Thermoformable automotive composites containing kenaf and other cellulosic fibers

Currently, there is a major upsurge in research on the use of recyclable and biodegradable materials in manufactured products. This has triggered a need for biodegradable nonwovens for nearly forty automotive interior components, which currently contain traditional materials such as glass and other manufactured fibers and foams that are difficult to recycle. By incorporating agricultural lignocellulosic (bast) fibers such as kenaf, jute, hemp, and flax in the manufacture of automotive nonwovens, their biodegradability can be enhanced. Because of the different densities of kenaf and glass fibers, kenaf-based nonwovens may be lighter than those containing glass fibers, which may lead to lightweight, green automotive interiors. Furthermore, preliminary research has shown that several cellulosic-based (kenaf, jute, and other less expensive vegetable bast fibers) nonwovens are efficient sound absorbers and reduce the noise level in cars. Overall, these nonwovens meet or exceed industry specifications of flammability, odor, mildew, bond strength, drapeability and tensile strength, elongation, and compression properties. In this paper, we briefly describe the fabrication and physical, mechanical, and acoustical properties of needlepunched thermoformable nonwoven fabrics for certain automotive interior applications. These nonwoven fabrics were developed using optimally retted kenaf and jute fibers in various blends with greige cotton, recycled polyester, and off-quality polypropylene. Successful use of kenaf fibers in automotive nonwovens would be environmentally benign and should lead to a considerable expansion in kenaf cultivation.