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.