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Article history: Textile waste fiber-reinforced polymer matrix composites are usually reinforced with fiber, bands, fab-
Received 30 October 2020 rics, tows, woven and non-woven textiles, it is also possible to combine different types of materials in
Received in revised form 16 November 2020 one composition. Individual textile plies of a polymer matrix component can be reinforced. This is a rea-
Accepted 24 November 2020
son why the different textile waste are increasingly use it as a bio-based components in structural mate-
Available online 22 January 2021
rials like sandwich structure composites with multiple layers bound in a monolith by a polymer matrix
material. Also, hybrid sandwich structure composites can be manufactured, combining different textile
Keywords:
waste plies with carbon fiber and/or glass fiber reinforcement. Having in view that a cotton fibers (i.e.
Sandwich structure composites
Fiber-reinforced composites
denim or chambray weave) and bast fibers (i.e. jute, flax or hemp hessian fabric), as woven textile mate-
Polymer matrix rials, destined to the textile waste fiber-reinforced polymer matrix composites are highly mouldable,
Woven textile materials (denim fabric, lightweight and tough, several possibilities for industrial applications, sustainable material for architec-
hessian fabric bags) tural and consumer products along with other custom production make this bio-based products unique.
Textile waste In our research, polymer matrix based composite structures were studied by using different natural-
reinforcements from eco-friendly, breathable, biodegradable and recyclable post-industrial and post-
consumer waste (woven fabrics made of cotton fibers – like denim textile fabric and bast fibers – like jute
hessian fabric bags).
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 8th International Con-
ference on Advanced Materials and Structures - AMS 2020.
https://doi.org/10.1016/j.matpr.2020.11.927
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 8th International Conference on Advanced Materials and Structures - AMS 2020.
Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
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Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
In recent years, textile waste fiber-reinforced polymer matrix recycled cotton and jute derived fabrics [6–13]. While the rein-
composites have gained commercial success in different applica- forcement fibers or fabrics provide the primary strength for a lam-
tions [6–13]. In this sense, the composite industry can have various inate, the role of the resin, transferring that load to across an array
sources for their reinforcements in the post-industrial and post- of fibers, is also paramount to the overall strength and stability of a
consumer textile waste (mix of long and/or short, coarse and/or part. The properties of the composites can be considered as a com-
fine fibers, as well as threads and intact pieces of woven textile bination between the properties of the polymer matrix and recy-
material). Therefore, recycling of textiles is an issue that requires cled cotton and jute derived fabrics in addition to the properties
immediate attention in order to address the management of tex- of interfaces between the inserts and the matrix [6–13]. The pre-
tiles derived from household waste, as well as scraps generated impregnated reinforcement specimens (prepregs) were manufac-
throughout manufacturing textile processes [6–13]. The present tured using a simple hand lay-up moulding process. Prepregs are
study aimed to produce composites employing thermoset resins purchased with bi-directional fabric, already infused with the
reinforced with recycled cotton textile waste (denim knitted fab- resin, partially cured [6–13]. The final composites were manufac-
ric) and recycled hessian jute fabric. tured by compression moulding, most suitable for secondary struc-
The traditional denim is hard-wearing, high-density fabrics ture, using an original compression press.
with a high mass per unit area with a twill weave (denim) and
plain weave (chambray) construction (Fig. 3.a, Fig. 3.b). Denim is 3.1. Materials for matrix
a knitted fabric has certain special characteristics (comfortable,
fashionable, affordable and durable) that make it suitable for creat- Resin types come from a variety of chemical families, each type
ing a wide range of garments and accessories. Denim is a plain cot- designed to offer different advantages, such as economic perfor-
ton twill fabric, traditionally coloured in indigo blue, being a mance, structural or resistance to various factors [6–13]. For com-
lighter cotton textile, easily recognizable because of the noticeable posite laminates, there are three main types of resins used in the
diagonal weave or texture [6–13]. Chambray is a typically 100% production of both parts and moulds: polyester, vinyl ester, and
cotton plain-weave soft fabric made with a white weft and epoxy [6–13]. Epoxies are compatible with most composites man-
coloured warp (typically light blue in colour), characterised by ufacturing processes particularly compression moulding and hand
diagonal ridges in a weaving pattern. Chambray is often mistaken lay-up, the advantages being the excellent adhesion to reinforce-
for denim because of its similar weave: a blue warp and a white ments and the extremely low shrinkage. Also, the composite’s
weft woven together. While it may look like denim, chambray is strength can be increased (or decreased) by altering the proportion
lighter and is woven differently. It has a softer texture than denim of reinforcement and the layer’s number [6–13].
and is thinner in construction [6–13]. Applications with the highest mechanical strength/weight
Plain linen weave is the simplest of all weaves, having the sim- requirements use almost exclusively epoxy resins. They have
plest interlacing but it makes for a very strong and firm fabric excellent resistance, high surface hardness, high temperature resis-
because these interlacings are more frequent than for any other tance. Disadvantages include higher price and difficulties of use
one (Fig. 3.c). The advantage of this weave is that it is quite strong (the quantities of resin and hardener must be measured accurately,
and durable and produces very fine good quality fabrics. Hessian is often heat intake is needed for polymerization, etc.).
a rough, coarse, loosely woven natural fabric normally made from For the matrix, epoxy resin and its hardener were used (Fig. 4).
natural plant fibres (jute fibres). Hessian fabric is traditionally used Mixing the resin and hardener together prompts a chemical reac-
to make bags for store and transport all types of materials, such as tion between the two components, transforming them from a liq-
industrial goods and nearly all types of raw agricultural products. uid into a solid state. Measuring accurately and mixing thoroughly
Today, the hessian fabrics are used in a variety of applications, is essential to making sure the resin cures properly. For the prepa-
for use in all type of industries, including agriculture, construction, ration of each type of composite the base resin was dosed in an
transportation, upholstery, and even for making clothing [6–13]. appropriate container and the corresponding proportion of hard-
ener was added to it. The resin matrix keeps all the material bound
and transfers the mechanical loads through the reinforcement
3. Materials and methods fibres to the rest of the structure. In addition, resin protects the
composite from impact, abrasion, corrosion, environmental factors
In order to find possibilities of recycling, the present study and careless handling [6–13]. Therefore, the resin holds the rein-
aimed to produce composites employing thermoset resins (epoxy) forcement fabrics together while helping it conform to the desired
reinforced with recycled woven textile materials (denim fabric and shape. Without a hardened resin to provide shape, reinforcement
hessian fabric bags). Their possibilities for manufacturing using fabrics are shapeless and can easily be separated. The mixing ratio
compression moulding were evaluated [6–13]. The preliminary has to be very precise, otherwise the epoxy resin will not harden or
results presented here belong to the manufacturing of vegetal it will not work optimally. The components are weighed or dosed
woven fabric reinforced composites with resin as the matrix and volumetrically in the proportions indicated by the manufacturer
Fig. 3. Weaving techniques and fabric types. (a) denim, plain cotton twill fabric; (b) chambray, cotton plain-weave soft fabric; (c) hessian fabrics, plain linen weave.
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Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
Fig. 4. The epoxy resin and its hardener. (a) preparing the resin components, (b) mixing the components (c) final mixing, before the lay-up process.
in the documentation. Weighed each component in a clean con- chrome plated for enhanced durability. The moulds are heated
tainer with straight walls and bottoms so that it could shave the using steam, hot oil, or electricity.
material well when mixing. Mix the resin and hardener until In wet (liquid) lay-up compression moulding there are the fol-
smooth (Fig. 4). lowing considerations must be analysed:
3.2. Materials for inserts - determining the nature of materials used for reinforcements
(unidirectional tapes, woven fabrics, randomly oriented fiber
The armature provides the structural performance required for mat or chopped strand);
the finished piece, and have several structural forms contributing - determining the nature of materials used for matrix (polyester,
fundamentally to the properties of the composite (rigidity, vinyl ester or epoxy resin);
strength, etc.). The textile inserts used as reinforcement are ecolog- - determining the proper amount of material which will be used
ical, non-toxic and biodegradable and they contain bast fibres (flax, in the lay-up process.
hemp, jute, divided or in combination) or cotton fibres (derived
from denim materials), which can replace glass and/or carbon rein- Compression moulding is a high-volume and high-pressure
forcements commonly used in these polymeric composites. The method suitable for moulding various reinforced polymer compos-
fabric samples resulting from the recovery of textile waste, which ites, featuring fast moulding cycles and high part uniformity. In
serve to obtain nonwoven products, are used in the form of fibrous fact, this method is a manufacturing process in which composite
layers. These are textile supports, consist of fiber-oriented agglom- materials are sandwiched between a pair of heated plated or
erations or multidirectional [11–18]. Practically, all types of fibre, curved moulds (mounted in large hydraulic presses) under intense
including fibres recovered from reusable materials, can be used pressure and heat (from 120 °C to 200 °C) until the curing process
as starting materials for technical textiles [11–18]. (less than a minute to about five minutes, depending on thickness,
Two different recycled textile wastes were investigated in the size and shape of the composites).
present study: denim fabric and hessian fabric bags (Fig. 5). These The process parameters includes moulding time, temperature,
recycled textile wastes were produced by cutting for fabric-resin and pressure. The process can be automated, this technique being
composite fabrications (Fig. 6). used to rapidly cure large quantities of simple or complex rein-
forced polymer composites. In addition, the manufacturing costs
are relative low and it provides design flexibility and good surface
4. Experimental setup finishes are obtainable. Subsequent trimming and machining oper-
ations are minimized in this method.
The textiles are prepared separately and are incorporated into In compression moulding there are the following considerations
the matrix by simple lay-up process, the synthetic resin matrices need to be correlated:
being applied in alternating layers of textile layers (Fig. 7 and
Fig. 8). The process is completed by a compression moulding in - determining the proper amount of material which will be com-
an experimental press, designed specifically for laboratory experi- pressed into the mould;
ments, in Faculty of Engineering Hunedoara (Fig. 7 and Fig. 9). - determining the appropriate heating technique and a proper
Wet lay-up compression moulding (Fig. 8), also called liquid temperature range to heat the material;
lay-up compression moulding, is a composites moulding process - determining the minimum time required to heat the material;
where the resin is applied on the fabric layers and compressed - determining the required pressure, to ensure the total compres-
between two heated steel moulds (plate, single or multiple- sion and the proper shape.
cavity configurations). Steel moulds are hardened and sometimes
Fig. 5. Recyclable textile wastes. (a) denim fabric; (b) hessian fabric bags.
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Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
Fig. 6. Textile fabric reinforcement samples. (a) denim fabric samples; (b) hessian fabric bags samples.
Fig. 7. The experimental setup (schematic). (a) the simple lay-up process components; (b) the compression moulding.
Fig. 8. The wet lay-up process. (a) alternating first textile layers; (b) applying the resin matrix; (c) alternating the next textile layers; (d) applying the resin matrix, again;
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Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
- Step 2, consisting of pre-heating of the layers without applying research arises from our interest on making an effort to reuse the
any load (the textile insert was put inside and upper platen was denim scrap and used jute fabrics to manufacture a different kind
closed quickly), above the melting point of the thermoplastic of composite product. These composites are formed from densely-
matrix (pre-heating process); packed layers of fabric suspended in thermosetting plastic (resin or
- Step 3, consisting of consolidation of resin between the rein- epoxy), using our own installation for compression of the studied
forced textile layers (the curing process), under loading and composites
heating the press; Following the analyses carried out, the research on the develop-
- Step 4, consisting of cooling of the final formed composite, ment of competitive technologies for processing textile waste into
under loading and cooling the press (the cooling process). products with high added value (such as composite materials)
proves to be feasible and fully justified. With a knowledge of the
In fact, the manufacturing processes involved the impregnation various factors and influences discussed above, product prototypes
of fibers with resin, consolidation to remove excess resin and solid- can be produced from different material configurations, using dif-
ification of polymer in the required shape. The obtained composite fering forming speeds, mould temperatures, blank clamping meth-
(laminates) have a sandwich structure with separate layers bound ods and tooling arrangements. Offering a combination of high
in a monolith by a matrix material. Plates made of fabric- strength-to-weight ratio, chemical resistance and relatively
reinforced polymer matrix composites (Fig. 11) can be processed straightforward processing, these composites, in general, are grow-
with conventional machining methods. ing in popularity across a number of sectors where light weighting
and short cycle times are key targets.
Reduced weight, along with their enormous availability, make
6. Conclusions the recycled fabrics, such as denim jeans, promising substitutes
for e-glass or carbon fibres. The reason for this replacement lies
A major direction of research concerns the development of in their easier recyclability and in their possible coupling with var-
environmentally friendly technologies and materials, with a focus ious polymers, with the idea of producing new composites, as tex-
on the design and complete characterization of composite materi- tile reinforcements. In particular, the success of fabric for
als obtained from recycled waste. The unique properties of poly- composite’s component production is likely to be eased by the pos-
mer composite materials with textile inserts, as well as the sible improvements in mats and/or fabrics fabrication, which will
possibility of adapting them to the application needs, have led to have a further positive effect on properties of the new reinforced
the expansion of their use in all areas of human activity. From an materials. The moulding equipments used for manufacturing
applicative point of view, this direction is an extremely interesting fabric-reinforced polymer matrix composites using bio-based com-
one, the materials and technologies developed can be used in dif- ponents from post-consumer textile waste are relatively cheaper
ferent areas of interest. The results achieved so far in the field of as there is no need to rise till very high temperature and pressure.
obtaining composite materials obtained through waste recycling Most household textiles and clothing can be recycled, regard-
and environmentally friendly technologies together with the gen- less of quality and wear. Denim materials are the most used cloth-
erous research opportunities offered by these topics has led us to ing in the world, and they are elaborated by one of the most
continue and develop them. The novelty of the present study lies commonly used natural textile fibers—cotton. The use of waste or
in exploring the combination of naturally available woven fabrics recycled materials for creation of the new raw materials for the
and polymer matrix combination. composite manufacturing is a topical issue, with a promising
Based on these preliminary findings and the inherent attributes future. Also, the composites are a growing and innovative industry
of denim and jute fabrics, we use these materials to design new and the global demand for composites is accelerating across all key
products. The results of the whole process yield a first approach sectors thanks to the unique properties and benefits they offer. In
to configure future experiments using combinations of denim fact, the fiber-reinforced composites growth is the subject of sev-
scrap and used jute fabrics with polymers in order to use them eral exciting technology innovations in all areas, in diverse applica-
in new product development. The growing interest of use different tions. Besides a favourable life cycle analysis, research and
scraps as raw material to design and develop alternate products development of bio-based products like denim fabric and hessian
has led them to new ways of processing them. The present fabric bags should consider the limits that will maintain sustain-
Fig. 10. The main steps in the compression moulding process of woven fabrics composites. (a) heating of the moulds; (b) preheating; (c) consolidation of resin between the
layers; (d) cooling of the composite.
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Mihai-Paul Todor, I. Kiss and Vasile George Cioata Materials Today: Proceedings 45 (2021) 4150–4156
Fig. 11. Plates made of fabric-reinforced polymer matrix composites (prototypes). (a) denim-reinforced polymer matrix composites; (b) jute fabric-reinforced polymer
matrix composites.
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