Nature inspired developments with fiber based materials

IFAI, Dallas, USA October 15-18 2018 – Thomas Stegmaier, Götz Gresser

German Institutes of Textile and Fiber Research

• Europe‘s largest textile research center

• Founded in 1921, foundation under public law

• 3 research centers, 1 production company (ITVP)

• Application oriented research from molecule to product on 25,000 m2

• Research with industrial pilot facilities, focus on technical textiles and life sciences

• Connected to University of Stuttgart and Reutlingen University by 3 chairs and 2 professorships

2

German Institutes of Textile and Fiber Research

• Employees: approx. 300

• Turnover: approx. 27 Mio. € (12 Mio. € public, 15 Mio. € industry)

• Industry: 31% Baden-Württemberg

(without ITVP) 51% national

18% international

49% small and medium-sized enterprises

Application oriented research from molecule to product

Key figures 2017

3

German Institutes of Textile and Fiber Research

4

Architecture and Construction

Health and Care

Mobility

Energy and Environment

Production Technologies

Clothing and Home Textiles

Research fields Application fields

High Performance

Fibers and Yarns

Functionalized

Textiles and

Finishing

Lightweight Design

and Fiber

Composites

Medical

Technologies

Smart Textiles

Textile 4.0

Content

6. Oktober 2018 PD Dr. Thomas Stegmaier

Definitions, basics of Bionics

Bionic networks

Textile materials

Self cleaning textile surfaces

- certified textiles „inspired by nature“

Aerosol separation

- fog harvesting

Hydrodynamic potentials

- not wetting, reduction of friction

Oleodynamics

- easy handling of oil

Solar thermal energy

- polar bear: archetype for flexible solar collectors

Bionics / Biomimetics combines biology and technology with the goal of solving technical problems by means

of abstraction, transfer and application of knowledge of biological research, and merges life sciences with

technical disciplines.

(BIOKON international)

Definition of Bionics / Biomimetic

6. Oktober 2018 PD Dr. Thomas Stegmaier

Bionics / Biomimetic

6. Oktober 2018 PD Dr. Thomas Stegmaier

Biology and Technics =

Bionics

first Jack E. Steel 1960 used

English spoken countries:

Biology and mimesis =

mimesis (griechisch): mimik

Bionics: Transfer of knowledge from biology to technical

applications

• Learning from principles in biological constructions in the creation

• Identification of functional mechanism

• Engineering in transfer into technical feasibles

• no direct transfer, but creative thinking

What is Bionics / Biomimetics?

6. Oktober 2018 PD Dr. Thomas Stegmaier

Market Pull (Top down Prozess in Bionics)

6. Oktober 2018 PD Dr. Thomas Stegmaier

Starting point:

Demands of markets / technoloy,

needs of industry

quick; low innovation degree

result: improved product

Biological knowledge

Biology driven (bottom up Process in Bionics)

6. Oktober 2018 PD Dr. Thomas Stegmaier

Slow, higher innovation degree Starting point:

biological knowledge

result: new product

Demands of market / technology,

Needs of industry

Biomimetic Associations and Networks

6. Oktober 2018 PD Dr. Thomas Stegmaier

national or regional Biomimetic Associations

international Biomimetic Associations

International Bionic Network

6. Oktober 2018 PD Dr. Thomas Stegmaier

Historic examples

6. Oktober 2018 PD Dr. Thomas Stegmaier Quelle: Dean Harder 2006

Historic examples

6. Oktober 2018 PD Dr. Thomas Stegmaier

source: Dean Harder 2006

Extreme lightweight materials

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First functioning

ornithopters source: Festo Projects 2011

• Bionics

• a highly innovative science

• jumps over frontiers of traditional thinking

• effects inspiring

(technical use of proofed technologies in nature)

• but:

will and cannnot replace traditional engineering

• high potential for sustainable developments

(material- and energy savings, recycling, lifetime)

What can be delivered by bionic R&D?

6. Oktober 2018 PD Dr. Thomas Stegmaier

Famous example: Velcro fastener

PD Dr. Thomas Stegmaier

photo: Tigerente.

source: de.wikipedia

Biological archetype: Große Klette (Arctium lappa)

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Famous example: Velcro fastener

6. Oktober 2018

George de Mestral (1907–90)

• 1941 A hunting trip

• 1951 Patented velour (loops) and crochet (hooks)

• Established Velcro Industries

• 1959 First Velcro fastener on the market

• 3000 empls., $260 million

above: frieze band

below: Hook tape

source:

Alexander Klink

source: Plant

Biomechanics Group

Freiburg

Technology:

greater raw materials

treatment functional smaller units

assembly product

Nature:

atoms/molecules

growing complex systemes

advantages:

• optimal material efficiency

• small energy demand

Potentials fiber-based materials: from micro- to macro structures

photos: above: Florian Schott; right: Glenn McKechnie;

left: Solaris2006

source: http://en.wikipedia.org/wiki/Metalworking

photo left: IKAI. source: http://de.wikipedia.org/wiki/Gemeine_Esche;

photo right: http://de.wikipedia.org/wiki/Schneckenhaus 6. Oktober 2018

Potentials fiber-based materials: from micro- to macrostructure

6. Oktober 2018 PD Dr. Thomas Stegmaier 20 / Folienzahl

Fiber and textile technologies

• Single fiber

step processes

greater parts

• advantages:

low waste,

small energy consumption

photos: left: Begonia. source: http://de.wikipedia.org/wiki/Baumwolle;

oben right: Rieter AG

photos: right: NASA: source: http://de.wikipedia.org/wiki/ISS-

Expedition_13;

right: Tadeusz Rudzki. Source:

http://en.wikipedia.org/wiki/Retractable_roof

Potentials fiber-based materials: hairy surfaces

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Hairs in nature: leaves: upper and down side, feet and head of insects, gasget- and slippering elements,

feathers of birds, fur of animals, spiderweb, ...

Fiber and textile technology:

fiber processing, fiber assembly and finishing/coating

Best base for bionic developments

photos: Süße Wolfsmilch (Euphorbia dulcis): Kurt Stüber.

http://de.wikipedia.org/wiki/Wolfsmilch; spider web: Stebra.

http://de.wikipedia.org/wiki/Spinnennetz

Left:Gefieder männlicher Silberfasan: 4028mdk09.

http://commons.wikimedia.org/

Weißstirn-Weißspanner: Olaf Leillinger.

http://de.wikipedia.org/wiki/Spanner_%28Schmetterling%29

right: Epidermis mit Trichom der Acker-Schmalwand: Heiti Paves.

http://commons.wikimedia.org/

Fibers in composites:

in living nature: in technology

Potentials of fiber-based materials: fibers in composites

PD Dr. Thomas Stegmaier

Bambus: Manfred

Heyde

http://de.wikipedia.org

/wiki/Bambusgewächs

e

others:

Plant Biomechanics

Group Freiburg

ceramic composite (right): MT Aerospace AG, Augsburg.

http://de.wikipedia.org/wiki/Keramischer_Faserverbundwerkstoff

Glider: DG Flugzeugbau.

http://en.wikipedia.org/wiki/File:Dg800.jpg

nano-scaled fibers, additives, gradual transfer, high strength

materials, functional surfaces, organic and anorganic elements

high attractive R+D items

6. Oktober 2018 PD Dr. Thomas Stegmaier

Self cleaning

More examples in nature

6. Oktober 2018 PD Dr. Thomas Stegmaier Tropaeolum majus (Kapuzinerkresse)

cooperation with biologists:

• NEES Institute at University in Bonn, Germany

cooperation with industry:

• chemical industry,

• textile producers,

• users

Nano structured superhydrophobic surface

6. Oktober 2018 PD Dr. Thomas Stegmaier

The structural levels of a fabric with a hydrophobic nanoparticle coating

6. Oktober 2018 PD Dr. Thomas Stegmaier

• hydrophobic micro- and

nano-rough surface

• non wettable

(super hydrophobic)

• water droplets roll off

• adhesion of particles is

higher to water than to

surface

Self cleaning effect

6. Oktober 2018 PD Dr. Thomas Stegmaier

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Self cleaning

6. Oktober 2018 PD Dr. Thomas Stegmaier

Nano structured superhydrophobic surface

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sprinkling sprinkling

Self-cleaning surfaces: Denkendorf quality mark

6. Oktober 2018 PD Dr. Thomas Stegmaier

low roll-off

angle

micro

&

nano

rough

self-

cleaning

non-wetting

certified products: awnings

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Schmitz-Werke

GmbH + Co. KG Product: Sunsilk SNC

Emsdetten

Technical development:

From 2005: nano-structured coating, initially still with a relatively thick layer of coating and restricted functionality

Coating process refined during a 3-year Ministry of Education and Research project (incorporating plasma-technology)

2011: introduction of a PET fiber yarn variant together with the new coating technology

The SNC coating's share of total sales of awning fabric (approx. 2 million m²/year):

2005 to 2011: approx. 30%

from 2011: approx. 60%

2015: approx. 80%

Product guarantee: 5 years

Innovative coating – Schmitz Nano Clean (SNC)

6. Oktober 2018 PD Dr. Thomas Stegmaier

Source: Schmitz-Werke GmbH + Co. KG

6. Oktober 2018 PD Dr. Thomas Stegmaier

Hydrodynamic potentials

Superhydrophobic Interfaces

PD Dr. Thomas Stegmaier

water strider water ouzel water hunt spider water shrew

Analysed structure functions

PD Dr. Thomas Stegmaier 36 / Folienzahl Quelle : Nees-Institut, Bonn

Superhydrophobic interfaces

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Superhydrophobic

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Yoshiaki kodama et. al

Air retained by very fine covering of hairs

6. Oktober 2018 PD Dr. Thomas Stegmaier

The yarn count of extremely fine filaments

Fine hairy structures strong beading

effect

Fiber flocking:

flock length

variation

Hairs on the hairs:

Separation of

filaments from the

gas phase

Reduced friction using a non-wettable textile-covered hull

6. Oktober 2018 PD Dr. Thomas Stegmaier

10% reduction

(at low speeds and shallow immersion depth)

Source: Rivers & Tides

Boat hull sheathed in textile

Development Center for Ship Technology

and Transport Systems (DST), Duisburg

Micro structured surface with special geometries:

Self renewable low friction surface:

- catching small air bubbles by coalescence

- self renewable surface with thin layer of air bubbles:

reduction of friction

Outgassing process:

- disolving solved air in water

- after complete filling of cavities discharge bigger air

bubbles

- easy physical separation of big air bubbles

- new outgassing processes for liquid/gas and liquid/liquid

mixtures

New: Self renewable air containg surfaces, potential for self-outgassing materials

6. Oktober 2018 PD Dr. Thomas Stegmaier

water flow 1,5 m/sec

6. Oktober 2018 PD Dr. Thomas Stegmaier

Fog harvesting

Biological models

6. Oktober 2018 PD Dr. Thomas Stegmaier

Black beetle in Namib desert

Onymacris unguicularis

Harvesting fog from the desert beetle

Spider web with mist Stipagrostis sabulicola

Aims: Separation of water droplets in air by new

3D nets

• water for dry regions

• for drinking water

• for irrigation

• robust systems

• withstanding high wind speed

• UV durable

• using micro- and nanostructures

• using new textile constructions for the third dimension

• using knowledge from filtration (coalescence)

• Project partners:

Fog Harvesting

PD Dr. Thomas Stegmaier

Scientific work at the ITV Denkendorf

PD Dr. Thomas Stegmaier

Fog generation and test of harvesting efficiency of innovative textile nets

Water aerosol size distribution

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Fog Harvesting: results

6. Oktober 2018 PD Dr. Thomas Stegmaier

gained water:

Namib: up to 3 l/m²d

S-Africa: up to 55 l/m²d

Desert beetle: archeteype for new irrigation systems

6. Oktober 2018 PD Dr. Thomas Stegmaier

architectural vision – water tower for irrigation

6. Oktober 2018 PD Dr. Thomas Stegmaier

Fog harvesters – current state of development

6. Oktober 2018 PD Dr. Thomas Stegmaier

DITF Fog Harvesting net (FogHa-TiN)

Product in market: CloudFisher

Application: Water harvesting from fog

Textilien: Spacer warp knitting

• The ‘FogHa-Tin’ product is available

Fog Harvesting – Textiles inspired by Nature

• Collaboration with

Nextrusion (Monofilaments),

Essedea (3D warp knitting),

Water Foundation (marketing CloudFisher)

• Harvesting costs: €2-4/m³ of water

• Currently: large-scale field trials in several coastal countries

• Set up of a big fog harvesting plant in Marokko

Fog harvesters – current state of development

6. Oktober 2018 PD Dr. Thomas Stegmaier

Task: to dehumidify the extracted air

• Air extracted from the drying process after

cleaning the machinery parts is saturated with

water

• The extracted air is discharged into the workshop

• It must not adversely affect people working in the

area (clean air, working environment)

• Development of a sustainable dehumidification

system (heat recovery, elimination of odorous

substances)

Fog harvesters – industrial dehumidification

PD Dr. Thomas Stegmaier

MAFAC, Alpirsbach, Germany:

Systems for cleaning

machinery parts

Source: J. Schwarz: Presentation given at the 'Fiber-based Materials for Energy and

Environment' Colloquium, Denkendorf, 20 May 2015

Fog harvesters – industrial dehumidification

6. Oktober 2018 PD Dr. Thomas Stegmaier

Source: J. Schwarz: Presentation 'Fiber-based Materials for Energy and Environment' Colloquium, Denkendorf, 20 May 2015

6. Oktober 2018 PD Dr. Thomas Stegmaier

Oleodynamic

Oil transport and removal systems for

• accidents and disasters on land and see

• production tools, fuel and lubricant

(especially low viscous) in production of different industries

• cleaning cloth and floor cloth

• industrial washing units

Oleodynamik: New ways for the handling with oil

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Nature's role model: oil bees

PD Dr. Thomas Stegmaier

They collect oil from blossoms and carry it in hair sacks (scopae) their

rear legs.

The oil provides nutrition for the larvae and is used to impregnate the

brood cells.

Characteristics of the carrying structure (scopa)

• Rapid oil absorption

• Loss-free storage

• No residues left after discharging

• Re-usability

• Extremely favourable 'own weight to carrying capacity'

ratio

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Oleodynamic - Analysis of bionic models

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Oil charge in

Scopae

source: INRES

PD Dr. Thomas Stegmaier

Nonwovens of PP (OilSep_TIN)

Oleodynamic – Technical transfer

6. Oktober 2018 PD Dr. Thomas Stegmaier

source: INRES

Increase of oil concentration from 10 % to 89 % by using OilSep_TIN (Typ 3636)

Oleodynamic – Laboratory tests on foulard

6. Oktober 2018 PD Dr. Thomas Stegmaier

Results

oil concentration

(before)

10% (200ml oil/

1800ml water)

oil concentration

(after)

89% (168ml oil/

20ml water)

separated oil in the drip-try with a small amount of water

and cleaned water

at end of experiment

concentrated oil.

Manta ray and Mobula

Nutrition by cross-flow filtration

OilManta – Biomimetic approaches

6. Oktober 2018 PD Dr. Thomas Stegmaier

farm4.static.flickr.com/3922/15046905659_f2952afd40_m.jpg http://s57.photobucket.com/user/tablechair_2006/media/Manta

RayNautilusLiveaboard.jpg.html

Filtration mechanism

• Inflow of water and particles

OilManta – Analysis of bionic models

6. Oktober 2018 PD Dr. Thomas Stegmaier

Cross-Flow-Mechanism

• Micro filtration on filter

• Macro filtration on belly of skate

Lamellae coalescer of PP Plates and OilSepTIN for oil separation in water flow

• Optimization through bionic inspiration

• Transmission filter element (cartilage framework) and absorbent tissue

OilManta – Technical transfer & Lab tests

PD Dr. Thomas Stegmaier

source: E.W. Misty Paig-Tran, Thomas

Kleinteich, and Adam P. Summers; The

Filter Pads and Filtration Mechanisms of

the Devil Rays: Variation at Macro and

Microscopic Scales

• oil addition in the water flow

• oil absorption in OilSepTIN

• no penetration with water

ca. 80% oil separation*

*oil addition: 30 ml

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Oil absorption and save body

OilManta – Technical transfer & Lab tests

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OilManta – field test & future…

Absorption

area

Schott walls textile-grid

Trawl board

A

B

C D

Inflow area

Smoothing area

Oil take up

area

6. Oktober 2018 A. Krebs

• Prototyp

• Functional tests on the river Elbe

• Aim for serial production

• Certification / TÜV

OilManta – status quo and outview

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• OilManta – target group

• Voluntary fire brigades

• Professional fire brigades

• Plant fire brigades

• OilManta – demand and potential

• waters

• Case of damage

• Equipment density

OilManta – market potential

6. Oktober 2018 A. Krebs

6. Oktober 2018 PD Dr. Thomas Stegmaier

3-D textiles for solar thermal applications

Natural archetype: Fur and skin of the polar bear

Technical relevant characteristics:

dense heat insulated fur with colourless hairs

black epidermis with absorber function

=> heat losses only through eyes and mouth

Polar bear

Polar bear (Ursus maritimus) black skin of polar bear limited heat losses PD Dr. Thomas Stegmaier

black skin

yellowish fur

fat layer sun radiation: transfer to skin

Heat insulation

Infrared blocking

Polar bear fur - solar functions

PD Dr. Thomas Stegmaier

Application examples – flat collectors

6. Oktober 2018

With selective coating (IR reflexion)

PD Dr. Thomas Stegmaier

outer skin

radiation permeable insulation

heat transporting layer for air

sun radiation

absorber: heated up

by radiation

inner

insulation

insulation thermo chemical storage ventilation

Energy concept of Polar Bear Pavilion

PD Dr. Thomas Stegmaier

Upscaling in several steps

6. Oktober 2018 PD Dr. Thomas Stegmaier

Results of experimental tests

6. Oktober 2018 PD Dr. Thomas Stegmaier

Preliminary work – solar active Polar Bear Pavilion with seasonal energy storage system

Data

• Ground floor: 121m²

• hight: 5,14m

• 5 air collectors with

each 7,3m² on south

side

• Silica gel storage with

each 60kg in mobile

container

PD Dr. Thomas Stegmaier

Solar thermal energy generation in winter, January 2013

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Polar Bear Pavilion completed installation – fully digitalised and controlled

PD Dr. Thomas Stegmaier

results of experiments

6. Oktober 2018 PD Dr. Thomas Stegmaier

Findings in long term test 2013-2018

Solar collector

• Air temperature rises up to 150°C

• Solar thermal efficiency with piping:

ca. 51 %

Saisonal energy storage with Silica gel

• Charge and discharge efficiency: ca. 70-74%

• During storage of energy: no technical losses

PD Dr. Thomas Stegmaier

System: Energy

6. Oktober 2018 PD Dr. Thomas Stegmaier

Legend:

1 Spacer fabric

2 Top layer

3 Top layer

4 Pile threads

5 (Upper coating on the side facing towards the light)

7 Cavity

8 Coating on the side facing away from the light (light

absorbent, flexible)

Innovative façade system for solar-thermal power generation

PCM storage: PCM in knitting with monofilaments

PD Dr. Thomas Stegmaier

Side view, in bended situation

PCM-

knitting

collector PCM-

knitting

collector

Isolation

Scheme for collector (foil and textile) in storage

PD Dr. Thomas Stegmaier

Demonstrator – knitting

0

10

20

30

40

50

60

70

80

0 60 120 180 240 300 360

Te

mp

era

tur

[°C

]

Zeit [min]

Charging and discharging with PCM in knitting

T_KA

T_Umgebung

T_SA

Te

mp

era

ture

[°C

]

Time [min]

Integration in glas facade source: Gerhard Weber and Lukas Eisenhut:

From nature inspired: Textile based collecor with decentral longtime

storage. Journal „Fassade -Technik und Architektur“ 6/2017

http://flippingbook.verlagsanstalt-handwerk.de/die-

fassade/2017/fassade_0617fb/files/assets/basic-html/page-26.html

Self – x characteristics:

- Self-repairing

- Self-adaptation

- Self-orientation

- Self-.....

The future for bionic research

6. Oktober 2018 PD Dr. Thomas Stegmaier

Radiation properties:

- transmission, reflection,

absorption in the near and

medium infrared

and many more applications

Future is textile

Thank you very much for your attention!

Dr. Thomas Stegmaier

thomas.stegmaier@ditf.de

Tel.: +49 (0)7 11/93 40-0

Fax: +49 (0)7 11/93 40-297

www.ditf.de

Körschtalstrasse 26

D-73770 Denkendorf

6. Oktober 2018 PD Dr. Thomas Stegmaier