flow Rate
Cellulose Filler Content
Density
Tensile Strength at Yield
Elongation at Yield
Tensile Modulus
Flexural Modulus
Heat Deflection Temperature
Flammability
Mold Shrinkage
Coefficient of Linear Thermal
Expansion (per condition)
(CLTE)
Water Absorption
Impact Strength Notched
Charpy
23°C
0 °C
-40 °C
Recycled Content
Test Method FT 2.1 2nd Production (ISO)
ISO 1133, 230°C, 2.16 kg 3.6 g/10 min.
Report method used, sample size and value >20%
ISO 1183, Method A 1.07 g/cm3
ISO 527-1 & ISO 527-2, Specimen A, 50 mm/
minute test speed, Strength
33 MPa
ISO 527-1 & ISO 527-2, Specimen A, 50 mm/
minute test speed
5.3%
ISO 527-1 & ISO 527-2, Specimen A,1 mm/
min test speed
2170 MPa
ISO 178, Specimen D, 64 mm support span, 2
mm/min test speed
1930 MPa
ISO 75-1 & ISO 75-2 Specimen D, flatwise,
0.34 +/- 0.1 mm deflection. 264 psi
63 °C
ISO 3795/SAE J369 Specimen B smooth surface 32.2 mm/min
Report method used, sample size and value)
After 48 h at 23 +/- 2 °C Flow (F), Cross Flow
(CF)
F .90% CF .99%
(ISO 11359-2, -30 +/- 2 to 100 +/- 2 °C)
Flow and Cross Flow
F 62.6 um/m/C CF 186 um/m/C
ISO 62, 24 h immersion, Specimen H 0.21%
ISO 180/1A, Specimen D, At 23 +/- 2 °C, -40
+/- 2 °C, and 0 +/- 2 °C
2.68 J/m2
2.28 J/m2
1.54 J/m2
>50%

15. Innovative Plastics and Molding
Recycle PP benefits with FibreTuff 2.1
versus other traditional fillers
• Lower weights versus glass
filled and talc filled PP
• Good cost equation.
• Weight savings +10%
• Less wear on screw and barrels.
• Energy savings.
• Performance
• Less warp
• Good Hot stamp performance...no
adhesion promoter required.
• Good TPE bond strength ...
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Auto part molded with FibreTuff 2.1
Auto part for interior molded with
FibreTuff 2.1

16. Innovative Plastics and Molding
Specialty Development with FibreTuff 2.1
• Automotive Under hood
• Target markets: Injection molded 30% talc
filled PP...
• Applications: Battery boxes, Fan Shrouds...
• Advantages...Strength to weight ratio,
improved heat deflection temps...
•Automotive Exterior
• Target markets: Injection molded 20% talc
filled TPO, 40% Talc filled PP..
• Applications: Substrates, trunk area..
• Advantages...good weld ability, improved
heat deflection temps...
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Fan shroud molded with
FibreTuff 2.0 cellulose pellet
FibreTuff 2.1 cellulose pellet

17. Innovative Plastics and Molding
Extrusion blow molding development
with FibreTuff cellulose composite
• Loudspeakers / Resonators
• Improved acoustics and insulation
compared to traditional plastics or
laminates or fiber boards
• Offer a high quality satin-like
surface for modern and attractive
design.
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Extruded tube with FibreTuff cellulose pellet

18. Innovative Plastics and Molding
Automotive Specialty Development
with FibreTuff 2.1
• Automotive Electrical
• Target markets: Injection molded
applications that need high strength
with lower weights versus glass
reinforced and talc filled PP for clips /
fasteners.
• Applications: Fuse holders, IP
Consoles..
• Advantages: Toughness - living
hinge, Lower weights, Energy
Savings, less warp, and improved
cycle times..
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Fuse holder with FibreTuff
cellulose pellet

19. Innovative Plastics and Molding
• Utilize existing Physical foaming agents and Chemical foaming
agents.
• Require 8 to 10% or more weight reduction to offset costs.
• Drop in replacement.
• Reduce warp.
• Increase melt flow.
• Maintain Good Strength is a challenge.
• Very good increase in stiffness.
Processing methods to promote further light
weighting BioPolymer
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20. FibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with MucellFibreTuff 2.1 with Mucell
Method Solid
Reduction
5%
Reduction
10%
Injection
Pressure
12,000 psi 9,975 psi 9,630 psi
Shot Size “ per
stoke 2.2 2.02 1.88
Specific Gravity
g/cc
ASTM D792 1.05 0.973 0.938
Tensile Strength
at Break (MPa)
ISO 527 30 23.3 21.2
Flexural Modulus
(MPa) ISO 178 1800 1980 1810
Impact Strength
(KJ/M²) ISO 180 3.2 2.25 2.23
Innovative Plastics and Molding
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• Weight reduction at 11%
• Maintain or increase Flexural Modulus by 10%
• Decrease strength by 25 to 30%

21. Innovative Plastics and Molding
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FibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFAFibreTuff 2.1 with Reedy International CFA
Sample Water Bath Density (g/cc) % Reduction
2% Control 0.85 -
2% PN40E NO 0.76 11%
2% RIC50FP YES 0.66 22%
Results: In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
In the extrusion process, the control sample as well as PN40E
was not run through a water bath. RIC50FP was sent through a
water bath to yield a 22% density reduction.
FibreTuff 2.1 with RIC50FP
0
0.225
0.450
0.675
0.900
2% Controlled 2% PN40E 2% RIC50FP
0.66
0.76
0.85
Density(g/cc)

22. Innovative Plastics and Molding
22
FibreTuff 2.1
3mm thickness
450um bubbles
FibreTuff 2.1
6mm
thickness 200
um bubbles

23. Innovative Plastics and Molding
Questions
More information
www.woodcompositesandmolding.com
Thank You
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