ORNL is managed by UT-Battelle for the US Department of Energy

NanocelluloseReinforced Polymers

Cliff EberleSoydan OzcanOak Ridge National Laboratory

Presented at Cellulosic Nanomaterials Workshop

Washington, DC21 May 2014

ORNL is DOE’s largest science and energy laboratory

$1.6B budget

World’s most intense

neutronsource

4,400employees

World-class research reactor

3,000researchguests annually

$500M modernization

investment

Nation’s largest

materials research portfolio

Most powerful open

scientific computing

facility

Nation’s most diverse

energy portfolio

Managing billion-dollar U.S. ITER

project

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40% of US Energy Demand Uses Oil….

Source: 2012 Transportation Energy Data Book

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.…2/3 Being Used for Transportation

Source: 2012 Transportation Energy Data Book

Vehicle lightweighting with composites can potentially reduce US transportation petroleum demand by 2 – 3 Mbpd

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Nanocellulose Has Interesting Properties

Material Density Tensile Strength

Tensile Modulus Cost

g/cc MPa GPa $/kgHi Strength Steel 7.9 600 210 ~1Aluminum 6061-T6 2.7 275 70 ~2E-glass fiber 2.5 3,500 80 ~2Carbon fiber 1.8 4,000 230 >20Cellulosic Nanocrystals* 1.5 7,500 135 4-10

Cellulosic nanomaterials are potentially useful as either primary or secondary reinforcements in polymer matrix composites

*Source: Ted Wegner, seminar at Oak Ridge National Laboratory, Nov 2012

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Functional Attributes• Piezoelectric constant similar to that of quartz

– Sensing, dynamic shape control

• Forms nematic liquid crystal phase yielding control over optical properties– In-molded color, transparency

• NCC exhibits excellent, tailorable barrier properties• Magnetically responsive• Aerogel/ foam capable, highest surface area among

cellulosic aerogels• Can be made highly hydrophobic or hydrophilic• Can be generated by bacteria including certain algae

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Challenges: Strength Translation

Sources: (1) Henning and Gleich, Composites Tutorial at

SPE Automotive Composites Conference and Exposition, Troy MI Sept 2012

(2) Ted Wegner, seminar delivered at Oak Ridge National Laboratory, Nov 2012

CNC aspect ratio limits strength translation in composite

Proprietary Atmospheric Plasma Technique

Surface has to be engineered to achieve good dispersion and bonding to matrix

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Challenges: Stability

• For the automotive environment:– Thermal: E-coat process can be 200C for up to an hour– Must maintain dimensional stability, structural integrity,

and appearance for 15 years in• Desert heat and arctic cold• UV exposure – intense sunlight• Wet and humid conditions, including summer heat (hot-wet)• Chemical exposures – fuel spills, hydraulic fluids, acids, etc.• Mild impacts (insects, pebbles, etc)

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Challenges: Qualification

• Aircraft– Limited/incremental material qualification can cost > $1M– Material or process changes require requalification– Cost of a revolutionary platform qualification program

(e.g., Boeing 787) can approach $100M

• Automotive– Qualification requirements less regulated– Combination of liability and large volumes drives risk– Extreme penalties for suppliers that fail to deliver

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Challenges: Timing• Insertion into aircraft and automotive programs is

excruciatingly slow– Major aircraft programs can require well over a decade

from concept to full production (see 787 timeline below)– 2018 automotive platform design decisions are being

made NOW– Automotive production schedules WILL NOT be delayed

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Steel

Challenges: Scale –“The Million Ton Question”

Aluminum

Automobiles

E-glass fibers

AircraftCarbon fibers

Annual global production tonnage is proportional to area shown

1M tpy

How to manage cost and start small but grow big?

Potential automotive composite content

Potential nano-cellulose content

Sources: WorldSteel Association; International Aluminum Institute; Owens Corning; Chris Red, Carbon Fibers 2012; 2012 Transportation Energy Data Book

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Key Drivers for Deployment

• Aircraft – operational efficiency and passenger comfort

• Freight- increased payload• Automotive – fuel economy, emissions regulations,

safety and reliability• Buildings, infrastructure, etc – energy efficiency,

enhanced functionality

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Summing it up

• Cellulosic nanomaterials potentially offer a unique and wonderful combination of properties and cost as a polymer reinforcement

• High volume, cost-sensitive markets are likely to be good cellulosic nanomaterials applications

• The road to commercial deployment is long and difficult

• There are markets that will reward those who stay the course