Researchers at Baylor University have developed a simple and inexpensive process to manufacture automotive parts from coconut husks — an abundant, renewable resource in many developing countries located at or near the Equator. The technology uses coconut fiber to replace synthetic polyester fibers in compression-molded composites, which can be fabricated into trunk liners, floorboards, and interior door covers. The mechanical properties of coconut fibers are equal to or better than those of synthetic and polyester fibers when used in automotive parts, according to Walter Bradley, PhD, distinguished professor of engineering at Baylor, and coconuts don’t burn easily or emit toxic fumes — characteristics that are crucial for commercial automotive parts. Automotive parts using the coconut fiber are undergoing tests to ensure the fiber meets safety performance specifications, and Bradley hopes to have the coconut car parts in use by this summer.

While the Baylor team awaits approval of its patent application, the group has partnered with Waco, TX-based Hobbs Bonded Fibers, which supplies unwoven fiber mats to four major automotive companies, to begin developing commercial automotive applications. Along with the royalty revenue it hopes to generate, Baylor hopes to triple the annual income of the world’s 11 million coconut farmers by increasing the market price for each coconut to 30 cents. That price would still make the composites cheaper than petroleum-based fibers currently used by automotive suppliers, which cost about 60 cents per pound. Bradley sees a potential market for 300 million pounds of coconut castoffs every year, noting that Mercedes-Benz already uses natural fibers, including coconut fibers, in the interiors of some models.

Go to: Waco Tribune-Herald

Posted January 14th, 2009 under Innovation of the Week, Tech Transfer

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