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This study describes the production of a new biobased epoxy thermoset and its use with long hemp fibres to produce high-performance composites that are totally biobased. The synthesis of BioIgenox, an epoxy resin derived from a lignin biorefinery, and its curing process have been optimised to decrease their environmental impact. The main objective of this study is to characterise the rheology and kinetics of the epoxy system with a view to optimising the composite manufacturing process. Thus, the epoxy resin/hardener system was chosen considering the constraints imposed by the implementation of composites reinforced with plant fibres. The viscosity of the chosen mixture shows the compatibility of the formulation with the traditional implementation processes of the composites. In addition, unlike BPA—a precursor of diglycidyl ether of bisphenol A (DGEBA) epoxy resin—BioIgenox and its precursor do not have endocrine disrupting activities. The neat polymer and its unidirectional hemp fibre composite are characterised using three-point bending tests. Results measured for the fully biobased epoxy polymer show a bending modulus, a bending strength, a maximum strain at failure and a Tg of, respectively, 3.1 GPa, 55 MPa, 1.82% and 120 °C. These values are slightly weaker than those of the DGEBA-based epoxy material. It was also observed that the incorporation of fibres into the fully biobased epoxy system induces a decrease in the damping peak and a shift towards higher temperatures. These results point out the effective stress transfers between the hemp fibres and the fully biobased epoxy system. The high mechanical properties and softening temperature measured in this work with a fully biobased epoxy system make this type of composite a very promising sustainable material for transport and lightweight engineering applications. [ABSTRACT FROM AUTHOR]

To address the weight, cost, and sustainability associated with fibreglass application in structural composites, plant fibres serve as an alternative to reduce and replace the usage of glass fibres. However, there remains a gap in the comprehensive research on plant fibre composites, particularly in their durability for viable structural applications. This research investigates the fatigue and impact properties of pultruded kenaf/glass-reinforced hybrid polyester composites tailored for structural applications. Utilising kenaf fibres in mat form, unidirectional E-glass fibre direct roving yarns, and unsaturated polyester resin as key constituents, pultruded kenaf/glass hybrid profiles were fabricated. The study reveals that pultruded WK/UG alternate specimens exhibit commendable fatigue properties (18,630 cycles at 60% ultimate tensile strength, UTS) and fracture energy (261.3 kJ/m2), showcasing promise for moderate load structural applications. Notably, the pultruded 3 WK/UG/3WK variant emerges as a viable contender for low-load structural tasks recorded satisfactory fatigue properties (10,730 cycles at 60% UTS) and fracture energy (167.09 kJ/m2). Fatigue failure modes indicate that the stress applied is evenly distributed. Ductile failures and delaminations during impact test can be attributed to damping and energy absorbing properties of kenaf fibres. Moreover, incorporating kenaf as a hybrid alternative demonstrates substantial reductions in cost (35.7–50%) and weight (9.6–19.1%). This research establishes a foundation for advancing sustainable and efficient structural materials and highlights the significant role of materials design in shaping the future of engineering applications. [ABSTRACT FROM AUTHOR]

This study describes the production of a new biobased epoxy thermoset and its use with long hemp fibres to produce high-performance composites that are totally biobased. The synthesis of BioIgenox, an epoxy resin derived from a lignin biorefinery, and its curing process have been optimised to decrease their environmental impact. The main objective of this study is to characterise the rheology and kinetics of the epoxy system with a view to optimising the composite manufacturing process. Thus, the epoxy resin/hardener system was chosen considering the constraints imposed by the implementation of composites reinforced with plant fibres. The viscosity of the chosen mixture shows the compatibility of the formulation with the traditional implementation processes of the composites. In addition, unlike BPA—a precursor of diglycidyl ether of bisphenol A (DGEBA) epoxy resin—BioIgenox and its precursor do not have endocrine disrupting activities. The neat polymer and its unidirectional hemp fibre composite are characterised using three-point bending tests. Results measured for the fully biobased epoxy polymer show a bending modulus, a bending strength, a maximum strain at failure and a Tg of, respectively, 3.1 GPa, 55 MPa, 1.82% and 120 °C. These values are slightly weaker than those of the DGEBA-based epoxy material. It was also observed that the incorporation of fibres into the fully biobased epoxy system induces a decrease in the damping peak and a shift towards higher temperatures. These results point out the effective stress transfers between the hemp fibres and the fully biobased epoxy system. The high mechanical properties and softening temperature measured in this work with a fully biobased epoxy system make this type of composite a very promising sustainable material for transport and lightweight engineering applications.

To address the weight, cost, and sustainability associated with fibreglass application in structural composites, plant fibres serve as an alternative to reduce and replace the usage of glass fibres. However, there remains a gap in the comprehensive research on plant fibre composites, particularly in their durability for viable structural applications. This research investigates the fatigue and impact properties of pultruded kenaf/glass-reinforced hybrid polyester composites tailored for structural applications. Utilising kenaf fibres in mat form, unidirectional E-glass fibre direct roving yarns, and unsaturated polyester resin as key constituents, pultruded kenaf/glass hybrid profiles were fabricated. The study reveals that pultruded WK/UG alternate specimens exhibit commendable fatigue properties (18,630 cycles at 60% ultimate tensile strength, UTS) and fracture energy (261.3 kJ/m2), showcasing promise for moderate load structural applications. Notably, the pultruded 3 WK/UG/3WK variant emerges as a viable contender for low-load structural tasks recorded satisfactory fatigue properties (10,730 cycles at 60% UTS) and fracture energy (167.09 kJ/m2). Fatigue failure modes indicate that the stress applied is evenly distributed. Ductile failures and delaminations during impact test can be attributed to damping and energy absorbing properties of kenaf fibres. Moreover, incorporating kenaf as a hybrid alternative demonstrates substantial reductions in cost (35.7–50%) and weight (9.6–19.1%). This research establishes a foundation for advancing sustainable and efficient structural materials and highlights the significant role of materials design in shaping the future of engineering applications.