JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 45

FEATURE
natural fibre
Towards lightweight
flax fibre-reinforced automotive headliners
Laurent Mougnard,
Innovation Research & Development Engineer
Howa-Tramico
KariM BehLouLi, Managing Director
MaxiMe haugueL, Research & Development Engineer
Eco-Technilin
SyLvie durand, Assistant Engineer
Johnny Beaugrand, Research Director
INRAE, BIA
antoine KervoëLen, Assistant Engineer
Université de Bretagne Sud
darShiL Shah, Associate Professor
University of Cambridge
aLain BourMaud, Research Engineer
Université de Bretagne Sud
possible to develop a new range of low-areal-density
non-wovens (about 100 g/m2
F
lax fibres are of growing interest in
the composite sector due to their low
environmental impact and good specific
mechanical properties [1]. For about
20 years, flax-based non-woven reinforcements
have been developed and used in the
automotive industry to lighten parts but
also to bring additional functions due to
their acoustic properties [2].
A wide range of reinforcements are now
available for both semi-structural and structural
applications [3]. In addition to their
low environmental impact, these bio-based
composites exhibit good end-of-life behaviour,
and in particular strong recycling performance,
due to the particular structure
of the fibre bundles, resulting from their
in-planta organisation, and their progressive
splitting as the processing cycles progress.
This makes them suitable materials for endof-life
mechanical recycling.
Developments have been made to integrate
a significant ratio of production waste into
poly-(propylene) flax nonwovens [4].
As part of the FLOWER project within
the framework of the INTERREG France
(Channel) England cross-border cooperation
programme [5], joint developments
between companies and academics made it
)
and to use them to manufacture more environmentally-friendly
car headliners, while
meeting the technical specifications of vehicle
manufacturers. The first part of this work
presents the production of the flax fabric as
well as microdroplet debonding tests to validate
the quality of the interface between the
fibre and the resin. Then, the manufacture
of the headliners is discussed, as well as the
technical and environmental assessment
carried out through a lifecycle analysis.
Flax preform development
The preform developed as part of the
FLOWER project is 100% made of flax tow
fibres using innovative forming and consolidation
technologies. To limit the environmental
footprint, the light non-woven reinforcement
was developed in the premises
of Eco-Technilin in Normandy, as close as
possible to the flax fields and fibre production
sites.
Flax tow is a co-product of scutching, a fibre
processing step used in the textile industry.
Thus, this veil makes it possible to upcycle
short flax bundles (under 100 mm in length)
that cannot be used by the textile industry.
Indeed, this innovative preform especially
developed for the composite industry and
the specific requirements of Howa-Tramico
required the design and configuration of a
completely new manufacturing process. A
prototype manufacturing line was funded
by the Interreg programme.
The collaborative work presented in this paper focuses on the
manufacturing of a lightweight flax-reinforced headliner for the
automotive industry. The development of the preform is discussed
and the technical and environmental validation presented through
interfacial tests and a full lifecycle analysis.
Fig. 1: Winding the flax preform produced under the FLOWER project (left) and
graphical representation of the fibre orientation in the preform (right)
N°147 September - October 2022 / jec composites magazine
45
Feature Automotive

JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022

Cover
Edito
Creating the interior of “The most beautiful building in the world”
Contents
NEWS
In brief
Agenda
Perspectives - Creating a forum to work together
Opening - New fibreglass factory in the heart of Central Asia
BUSINESS
Graphene - Effectiveness of graphene nano-platelets in composites
Carbon fibre - Sinopec intends to lead by example in China
Glass fibre - China promotes the use of glass fibre in construction
MANUFACTURING
Additive manufacturing - Towards a digital twin of UD tapes for automated fibre placement
Testing - Optical data rectification and ML-aided impedance analysis for quality assurance of carbon fibre
FEATURE AUTOMOTIVE: How are composites driving the future of automotive?
- Transportation - Thermoplastic composites: the path towards zero CO2 emissions in transport
- Compounding: Cutting-edge FDC technology reduces costs and CO2 emissions
- Pressure vessels: Enabling superior storage efficiency for Type 4 tanks with FPP dome reinforcements
- Battery: A new generation of battery packs with a recyclable epoxy SMC casing
- Lightweighting: Serial CFRTP structural part for BMW body-in-white application
- Natural fibre: Towards lightweight flax fibre-reinforced automotive headliners
SOLUTION
Sustainability - Upcycling gives a boost to coffee waste management
Defence - On field applications with composites
TECHNOLOGY
Ceramic: Cerapreg – a new concept for cost-effective reinforced ceramic composites
Index
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JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Cover
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 2
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Edito
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Creating the interior of “The most beautiful building in the world”
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 5
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Contents
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 7
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - In brief
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Agenda
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Perspectives - Creating a forum to work together
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Opening - New fibreglass factory in the heart of Central Asia
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 12
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 13
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Graphene - Effectiveness of graphene nano-platelets in composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 15
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 16
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Carbon fibre - Sinopec intends to lead by example in China
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 18
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 19
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Glass fibre - China promotes the use of glass fibre in construction
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 21
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 22
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Additive manufacturing - Towards a digital twin of UD tapes for automated fibre placement
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 24
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Testing - Optical data rectification and ML-aided impedance analysis for quality assurance of carbon fibre
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 26
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 27
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 28
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 29
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Transportation - Thermoplastic composites: the path towards zero CO2 emissions in transport
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 31
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Compounding: Cutting-edge FDC technology reduces costs and CO2 emissions
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 33
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 34
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Pressure vessels: Enabling superior storage efficiency for Type 4 tanks with FPP dome reinforcements
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Battery: A new generation of battery packs with a recyclable epoxy SMC casing
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 37
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 38
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 39
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Lightweighting: Serial CFRTP structural part for BMW body-in-white application
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 41
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 42
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 43
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 44
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - - Natural fibre: Towards lightweight flax fibre-reinforced automotive headliners
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 46
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 47
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Sustainability - Upcycling gives a boost to coffee waste management
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 49
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Defence - On field applications with composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 51
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Ceramic: Cerapreg – a new concept for cost-effective reinforced ceramic composites
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 53
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 55
JEC COMPOSITES MAGAZINE - Issue #147 - September/October 2022 - 56
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