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Automotive Bio-PA composites Renewable 1,5 pentanediamine based polyamide composites for automotive applications 250 — 200 — 150 — 100 — 50 — Comparison of basic physical properities of different materials Cathay Biotech, Shanghai, China, is a leader in synthetic biology specializing in the production of biobased polyamides that are based on its 100 % renewable 1,5-pentanediamine (DN5). The option of using either fossil-based or renewable diacids enables the biocontent level of PA5X to be as high as 100 %. Cathay has been engaged in the application and development of biobased PA5X and marketed these engineering polyamides under the tradename ECOPENT ® . The melting point of its Ecopent engineering materials can be varied from 197 ºC of Ecopent 3300 (E-3300) to 300 ºC of Ecopent 6300, which fulfils a plethora of different application requirements of polyamides. Recently, Cathay focused on the investigation and production of fibre-reinforced PA5X composite such as prepreg tape, which is an alternative solution for metal replacement. The continuous glass/carbon fibre-reinforced biobased PA5X (CFRT-PA5X) shows excellent mechanical properties, high specific strength, and specific modulus, among others. By modifying the manufacturing process, the fibre content of such CFRT-PA5X could be tuned flexibly from 50 % to 70 %, by weight, which provides for a high design flexibility of these products and would contribute to a significant weight reduction for automobile applications (among others). Using Ecopent 2260 (E-2260) as the matrix and glass/ carbon fibre as reinforcement, composites with different mechanical properties could be easily produced by employing proper processing technology. The produced composite exhibits increased tensile strength and tensile modulus with increasing fibre retention length. For example, the CFRT of E-2260 70 % GF possesses tensile strength higher than 1,000 MPa, while its density is onefourth that of steel. More importantly, its specific strength is three times that of super-steel. Moreover, CFRT-PA5X composites with higher mechanical properties could be produced by using continuous carbon fibre instead of glass. For instance, the CFRT of E-2260 50 % CF has only one-third the density of super-steel but exhibits 10 % higher tensile strength than it. In addition, the specific strength and specific modulus of CFRT of E-2260 50 % CF are six times and two times that of super-steel, respectively. Continuous fibre reinforced unidirectional prepreg tape Basically, the thickness of CFRT-PA5X unidirectional prepreg tape is between 0.25 mm and 0.30 mm. Their tensile strength is usually higher than 1,000 MPa, which is 0 — 1600 — 1400 — 1200 — 1000 — 800 — 600 — 400 — 200 — Steel Super steel Aluminium E-2260- 70%GF (CFRT) Tensile modulus (GPa) E-2260-70GF tape Tensile modulus (MPa) E-2260- 50%CF (CFRT) Specific modulus (GPa-cm3/g) Properities of different unidirectional prepreg tape 0 — E-3300-70GF tape 1200 — 1000 — 800 — 600 — 400 — 200 — 700 — 600 — 500 — 400 — 300 — 200 — 100 — Comparison of different composite board 0°C/90°C Bending strength (Mpa) E-2260-50CF 0 — E3300-70%GF board E-2260-70%GF board PP-composite board 0 — E-2260-50CF tape 0°C Bending strength (Mpa) 0°C Interlaminar shear strength (Mpa) 90°C Bending strength (MPa) Comparison of bending strength of PA5X-70%GF at 23°C and 70°C for 2h 546,26 E3300 603,20 631,02 23°C E-2260 666,76 70°C 434,52 PP 382,06 18 bioplastics MAGAZINE [<strong>01</strong>/22] Vol. 17
1800 — 1600 — 1400 — 1200 — 1000 — 800 — 600 — 400 — 200 — 0 — Comparison of basic physical properities of different materials Steel Super steel Aluminium E-2260- 70%GF (CFRT) Tensile strength (MPa) E-2260-70GF tape Tensile modulus (MPa) E-2260- 50%CF (CFRT) Specific strength (MPa-cm3/g) Properities of different unidirectional prepreg tape 90 — 80 — 70 — 60 — 50 — 40 — 30 — 20 — 10 — 0 — E-3300-70GF tape 70 — 60 — 50 — 40 — 30 — 20 — 10 — 0 — Comparison of different composite board E3300- 70%GF board E-2260- 70%GF board 0°C/90°C Bending modulus (Gpa) 90°C Bending modulus (Gpa) PPcomposite board E-2260-50CF E-2260- 55%CF board 0°C Bending modulus (Gpa) Comparison of bending modulus of PA5X-70%GF at 23°C and 70°C for 2h 25 — 23,83 21,80 By: Yuanpin Li, Qilei Song Engineering Plastics Application Development Engineer Cathay Biotech Inc. Shanghai, China affected by the fibre content and fibre type. Furthermore, through winding or moulding process technology, these prepreg tapes could be further applied in automobiles such as fender, front cover, and battery pack etc. Biobased PA5X composite board In terms of 70 % continuous glass fibre reinforced E-2260 composite, its 0° bending strength could be up to 1,033 MPa, twice as strong as a PP composite with the same glass fibre content. Its 0° bending modulus also reaches 38 MPa, which is 30 % higher than that of a 70 % glass fibre reinforced PP composite. Furthermore, the 90° bending strength and 0° interlaminar shear strength of such biobased PA5X composite are 1.5 times that of PP composites with the same glass fibre content. When CFRT of E-2260 70 % GF, CFRT of E-3300 70 % GF, and PP composite are baked at 70 ºC for 2 h, the bending strength of E-3300 70 % GF and CFRT of E-2260 70 % GF is increased by 5 %, while PP ones are reduced by 12 %. The bending modulus of CFRT of E-2260 70 % GF is higher 40 % than that of PP composite at 70 °C. Application CFRT of PA5X, due to their extremely high strength-toweight and stiffness-to-weight ratios, can be a sustainable lightweight solution to meet increasingly challenging requirements from different industries, e.g., automotive, construction, or shipping. In addition, CFRT of PA5X have shown excellent chemical resistance, anti-fatigue and antimar performance depending on the biobased polyamide selected. The increase in temperature will lead to a decrease in the rigidity of composites. CFRT of biobased polyamides (E-3300 and 2260) have proven its advantage of mechanical performance at 70 °C, when compared with general plastic, like PP. This can make CFRT of biobased polyamides strong candidates for new vehicles, compressed gas tanks, or shipping containers, which needs much lighter, safer, and more efficient materials. www.cathaybiotech.com Automotive 20 — 15 — 16,74 17,07 16,84 15,80 10 — 5 — 0 — E3300 E-2260 PP 23°C 70°C bioplastics MAGAZINE [<strong>01</strong>/22] Vol. 17 19
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