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17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

Development of PLA hybrid yarns for biobased self-

reinforced polymer composites

T Köhler1, T Gries1 and G Seide12

1
RWTH Aachen University, Institut für Textiltechnik (ITA), Otto-Blumenthal-Str. 1,
52074 Aachen, Germany
2
Maastricht Univ, Maastricht Sci Programme, NL-6200 MD Maastricht, Netherlands

Email: [email protected]

Abstract. Lightweight materials are a necessity in various industries. Lightweight design is in

the key interest of the mobility sector, e.g. the automotive and aerospace industry. This trend
applies also for the consumer industries, e.g. sporting goods. In addition, the worldwide
demand for replacing fossil-based materials has led to a significant growth of bioplastics. Due
to their low mechanical performance and durability, their use is still limited. Therefore, it is
necessary to develop biobased, sustainable polymeric materials with high stiffness, high impact
and high durability without impairing recyclability at a similar price level of non-biobased
solutions. Biobased self-reinforced polymer composites offer these unique properties.

1. Introduction
In general, fibre reinforced composites consist of at least two different materials. A reinforcing
material is embedded in a polymeric matrix material. Usually glass or carbon fibres are being used as
the reinforcement material. These fibres carry the loads applied to the composites. The matrix mainly
holds the reinforcing fibres in place and protects them from environmental conditions. Adding
reinforcing fibres cause an increase in mechanical properties of the matrix phase. As a result, fibre
reinforced composites combine the advantage of high mechanical properties (strength and stiffness)
with low weight compared to metals such as steel or aluminium. [1]

Self-reinforced polymer composites (SRPCs) are a special type of composite. In SRPCs the same
polymer is used for the reinforcing and the matrix phase [2]. Capiati and Porter introduced the concept
already in 1975 [3]. Due to the use of a thermoplastic reinforcing fibre, SRPCs combine high impact
and high durability. The density of SRPCs is lower compared to for example glass fibre reinforced
composites. The recyclability of such composites is also increased by using the same polymer type as
reinforcing and matrix material [4].

Self-reinforcing a polymer with fibres of the same polymer type results in an increase of the
following material properties:
 strength,
 stiffness,
 durability,
 and impact behaviour [5].

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17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

The most significant improvement is observed for the impact behaviour [5]. SRPCs also offer
superior fibre-matrix-adhesion compared to traditionally fibre filled polymers as fibre and matrix are
made of the same material. The high chemical similarity leads to a strong composite as well as to a
high nucleation density for the transcrystallization of the fibres into the matrix. The mechanical
properties are strongly affected by the fibre-matrix-adhesion. Poor fibre matrix adhesion leads to
peeling, cracking and reinforcement fibre pull-out. [5]

Using thermoplastic reinforcing fibres for self-reinforced composites also introduces some
disadvantages. The main problem is the dependency of the reinforcing fibre’s mechanical properties
on temperature. Therefore, the processing window for consolidation is limited. It has to be precisely
controlled in order to receive the best mechanical properties. The small processing window
(consolidation temperature and cycle time) is the major challenge for producing SRPCs.

In order to reduce the cycle time and therefore heat exposure, hybrid yarns with short melt flow
paths can be used. The reinforcing fibres as well as the matrix fibres are mixed on a filament level
during the Commingling process. The use of commingled yarns allows the combination of a large
variety of fibres and therefore a wide range of material properties. The melt flow paths of the matrix
material are considerably lower compared to the Film-Stacking process [6]. COMFIL ApS, Gjern,
Denmark currently produces SRPCs in form of high-tenacity PET mixed with low melting PET in
form of yarn, fabrics, consolidated plates and rods/tapes. Self-reinforced Polypropylene (PP) is also
available [7]. The production process of SRPCs using commingled yarns is illustrated in Figure 1.

Fibres made from Molten Self-reinforced

matrix material Matrix material composite
Commingling

Reinforcing
fibres
Figure 1. Consolidation process of commingled yarn based production process for SRPCs

2. Experimental
The material provided for the development of self-reinforced PLA is procured directly in filament yarn
form as part of the EU project BIO4SELF [8]. Two project partners are developing the fibres in their
research facilities. The reinforcing fibres (High Tm) are provided by by Centexbel, the Belgian
research centre for textiles and plastics, Gent, Belgium. The matrix filaments (Low Tm) have been
acquired from the AMIBM Aachen-Maastricht Institute for Biobased Materials, Maastricht,
Netherlands.

Both multifilament yarns (reinforcing and matrix fibres) are mixed using a modular commingling
machine at ITA. A mixing ratio of 50:50 is chosen. The filament yarns are delivered separately and
commingled inside a mixing box using an air jet nozzle. Compressed air is used to open and to
intermingle the fibres. This results in the production of a hybrid yarn. The turbulences causing the
mixing are controlled by increasing or decreasing the air pressure. The amount of filament breaks as
well as production costs rise with increasing air pressures. Both multifilament yarns can be overfed.
This influences the quality of the yarn (fibre distribution and orientation). The overfeeding is caused
by the relative speed between the delivery godets and the take-off godet. In addition, the production

2
17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

speed constitutes a relevant process parameter for the hybrid yarn quality as well as production costs.
The production process is shown in Figure 2. The production speed, pressure and overfeeding rate are
varied during the commingling trials to identify a parameter set that offers best properties for the
commingled yarn.

Take-off godet Air jet nozzle

Mixing box Spreading bars

Delivery
Direction of production

godets*

40 cm

Commingled yarn

Matrix fibres
Commingled *Heating possible
yarn Reinforcing fibres
Figure 2. The commingling process

3. Results
The reinforcing fibres and matrix fibres used in this paper are characterised regarding their thermal
and mechanical properties. Differential Scanning Calorimetry (DSC) from Mettler-Toledo GmbH,
Greifensee, Switzerland has been used to analyse the melting temperature of the fibres. It was not
possible to determine the melting temperature of the low melting PLA. Therefore, the melting
temperature from the data sheet is given. The yarn count of the fibres is tested according to DIN EN
ISO 2060. The tensile strength is analysed according to DIN EN ISO 2062 using a STATIMAT 4U
from Textechno, Herbert Stein GmbH & Co. KG Textile Mess- und Prüftechnik, Mönchengladbach,
Germany. The relevant fibre characteristics are presented in Table 1.

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17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

Table 1. Materials used for the experiments

Low Tm PLA High Tm PLA
SRPC phase Matrix phase Reinforcing phase
Ingeo™ Biopolymer
PLA grade PURAPOL L130
6302D
PLA manufacturer Nature Works Corbion
Yarn count Tt [dtex] 211,87 ± 0,64 248,52 ± 3,17
Tensile strength σt [cN/tex] 10,22 ± 2,15 30,09 ± 2,84
Melting temperature Tm [°C] 125 - 135 176,99
Filaments produced by AMIBM Centexbel

The development of the hybrid yarns is successful. Reinforcing fibres and matrix fibres are doubled
prior to the Commingling process in order to increase the yarn count of the hybrid yarn. In total 54
different parameter combinations are investigated. The first analysis of the hybrid yarns is a visual
examination. The hybrid yarns are graded regarding the intermingling as well as the yarn structure
(ondulation). The matrix fibres are coloured to ease the evaluation. An exemplary image of the hybrid
yarns is displayed in Figure 3.

5 cm
Figure 3. PLA-PLA hybrid yarns

The yarn count of the fibres is characterised according to DIN EN ISO 2060. The tensile strength is
analysed according to DIN EN ISO 2062 using a STATIMAT 4U from Textechno, Herbert Stein
GmbH & Co. KG Textile Mess- und Prüftechnik, Mönchengladbach, Germany. Three well performing
hybrid yarns are chosen for UD-composite production. The production of UD-composites is possible.
The manufacturing parameters and material properties of these hybrid yarns are displayed in Table 2.

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17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

Table 2. Manufacturing parameters and material properties of hybrid yarns

A B C
Pressure p [bar] 6 6 6
Manufacturing speed v [m/min] 150 200 200
Difference of overfeeding rate between
0,5 0,5 2
fibres ΔORrf/mf [%]
Yarn count Tt [dtex] 2070,71 ± 13,25 2070,10 ± 8,52 2079,81 ± 11,74
Tensile strength σt [cN/tex] 12,83 ± 0,97 12,33 ± 1,30 11,92 ± 1,38

4. Discussion
High production speeds during the commingling process can be used to produce hybrid yarns. The
best mechanical properties of the three processing parameter sets displayed in Tab. 3 are received at
low overfeeding rates (0.5 %) at a processing speed of 150 m/min. However, higher production speeds
(200 m/min) do not lead to a significant loss in tensile strength. The impact of an overfeeding ratio of
2 %, between reinforcing and matrix fibre, also does not reduce the tensile strength of the hybrid yarn
significantly.
A differentiation between the commingled yarns is difficult. Therefore, the production of UD
composites from the hybrid yarns is required. The production of such composites is possible. The
SRPCs are currently being tested according to DIN EN ISO 527-5. Previous results indicate high
quality PLA SRPCs [9].

5. Conclusion and Outlook

The research conducted demonstrates the possibility to produce hybrid yarns for biobased SRPCs.
Current research is conducted on the production of UD-composites to further investigate the quality of
hybrid yarns. The next research step includes the evaluation of different mixing ratios of reinforcing
and matrix fibres. In addition, the production of fabrics is investigated. The fabrics will also be
consolidated and tested as well. The effect of the processing window of the consolidation process on
the mechanical properties of the SRPC is going to be analysed. Further improvements on the material
side may include adding nanofillers in order to increase mechanical properties. Additional research has
to be conducted regarding the environmental impact of the biobased SRPCs.

Acknowledgments
The research leading to these results has received funding by the H2020 Funding Programme of the
European Union under grant agreement n°685614. The BIO4SELF consortium consists of the 15
actual partners (with an EC budget) and further a group of 9 partners who expressed their support to
the consortium via a Letter of Support. The latter group forms the so-called Innovation Support Group
or ISG. The material used for this paper has been provided by Centexbel, the Belgian research centre
for textiles and plastics, Gent, Belgium as well as the AMIBM Aachen-Maastricht Institute for
Biobased Materials, Maastricht, Netherlands. We thank our partner COMFIL ApS, Gjern, Denmark
who provided insight and expertise.

References
[1] Neitzel M, Mitschang P and Breuer U 2014 Handbuch Verbundwerkstoffe - Werkstoffe,
Verarbeitung, Anwendung (München: Carl Hanser Verlag) pp 1-27
[2] Kmetty Á, Bárány T and Karger-Kocsis J 2010 Self-reionforced polymeric materials: A review
Proress in Polymer Science 35 pp 1288-1310
[3] Capiati N and Porter R 1975 The concept of one polymer composites modelled with high
density polyethylene Journal of Materials Science 10 pp 1671-1677

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17th World Textile Conference AUTEX 2017- Textiles - Shaping the Future IOP Publishing
IOP Conf. Series: Materials Science and Engineering 254 (2017) 042016 doi:10.1088/1757-899X/254/4/042016
1234567890

[4] Karger-Kocsis J and Siengchin S. 2014 Single-Polymer Composites - Concepts, Realization and
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Eigenschaften (Berlin: Springer-Verlag) pp 32-33
[7] COMFIL ApS, Gjern, Denmark 2017 http://www.comfil.biz/srp, accessed 20.03.2017.
[8] Project BIO4SELF 2017 http://www.bio4self.eu, accessed 20.03.2017
[9] Ramaswamy S, Popzyk M.-I. and Gries T 2015 Development of biobased self-reinforced
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Institut für Textiltechnik der RWTH Aachen University pp 1-112