SBIR Phase IB: Coconut (Coir) Fiber Automotive Composites

这个小型企业创新研究(SBIR)一期项目将论证用更环保的椰子纤维织物复合材料取代用于汽车后备箱衬里的丙纶/聚酯复合材料的可行性。由椰子壳生产的环保椰子纤维，与目前使用的合成石油基聚酯纤维相比，具有更好的纤维直径、强度、硬度和延展性组合，使生产更环保、更低成本的行李箱衬里、门板和地板成为可能。由椰子纤维和聚丙烯纤维压缩模压共混制成的工程复合材料的初步结果非常有希望，但还需要进一步的研究来开发最佳的(1)椰子纤维和聚丙烯纤维的组合，(2)纤维之间的界面粘合，(3)加工路径(温度、压力和时间)，以满足通用汽车和其他汽车公司的汽车认证/规格测试。椰子纤维汽车复合材料的总市场潜力为3亿公斤/年。这项研究的更广泛影响包括每年减少200-400万桶石油消耗，以及每年潜在减少45万吨二氧化碳排放。有1000多万贫困的椰农(年收入约500美元)拥有全球每年95%的椰子收成。大约85%含有椰子纤维的椰壳被焚烧，因为对这种生物质的需求不足。椰子纤维汽车复合材料的成功开发，可以为这些农民带来额外的1-2亿美元的年收入。

Abstract This Small Business Innovation Research (SBIR) Phase I project will demonstrate the feasibility of replacing polypropylene/polyester composite materials used for automobile trunk liners with more environmentally friendly coconut fiber based fabric composites. The environmentally friendly coconut fibers, produced from coconut husks, have a superior combination of fiber diameter, strength, stiffness, and ductility compared to synthetic, petroleum based polyester fibers currently used, making it possible to produce greener, lower cost trunk liners, door panels and floor boards. Preliminary results on an engineered composite material made from a compression molded blend of coconut fibers and polypropylene fibers are very promising, but additional research is needed to develop the optimal (1) combination of coconut fibers and polypropylene fibers, (2) interfacial adhesion between fibers, and (3) processing path (temperature, pressure and time) to meet the automotive certification/specification tests for General Motors and other automotive companies. The total market potential for coconut fiber automotive composites is 300 million kg/year. The broader impacts of this research include the reduction of petroleum consumption by 2-4 million barrels per year and the potential reduction in carbon dioxide emissions by 450,000 tons per year. There are over 10 million poor coconut farmers (income ~ $500/year) who own 95% of the coconuts harvested annually worldwide. Approximately 85% of the coconut husks, which contain the coconut fiber, are burned because there is insufficient demand for this biomass. The successful development of coconut fiber based automotive composites could provide an additional $100-$200 million of annual income for these farmers.