SBIR-STTR Award

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. This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).

This Small Business Innovation Research (SBIR) Phase II project will resolve the technical issues associated with scaling up the manufacturing of non-woven fabric composites made from a blend of coir fiber (from coconut husks) and recycled polypropylene. Final product variability due to the coir fiber itself, the milling of coir fiber from coconut husks, and the manufacturing process to make the felted composite, will be minimized. The variability of the coir fiber feedstock will be determined, along with the resulting variation of the composite's flexural stiffness. The most cost-effective production process to produce consistently clean, 2-3" long fibers in-country from husks will be defined. Finally, the manufacturing processes required to produce these coir fiber composites with the required consistency for automotive applications will be developed. This project will include continuous input from a major automotive manufacturer as well as an automotive parts maker. This research will result in an improved readiness of a polypropylene/coconut fiber based non-woven fabric composite that meets industry certifications for use in automobile trunk liners, and which is greener, less expensive, and better performing than current all-synthetic parts. The broader/commercial impact of this project will take many forms. The total market for automotive non-woven fabric composites is 300 million kg/year. Each vehicle platform that adopts this technology will require 2 million kg/year just for the trunk liners. Replacing synthetic fiber with coconut fiber makes parts more environmentally friendly while utilizing a waste material. Petroleum consumption can be reduced 2-4 million barrels per year and CO2 emissions reduced by 450,000 tons per year by replacing polyester fibers with coir in automotive interior composites. Additionally, the improved performance and lower weight of these materials will lead to cost savings through increased fuel economy, saving up to 3 million gallons of gasoline per year in the U.S. Finally, this project will lead to great economic opportunities for poor coconut farmers and to a very positive environmental impact. Ninety-five percent of the 50 billion coconuts grown worldwide are owned by 10 million coconut farmers whose average income is less than $2/day. Approximately 85% of the coconut husks are currently disposed of as trash, creating pollution. The successful adoption of these materials would create a market for this material, in many cases doubling the annual income for these farmers