Foaming of rigid PVC/wood‐flour composites through a continuous extrusion process

The effects of chemical foaming agent (CFA) types (endothermic versus exothermic) and concentrations as well as the influence of all‐acrylic processing aid on the density and cell morphology of extrusion‐foamed neat rigid PVC and rigid PVC/wood‐flour composites were studied. Regardless of the CFA type, the density reduction of foamed rigid PVC/wood‐flour composites was not influenced by the CFA content. The cell size, however, was affected by the CFA type, independent of CFA content. Exothermic foaming agent produced foamed samples with smaller average cell sizes compared to those of endothermic counterparts. The experimental results indicate that the addition of an all‐acrylic processing aid in the formulation of rigid PVC/wood‐flour composite foams provides not only the ability to achieve density comparable to that achieved in the neat rigid PVC foams, but also the potential of producing rigid PVC/wood‐flour composite foams without using any chemical foaming agents.     

Foam extrusion of high density polyethylene/wood‐flour composites using chemical foaming agents

A one‐way analysis of variance and thermal analysis were performed in this study to examine the influences of the contents, types (exothermic vs. endothermic), and forms (pure vs. masterbatch) of chemical foaming agents (CFAs), as well as the use of coupling agents, on the density reduction (or void fraction) and cell morphology of extrusion‐foamed neat high density polyethylene (HDPE) and HDPE/wood‐flour composites. The CFA types and forms did not affect the void fractions of both the neat HDPE and HDPE/wood‐flour composites. However, a gas containment limit was observed for neat HDPE foams whereas the average cell size achieved in the HDPE/wood‐flour composite foams remained insensitive to the CFA contents, irrespective of the foaming agent types. The experimental results indicated that the use of coupling agent in the formulation was required to achieve HDPE/wood‐flour composite foams with high void fraction. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 3139–3150, 2003     

Manufacture of rigid PVC/wood‐flour composite foams using moisture contained in wood as foaming agent

Relatioships between the density of foamed rigid PVC/wood‐flour composites and the moisture content of the wood flour, the chemical foaming agent (CFA) content, the content of all‐acrylic foam modifier, and the extruder die temperature were determined by using a response surface model based on a four‐factor central composite design. The experimental results indicated that there is no synergistic effect between teh CFA content and the moisture content of the wood flour. Wood flour moisture could be used effectively as foaming agent in the production of rigid PVC/wood‐flour composite foams. Foam density as low as 0.4 g/cm³ was produced without the use of chemical foaming agents. However, successful foaming of rigid PVC/wood‐flour composite with moisture contained in wood flour strongly depends upon the presence of all‐acrylic foam modifier in the formulation and the extrusion die temperature. The lowest densities were achieved when the all‐acrylic foam modifier concentration was between 7 phr and 10 phr and extruder die temperature was as low as 170°C.     

Microcellular foaming of impact‐modified rigid PVC/wood‐flour composites

Solid state microcellular foaming technology was employed to investigate the influence of impact modification on the foamability of neat rigid PVC and rigid PVC/wood‐flour composite samples. The effects of impact modifier types (crosslinked versus uncrosslinked) and concentrations on the void fraction of foamed samples were examined. The influence of impact modification on the sorption behavior of CO₂ in the samples was also studied. The experimental results indicate that impact modification accelerates the rate of gas loss during the foaming process, which impedes the growth of nucleated cells, independent of modifier type. Because of this accelerated gas loss, impact modification inhibits the potential of producing foamed samples with void fractions similar to those achieved in unmodified samples.     

PVC微孔塑料的研究进展

阐述化学发泡剂、物理发泡剂和添加剂对PVC微孔发泡的影响,综述了PVC微孔发泡成型方法的研究进展,包括间歇成型法、连续挤出成型法和电磁动态挤出成型法。将振动力场引入到微孔发泡过程为PVC微孔塑料连续挤出成型提供了新的思路和研究方向。     

Fusion characteristics of rigid PVC/wood‐flour composites by torque rheometry

This study was aimed at examining the effects of wood flour contents, wood species (softwood vs. hardwood), and particle size on the fusion characteristics (fusion time, fusion temperature, fusion torque, and fusion energy) of rigid PVC/wood‐flour composites in a torque rheometer. Neat rigid PVC exhibited one fusion peak, whereas the addition of wood flour into the PVC matrix led to two fusion peaks. Increased wood flour content caused a significant increase in the time, temperature, and energy at which fusion between the primary particles started, thereby leading to increased fusion torque, irrespective of the wood flour species. These results implied that rigid PVC filled with wood flour must be processed at higher temperatures than neat resin. Although fusion characteristics of the composites were influenced by the wood species, a clear trend between softwood and hardwood species could not be established. However, finer particles fused more quickly and needed less energy than coarse ones. J. VINYL ADDIT. TECHNOL., 13:7–13, 2007. © 2007 Society of Plastics Engineers.     

Coextruded PVC/wood‐flour composites with WPC cap layers

Wood‐plastic composites (WPCs) can absorb moisture in a humid environment owing to the hydrophilic nature of the wood, thereby making the products susceptible to microbial growth and loss of mechanical properties. In this study, rigid poly(vinyl chloride) (PVC)/wood‐flour composites (core layer) were coextruded with either unfilled rigid PVC (cap layer) or rigid PVC filled with a small amount (5–27.5%) of wood flour (composite cap layers) in order to decrease or delay the moisture uptake. The thickness of the cap layer and its composition in terms of wood flour content were the variables examined during coextrusion. Surface color, moisture absorption, and flexural properties of both coextruded and noncoextruded (control) composite samples were characterized. The experimental results indicated that both unfilled PVC and composite cap layers can be encapsulated over rigid PVC/wood‐flour composites in a coextrusion process. The moisture uptake rate was lower when a cap layer was applied in the composites, and the extent of the decrease was a strong function of the amount of wood flour in the cap layer but insensitive to cap layer thickness. Overall, coextruding PVC surface‐rich cap layers on WPCs significantly increased the flexural strength but decreased the flexural modulus as compared with those of control samples. The changes in bending properties were sensitive to both cap layer thickness and wood flour content. J. VINYL ADDIT. TECHNOL., 2008. © 2008 Society of Plastics Engineers     

Wood/plastic composites co‐extruded with multi‐walled carbon nanotube‐filled rigid poly(vinyl chloride) cap layer

Wood/plastic composites (WPCs) can absorb moisture in a humid environment due to the hydrophilic nature of the wood in the composites, making products susceptible to microbial growth and loss of mechanical properties. Co‐extruding a poly(vinyl chloride) (PVC)‐rich cap layer on a WPC significantly reduces the moisture uptake rate, increases the flexural strength but, most importantly, decreases the flexural modulus compared to uncapped WPCs. A two‐level factorial design was used to develop regression models evaluating the statistical effects of material compositions and a processing condition on the flexural properties of co‐extruded rigid PVC/wood flour composites with the ultimate goal of producing co‐extruded composites with better flexural properties than uncapped WPCs. Material composition variables included wood flour content in the core layer and carbon nanotube (CNT) content in the cap layer of the co‐extruded composites, with the processing temperature profile for the core layer as the only processing condition variable. Fusion tests were carried out to understand the effects of the material compositions and processing condition on the flexural properties. Regression models indicated all main effects and two powerful interaction effects (processing temperature/wood flour content and wood flour content/CNT content interactions) as statistically significant. Factors leading to a fast fusion of the PVC/wood flour composites in the core layer, i.e. low wood flour content and high processing temperature, were effective material composition and processing condition parameters for improving the flexural properties of co‐extruded composites. Reinforcing the cap layer with CNTs also produced a significant improvement in the flexural properties of the co‐extruded composites, insensitive to the core layer composition and the processing temperature condition. Copyright © 2009 Society of Chemical Industry     

Expansion mechanisms of plastic/wood‐flour composite foams with moisture,dissolved gaseous volatiles,and undissolved gas bubbles

The large quantity of moisture in wood‐flour may lead to the deterioration of the cell structure of foamed plastic wood‐flour composites in terms of cell size, non‐uniformity, and poor surface quality. Since these anomalies can cause poor mechanical properties of the foamed composites, the removal of the moisture from wood‐flour becomes a critical issue with respect to the improvement of these properties. The wood‐flour in this experimental study was first oven‐dried at different temperatures and then subjected to acetone extraction and thermogravimetric analysis (TGA). The oven‐dried wood‐flour was blended with plastic and then subjected to extrusion foaming. The results obtained from the TGA studies indicate that most volatiles were released from the extractives. Conversely, a comparative experimental study of the foaming behavior of these plastic/wood‐flour composites versus that of undried wood‐flour composites confirms that removal of the adsorbed moisture from wood‐flour results in a better cell morphology. However, it seems that some gaseous emissions released from wood‐flour are soluble in plastic and thereby favorably contribute to the development of the cell morphology. This paper describes the expansion mechanisms of wood‐flour composite foams resulting from the adsorbed moisture and dissolved gaseous emissions as well as resulting from the finely dispersed undissolved gas bubbles released from a chemical blowing agent.     

Online measurement of rheological properties of PVC/wood‐flour composites

By using a factorial design approach, this study examined the effect of the component materials on the viscoelastic properties of PVC/wood‐flour composites. Statistical analysis was performed to determine the effects of wood‐flour content, acrylic modifier content, and plasticizer content on the die swell ratio and viscosity of the composites measured online on a conical twin‐screw extrusion capillary rheometer. The viscoelastic properties of the samples also were measured using dynamic mechanical analyzer (DMA). Wood‐flour content and acrylic modifier content were the two important variables affecting the die swell ratio, whereas the addition of a low level of plasticizer did not affect this ratio. The die swell increased with the increased acrylic modifier content, but it was reduced considerably by adding wood flour into the PVC matrix. The true viscosity of neat PVC and PVC/wood‐flour composites decreased with the plasticizer content, irrespective of the acrylic modifier content. However, the addition of acrylic modifier significantly increased the viscosity of unfilled PVC, while an opposite trend was observed for the composites, owing to the differing effect of acrylic modifier on the melt elasticity and viscosity of these materials. J. Vinyl Addit. Technol. 10:121–128, 2004. © 2004 Society of Plastics Engineers.     

Durability of wood flour‐plastic composites exposed to accelerated freeze–thaw cycling. Part I. Rigid PVC matrix

This study examined the effects of accelerated freeze–thaw actions on the durability of wood fiber‐plastic composites. Rigid PVC formulations filled with various concentrations of wood flour (both pine and maple) were processed in a counterrotating twin‐screw extruder and exposed to cyclic freeze–thaw actions according to ASTM Standard D6662. Freeze–thaw cycling was also modified by omitting portions of the test (either the water or freezing) to verify whether or not moisture was the primary cause for property loss. The durability of exposed samples was assessed in terms of flexural properties, density, and dimensional stability. Scanning electron micrographs of unexposed and freeze–thaw‐exposed samples were taken to qualitatively evaluate the interfacial adhesion between the wood flour and PVC matrix. The experimental results indicated that the density was not affected by freeze–thaw cycling. The dimensional stability was also relatively unaffected, although greater wood flour content exhibited greater dimensional change. The loss in stiffness of the composites was statistically significant after only two freeze–thaw cycles, regardless of both the wood species and content. Conversely, the strength of the composites was not significantly affected by five freeze–thaw cycles at lower wood flour contents (50 and 75 phr). The deleterious effects of the freeze–thaw actions on the strength of the composites became apparent at higher wood flour content (100 phr) after only two freeze–thaw cycles for maple flour and five freeze–thaw cycles for pine flour. The property loss was attributed primarily to the water portion of the cycling, which appears to have led to the decreased interfacial adhesion between the wood flour and the rigid PVC matrix. J. VINYL. ADDIT. TECHNOL. 11:1–8, 2005. © 2005 Society of Plastics Engineers.     

Effects of copper amine treatment on mechanical properties of PVC/wood‐flour composites

Copper amine–treated wood flour was added to PVC [poly(vinyl chloride)] matrix in order to manufacture PVC/wood‐flour composites. Effects of copper treatments on the mechanical properties of PVC‐wood composites were evaluated. Unnotched impact strength, flexural strength, and flexural toughness of the composites were significantly improved by the wood‐flour copper treatment. The optimum copper concentration range was 0.2 to 0.6 wt% of wood flour. Fractured surfaces were examined by using scanning electron microscopy (SEM) combined with energy‐dispersive spectroscopy (EDS). PVC/wood interfacial debonding was the main fracture mode of untreated wood‐flour composites, whereas wood‐particle pullout and breakage dominating the fractured surfaces of copper‐treated wood‐flour composites. On the fractured surfaces, more PVC could be found on the exposed copper‐treated wood particles than on untreated wood, a result suggesting improved PVC‐wood interfacial adhesion after copper treatments. J. Vinyl Addit. Technol. 10:70–78, 2004. © 2004 Society of Plastics Engineers.     

Development of poly(vinyl chloride)/wood composites. A literature review

Poly(vinyl chloride)/wood fiber (flour) composites are currently experiencing a dramatic increase in use. Most of them are used to produce window/door profiles, decking, railing, and siding by using conical counterrotating intermeshing twin‐screw extruders. Heat stabilizers, processing aids, impact modifiers, lubricants, and pigments are still important for PVC/wood composite formulations. Poly[methylene(polyphenyl isocyanate)] (PMPPIC), γ‐aminopropyltriethoxysilane, maleated polypropylene (MAPP), and copper metallic complex have proved to be effective coupling agents for this composite system. Mechanical properties of PVC/wood composites can be enhanced by combining wood with mica or glass fibers to form hybrid reinforcements. Ultraviolet light resistance and weathering dimensional stabilities of PVC/wood composites are superior to those of natural wood. Density reduction can be achieved through the microcellular foaming technique by using chemical blowing agents, such as azodicarbonamide and sodium bicarbonate, or physical blowing agents, such as carbon dioxide. J. Vinyl Addit. Technol. 10:59–69, 2004. © 2004 Society of Plastics Engineers.     

Microcellular Foamed Wood‐Plastic Composites by Different Processes: a Review

Wood fiber reinforced polymer composites represent a relatively small but rapidly growing material class, extensively applied in interior building applications and in the automotive industry. The polymer‐wood fiber composites utilize fibers as reinforcing filler in the polymer matrix and are known to be advantageous over the neat polymers in terms of the materials cost and mechanical properties such as stiffness and strength. Wood fiber reinforced polymer composites are microcellularly processed to create a new class of materials with unique properties. Most manufacturers are evaluating new alternatives of foamed composites that are lighter and more like wood. Foamed wood composites accept screws and nails like wood, more so than their non‐foamed counterparts. They have other advantages such as better surface definition and sharper contours and corners than non‐foamed profiles, which are created by the internal pressure of foaming. This paper represents a review on microcellular wood fiber reinforced polymer composites obtained by different processes (batch, injection molding, extrusion, and compression molding process) and includes an overview of foaming agents (physical and chemical) and the foaming of wood fiber‐polymer composites (changes in phase morphology, formation of polymer‐gas solution, cell nucleation, and cell growth control).

     

Reinforcement of rigid PVC/wood‐flour composites with multi‐walled carbon nanotubes

Multi‐walled carbon nanotubes (CNT) were compounded with PVC by a melt blending process based on fusion behaviors of PVC. The effects of CNT content on the flexural and tensile properies of the PVC/CNT composites were evaluated in order to optimize the CNT content. The optimized CNT‐reinforced PVC was used as a matrix in the manufacture of wood‐plastic composites. Flexural, electrical, and thermal properties of the PVC/wood‐flour composites were evaluated as a function of matrix type (nonreinforced vs. CNT‐reinforced). The experimental results indicated that rigid PVC/wood‐flour composites with properties similar to those of solid wood can be made by using CNT‐reinforced PVC as a matrix. The CNT‐reinforced PVC did not influence the electrical and thermal conductivity of the PVC/wood‐flour composites. J. VINYL ADDIT. TECHNOL., 2008. © 2008 Society of Plastics Engineers.     

Cell morphology and property relationships of microcellular foamed pvc/wood-fiber composites

Wood-fiber composites make use of cellulose fibers as a reinforcing filler in the polymer matrix and are known to have a lower material cost and a higher stiffness than neat polymers. However, the lower material cost and enhanced stiffness of wood-fiber composites are achieved at the expense of other properties such as the ductility and impact strength. Since microcellular plastics exhibit a higher impact strength, higher toughness, and increased fatigue life compared to unfoamed plastics, microcellular foaming of wood-fiber composites will improve the mechanical properties of the composites and therefore increase the usefulness of the materials. In this paper, microcellular foamed PVC/wood-fiber composites with unique cell morphology and material composition are characterized. Microcellular structures are produced in PVC/wood-fiber composites by first saturating the composite samples with CO₂ under high pressure followed by rapidly decreasing the solubility of gas in the samples. The void fraction of the microcellular foamed PVC/wood-fiber composites is controlled by tailoring the composition of materials and the foaming process parameters. The results indicate that tensile and impact properties of microcellular foamed PVC/wood-fiber composites are most sensitive to changes in the cell morphology and the surface modification of fibers.     

Effects of multi‐walled carbon nanotube functionalization on the morphological and mechanical properties of nanocomposite foams based on poly(vinyl chloride)/(wood flour)/ (multi‐walled carbon nanotubes)

Experimental results are presented for nanocomposite foams based on unplasticized poly(vinyl chloride)/(wood flour)/(multi‐wall carbon nanotubes) (PVC/WF/MWCNTs). The nanocomposite samples were prepared in an internal mixer and foamed via a batch processing method using compression molding. Nanoparticles were functionalized by sodium hypochlorite solution, and the functionalization process was monitored by Fourier‐transform infrared spectroscopy. The effects of MWCNTs (both neat and functionalized) and blowing agent concentration on the morphological properties (cell size and cell density) and mechanical properties (tensile and flexural strength) of the foam samples were studied. The results revealed that foam cell sizes decreased and cell densities increased with addition of MWCNTs. The dispersion of nanoparticles in the PVC medium was increased by functionalization, and the morphological properties of the foams containing functionalized nanoparticles were improved. Density of nanocomposite foams decreased more with functionalized MWCNTs as compared to other samples. Chemical blowing agent concentration had no significant effect on sample density. Mechanical properties of the samples were improved by using functionalized MWCNTs in comparison with those of foams without this component. J. VINYL ADDIT. TECHNOL., 18:161–167, 2012. © 2012 Society of Plastics Engineers     

Effects of impact modifiers on the properties of rigid PVC/wood‐fiber composites

This study examined the effects of impact modifier types and addition levels on the mechanical properties of rigid PVC/wood‐fiber composites. The impact resistance of rigid PVC/wood‐fiber composites depends strongly on the type and content of impact modifier. With the proper choice of modifier type and concentration, the impact strength of rigid PVC/wood‐fiber composites can be significantly improved without degrading the tensile properties. Methacrylate‐butadiene‐styrene and all‐acrylic modifiers performed in a similar manner and were more effective and efficient in improving the impact resistance of rigid PVC/wood‐fiber composites than the chlorinated polyethylene modifier.     

聚氯乙烯/木粉复合材料的研究进展

综述了近年来国内外聚氯乙烯（PVC）/木粉（WF）复合材料的研究进展,对新型的行星辊轮双螺杆挤出机、带有干燥器的锥形双螺杆挤出机以及能直接将木粉输送到挤出机中的"WoodTruderTM"挤出系统等新型设备和工艺进行了介绍,对PVC/WF复合材料中使用的润滑剂、冲击改性剂、增塑剂、相容剂等助剂的研究进展进行了总结,并对PVC/WF复合材料的微发泡工艺和环保性能进行了介绍和评述,在此基础上对PVC/WF复合材料的发展趋势进行了展望。     

Novel coupling agents for PVC/wood‐flour composites *

Effective interfacial adhesion between wood fibers and plastics is crucial for both the processing and ultimate performance of wood–plastic composites. Coupling agents are added to wood–plastic composites to promote adhesion between the hydrophilic wood surface and hydrophobic polymer matrix, but to date no coupling agent has been reported for PVC/wood‐fiber composites that significantly improved their performance and was also cost‐effective. This article presents the results of a study using chitin and chitosan, two natural polymers, as novel coupling agents for PVC/wood‐flour composites. Addition of chitin and chitosan coupling agents to PVC/wood‐flour composites increased their flexural strength by ～20%, their flexural modulus by ～16%, and their storage modulus by ～33–74% compared to PVC/wood‐flour composite without the coupling agent. Significant improvement in composite performance was attained with 0.5 wt% of chitosan and when 6.67 wt% of chitin was used. J. VINYL ADDIT. TECHNOL., 11:160–165, 2005. © 2005 Society of Plastics Engineers