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     

Effect of bark flour content on the hygroscopic characteristics of wood–polypropylene composites

The effects of the bark content on the water absorption and thickness swelling of wood–plastic composites prepared from polypropylene, wood flour, and bark flour were studied. Samples were made with a laboratory twin‐screw extruder. The results showed that among composites free of maleic anhydride polypropylene, those composites containing a higher bark flour content exhibited lower water absorption and lower thickness swelling. Maleic anhydride polypropylene reduced water absorption and thickness swelling in composites containing wood flour and a lower content of bark flour but had no influence on the hygroscopic properties of composites made with higher bark contents. Adding maleic anhydride polypropylene had no effect on the water diffusion coefficients and swelling rate parameters of composites made with a higher bark flour content. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Modeling the kinetics of water transport and hydroexpansion in a lignocellulose-reinforced bacterial copolyester

The governing kinetic behavior of water transport in a biopolymeric composite material derived from poly(β-hydroxybutyrate)-co-poly(β-hydroxyvalerate) and lignocellulosic wood flour were investigated along with the influence of temperature, wood flour content, and chemical modification (silane, maleic anhydride) on polymer and composite diffusivity. The water absorption process in both untreated and treated composites was found to follow the kinetics of Fickian diffusion theory. Diffusion coefficients for neat polymer and composite samples were experimentally determined, and the thermodynamics of diffusive water transport were observed to exhibit Arrhenius rate-law behavior. A model for predicting equilibrium moisture content in wood-polymer composites is presented and substantiated by obtained results and cited experimental data. Isodiffusion plots are presented to evaluate the effectiveness of chemical modifications, which were found to reduce the rates of water uptake. Both in- and out-of-plane dimensional changes were monitored during the absorption process, permitting the determination of moisture-dependent hydroexpansion coefficients.     

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.     

Mold susceptibility of rigid PVC/wood‐flour composites

Rigid PVC/wood‐flour composite lumber containing either hardwood (maple) or a softwood (southern pine) wood flour at different levels of wood‐flour content was evaluated for susceptibility to fungal colonization and discoloration by using standard tests that mimicked exterior (ASTM G21) and interior (ASTM D3273) environments, respectively. In the exterior test protocol, although both types of PVC/wood‐flour composite lumber exhibited fungal colonization and discoloration, the composites containing maple exhibited greater discoloration than those containing pine. Irrespective of wood species, fungal colonization and discoloration in the composite lumber were greater at the bottom faces where they were in constant contact with moisture. The wood content range (50–100 phr) used in this study showed no effect on extent of fungal colonization and discoloration. All composites showed no discoloration in the interior test protocol. Both optical microscopy and environmental scanning electron microscopy clearly demonstrated that wood flour particulates are not completely encapsulated by the PVC matrix, so that exposed wood flour in the surface crevices of the composite lumber may serve as points of moisture sorption and staging points for fungal colonization and discoloration. J. Vinyl Addit. Technol. 10:179–186, 2004. © 2004 Society of Plastics Engineers.     

The effect of epoxy‐polyester hybrid resin on mechanical properties,rheological behavior,and water absorption of polypropylene wood flour composites

The effect of epoxy resin on mechanical and Rheological properties, and moisture absorption of wood flour polypropylene composites (WPCs) were investigated. The reactive mixing of epoxy resin with 30, and 40 wt% wood flour and polypropylene (PP) was carried out in twin screw extruder with a special screw elements arrangement. PP grafted maleic anhydrides (MPP) were used as coupling agent to improve the interfacial interactions of wood flour, epoxy resin, and PP. The tensile strength of composites decreased, and elastic modulus and moisture absorption increased with increasing epoxy resin content. The complex viscosity η* increased with increasing epoxy resin content of composites, and a synergistic effect in increasing the η* was observed at 3 wt% resin. The epoxy resin modified wood‐PP composites that chemically coupled by MPP showed minimum water absorption with highest elastic modulus. The experimental oscillation rheologyical data were used to drive a model to predict the flow behavior of WPCs, in a wide range of frequencies. POLYM. ENG. SCI., 47:2041–2048, 2007. © 2007 Society of Plastics Engineers     

Durability of wood flour‐plastic composites exposed to accelerated freeze–thaw cycling. II. High density polyethylene matrix

This study examined the durability of extruded HDPE/wood‐flour composites exposed to 15 accelerated cycles of water submersion, freezing, and thawing, according to ASTM standard D6662. The durability of both maple and pine composites was assessed by testing the flexural properties and density. Mercury intrusion porosimetry and scanning electron microscopy were also used to evaluate the interfacial adhesion between the matrix and wood flour before and after exposure to accelerated freeze–thaw cycling. Freeze–thaw actions had no apparent effect on the density of the composites after exposure, regardless of the wood species. However, these actions led to moisture uptake, which decreased the interfacial adhesion and increased the pore size and quantity in the composites, which resulted in a significant loss in flexural properties. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 100: 35–39, 2006     

Effects of nanoclay and coupling agent on the physico‐mechanical,morphological, and thermal properties of wood flour/polypropylene composites

This article presents the effects of coupling agent and nanoclay (NC) on some properties of wood flour/polypropylene composites. The composites with different NC and maleic anhydride grafted polypropylene (MAPP) contents were fabricated by melt compounding in a twin‐screw extruder and then by injection molding. The mass ratio of the wood flour to polymer was 40/60 (w/w). Results showed that applying MAPP on the surface of the wood flour can promote filler polymer interaction, which, in turn, would improve mechanical properties of the composite as well as its water uptake and thermal stability. Composite voids and the lumens of the fibers were filled with NC, which prevented the penetration of water by the capillary action into the deeper parts of composite. Therefore, the water absorption in composites fabricated using NC was significantly reduced. Scanning electron microscopy has shown that the treatment of composites with 5 wt% MAPP, promotes better fiber–matrix interaction, resulting in a few numbers of pull‐out traces. In all cases, the degradation temperatures shifted to higher values after using MAPP. The largest improvement on the thermal stability of composites was achieved when NC was added. POLYM. ENG. SCI., 2011. © 2010 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.     

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.     

Long‐term water uptake behavior of lignocellulosic‐high density polyethylene composites

Composites of different lignocellulosic materials and high‐density polyethylene were prepared and their long‐term water absorption behaviors were studied. Wood flour, rice hulls, newsprint fibers, and kenaf fibers were mixed with the polymer at 25 and 50 wt % fiber contents and 1 and 2% compatibilizer, respectively. Water absorption tests were carried out on injection‐molded specimens at room temperature for five weeks. Results indicated a significant difference among different natural fibers with kenaf fibers and newsprint fibers exhibiting the highest and wood flour and rice hulls the lowest water absorption values, respectively. Very little difference was observed between kenaf fiber and newsprint composites and between rice hulls and wood flour composites regarding their water uptake behavior. The difference between 25 and 50% fiber contents for all composite formulations increased at longer immersion times, especially for the composites with higher water absorption. Kenaf fiber composites containing 50% kenaf fibers exhibited the highest water diffusion coefficient. A strong correlation was found between the water absorption and holocellulose content of the composites. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 3907–3911, 2006     

Surface tearing and wall slip phenomena in extrusion of highly filled HDPE/wood flour composites

The extrudate surface tearing of highly filled high‐density polyethylene (HDPE)/wood flour composites has been investigated in relation to the rheological properties and the wall slip phenomenon in capillary dies. Rotational and capillary rheometers were employed to measure the rheological properties. Mooney analysis was used for determination of wall slip velocity. The results showed considerable increase of storage modulus, dynamic and shear viscosity with increasing wood flour loading. It was also found that all wood filled composites did not obey the Cox–Merz rule. The wall slip velocity depends on wood filler content and shear rate. Generally, with increasing shear rate the slip velocity sharply increases leading to plug‐like flow. It was observed that the surface of the extrudates becomes smoother with increase in shear rate and wood flour content. POLYM. ENG. SCI., 46:1204–1214, 2006. © 2006 Society of Plastics Engineers     

Some studies on mechanical properties of wood flour/continuous glass mat/polypropylene composite

The mechanical properties and the surface property of wood flour/continuous glass mat/polypropylene composites have been investigated. The suitability of wood flour as a filler for continuous glass mat–reinforced polypropylene has been tested using different mesh sizes (e.g., 20 and 40 mesh), as well as by varying the weight percentage of wood flour from 0%– 30%. Moreover, different treatments such as coupling agent A‐1100 and functionalized polypropylene grafting with maleic anhydride, and so forth, have also been used to improve the compatibility of wood flour and glass fiber with the polymer resin. In addition, the effects of the surface weight of glass mat and matrix resin have been studied. The extent of the improvement in mechanical properties depends on the wood flour content and size, the surface weight of the glass mat, the matrix resin, and the surface treatment of wood flour. After adding wood flour, the contact angle of distilled water on the composite surface decreases and the polar component of surface tension increases. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 85: 536–544, 2002     

Waste pine cones as a source of reinforcing fillers for thermoplastic composites

In this study, we evaluated some physical and mechanical properties of polypropylene (PP) composites reinforced with pine‐cone flour and wood flour. Five types of wood–plastic composites (WPCs) were prepared from mixtures of cone flour, wood flour, PP, and a coupling agent. The water resistance and flexural properties of the composites were negatively affected by an increase in cone‐flour content. Extractives in the cone flour had a significant effect on the flexural properties of the WPCs. However, the flexural properties and water resistance of the WPC samples were not significantly affected by the addition of 10 wt % of the cone flour when compared to the WPC samples made from wood flour. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Effects of wood flour and chitosan on mechanical,chemical, and thermal properties of polylactide

Composites of polylactide (PLA, 100–60 wt%) and wood flour (0–40 wt%) were prepared to assess the effects of wood filler content on the mechanical, chemical, thermal, and morphological properties of the composites. The polysaccharide chitosan (0–10 wt%) was added as a potential coupling agent for the PLA‐wood flour composites. Addition of wood flour significantly increased the flexural modulus and the storage modulus of PLA‐wood flour composite, but neither the wood flour nor chitosan had an effect on the glass transition temperature (T_g). Fourier transform infrared spectra did not show any evidence of covalent bonding, but chitosan at the interface between wood and PLA is thought to have formed hydrogen bonds to PLA‐carbonyl groups. SEM images of fracture surfaces showed that fiber breakage was far more common than fiber pullout in the composites. No evidence of discrete chitosan domains was seen in SEM micrographs. When added at up to 10 wt% (based on wood flour mass), chitosan showed no significant effect on the mechanical, chemical, or thermal properties of the composites, with property changes depending on wood flour content only. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers.     

PARAMETERS INFLUENCING DRYING BEHAVIOR OF RUBBER WOOD (HEVEA BRAZILLIENSIS) AS DETERMINED FROM DESORPTION EXPERIMENT

In this study, the drying properties of rubber wood, which are the basic parameters for kiln scheduling design, were determined from desorption experiment. Equilibrium moisture content expression was developed. The diffusion coefficients at different drying environments were evaluated. It is more appropriate to determine the diffusion coefficients by the optimum scheme in comparison to other schemes; the logarithmic, square-root and half-fraction of evaporable moisture schemes. Finally, the diffusion coefficient of rubber wood was described by, instead of wood moisture content, the drying temperature and relative humidity, which are the parameters controlling the drying kiln operation.     

Thermoplastic polymers as modifiers for urea–formaldehyde wood adhesives. III. In situ thermoplastic‐modified wood composites

Acrylic monomers and free‐radical initiators were dispersed in an aqueous urea–formaldehyde (UF) suspension and polymerized in situ to afford a suspension containing 5 wt % thermoplastic (5 g of thermoplastic/100 mL of suspension). The viscosity of the thermoplastic‐modified UF suspension (65 wt % solids at 25°C) ranged from 240 to 437 cP versus 121 cP for the unmodified UF control. Wood‐flour composites (sugar maple and 50 wt % adhesive) were prepared with thermoplastic‐modified UF suspensions and cured with the same cycle used for the composites prepared with the unmodified UF adhesive (control). The effect of the thermoplastic‐modified UF adhesive was evaluated on the notched Izod impact strength and equilibrium moisture uptake of the wood‐flour composites. The notched Izod impact strength of the composites prepared with modified UF adhesives increased by as much as 94% above that of the control. The increase depended on the initiator and the monomer composition. The modification affected the equilibrium moisture uptake and rate of moisture uptake in the wood‐flour composites. Preliminary results for particleboard prepared with 10 wt % modified UF adhesive (5% thermoplastic in the UF resin) and unoptimized cure conditions confirmed a significant effect of the thermoplastic modification on both the internal‐bond strength and thickness swelling of the particleboard. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Molecular Transport of Aromatic Solvents through Oil Palm Micro Fiber Filled Natural Rubber Composites: Role of Fiber Content and Interface Adhesion on Transport

Cellulose micro fiber reinforced natural rubber composites were prepared and the diffusion and transport of aromatic solvents through these composites were studied in the temperature range 30–70°C. The diffusion parameters were investigated with special reference to the effect of fiber loading, penetrant size, temperature and interphase adhesion. The effect of chemical treatments on solvent uptake was also analyzed. The transport coefficients such as diffusion, permeation and sorption coefficients were determined to evaluate the influence of interphase adhesion on transport properties. The van't Hoff relationship was used to determine the thermodynamic parameters. The first order kinetic rate constant was evaluated. Finally, experimental results of the sorption properties of the composites were compared with theoretical predictions.     

Effects of soaking and freezing on composites made from wood‐based fillers and biodegradable plastics

Biodegradable plastic composites were subjected to prolonged soaking and freezing treatments to assess the effects on the mechanical performance. Radiata pine flour and thermomechanical pulp fibers were used as fillers at various addition levels in three different commercial polymer matrices. Two were bioderived, one oil‐derived, each with different hydrophobicities. Depending on the nature of the biodegradable polymer matrix, the rates and extents of water uptake were found to be either enhanced or reduced by the wood‐derived fillers. Although the higher aspect ratio of the pulp fibers improved mechanical performance, relative to the wood flour, water uptake was also significantly enhanced in some cases. POLYM. COMPOS. 27:323–328, 2006. © 2006 Society of Plastics Engineers