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.     

Mechanical properties of extrusion‐foamed rigid PVC/wood‐flour composites

This study was conducted to characterize the mechanical properties of extrusion‐foamed neat rigid PVC and rigid PVC/wood‐flour composites by using endothermic and exothermic chemical foaming agents (CFAs). The specific elongation at break (ductility) of the samples was improved by foaming, while the opposite trend was observed for the tensile strength and modulus of the samples, regardless of the chemical foaming agent type. In addition, experimental results indicated that foaming reduced the Izod impact resistance of both neat rigid PVC and rigid PVC/wood‐flour composites but that this reduction was not statistically significant for the composites. A comparison between batch microcellular processing and extrusion foam processing was made, which demonstrated that foams with very fine cells (microcellular processed) exhibit better impact strength than foams with larger cells (extrusion processed with CFAs).     

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.     

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.     

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.     

Accelerated ultraviolet weathering of PVC/wood‐flour composites

Ultraviolet weathering performance of polyvinyl chloride (PVC) filled with different concentrations of wood flour was studied. Extruded PVC/wood‐flour composite samples were subjected to cyclic ultraviolet lamps/condensation exposures and assessed over a total of 400 and 2600 hours. Each assessment consisted of DRIFTFTIR and XPS collections, contact angle measurement, color measurement, and tensile property testing. The experimental results indicated that wood flours are effective chromophore materials since their incorporation into a rigid PVC matrix accelerated the degradation of the polymeric matrix. Photodegradation converted unfilled PVC samples to a colored material of lower extensibility. Although composite samples exhibited greater discoloration than unfilled PVC samples, they retained all their original strength and stiffness properties even after 2600 hours of cyclic UV irradiation/condensation exposures.     

PVC/wood‐flour composites compatibilized with chlorinated polyethylene

Chlorinated polyethylene has been demonstrated to be an effective compatibilizer for dissimilar materials in various mixed‐polymer or recycled‐polymer systems. In this paper the use of chlorinated polyethylene to compatibilize polymer/natural‐fiber composites is discussed. Examples of applications in PVC/wood‐flour composites are given.     

Photoaging and stabilization of rigid PVC/wood‐fiber composites

Ultraviolet (UV) weathering performance of unpigmented and rutile titanium dioxide pigmented rigid polyvinyl chloride (PVC)/wood‐fiber composites has been studied. The composite samples were manufactured by dry‐blending PVC, wood fibers, and other processing additives in a high‐intensity mixer. The dry‐blended compounds were extruded and compression molded into panel samples. The manufactured samples were artificially weathered using laboratory accelerated UV tests. Composite samples were exposed to 340‐nm fluorescent UV lamps and assessed every 200 h, for a total of 1200 h of accelerated weathering. Each assessment consisted of a visual examination of surface roughness or erosion, a contact angle measurement, a FTIR collection, and a color measurement. The experimental results indicated that wood fibers are effective sensitizers and that their incorporation into a rigid PVC matrix has a deleterious effect on the ability of the matrix to resist degradation caused ultraviolet irradiation. The light stability of these composites could be improved quite efficiently with the addition of rutile titanium dioxide photoactive pigment during formulation. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 80: 1943–1950, 2001     

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     

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     

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.     

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.     

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     

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.     

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.     

Thermal and mechanical properties of polypropylene/wood‐flour composites

In this research, polypropylene/wood‐flour composites (WPCs) were blended with different contents of wood and/or maleated polypropylene (MAPP) and clay. We found that the addition of MAPP or clay in the formulation greatly improved the dispersion of the wood fibers in the composite; this suggested that MAPP or clay may have played the role of an adhesion promoter in the WPCs. The results obtained with clay indicate that it also acted as a flame retardant. The thermal tests carried out with the produced samples showed an increased crystallization temperature (T_c), crystallinity, and melting temperature (T_m) with wood loading. The increase of the two former parameters was explained by the incorporation of wood flour, which played the role of nucleating agent and induced the crystallization of the matrix polymer. On the other hand, the T_m increase was ascribed to the insulating properties of wood, which hindered the movement of heat conduction. The effects of UV irradiation on T_m and T_c were also examined. T_c increased with UV exposure time; this implied that UV degradation generated short chains with low molecular weight that could move easily in the bulk of the sample and, thus, catalyze early crystallization. The flexural strength and modulus increased with increasing wood‐flour content. In contrast, the impact strength and tensile strength and strain decreased with increasing wood‐flour content. All of these changes were related to the level of dispersion of the wood flour in the polymeric matrix. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Surface microencapsulated ammonium polyphosphate with beta‐cyclodextrin and its application in wood‐flour/polypropylene composites

In order to improve the hydrophilicity of ammonium polyphosphate (APP), as well as its compatibility with composite matrix, in this research, beta‐cyclodextrin (β‐CD) was crosslinked by polydiphenylmethane diisocyanate (PMDI) and used as clothing to prepare microencapsulated APP (MCAPP) via polymerization in situ . Then, APP and MCAPP were mixed with wood‐flour and polypropylene to manufacture wood‐flour/polypropylene composites (WPCs) by hot pressing. Both APP and MCAPP were characterized by Fourier transform infrared spectroscopy (FTIR), X‐ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), water solubility tests, and water contact angle (WCA) tests. Limiting oxygen index (LOI) and cone calorimetry tests were used to investigate the flame retardancy of WPCs. Moreover, laser Raman spectroscopy and real‐time FTIR (RT‐FTIR) were used to explore the flame retardant mechanism. Results indicated that APP was successfully coated by the crosslinked β‐CD. MCAPP showed lower water solubility and better surface hydrophobicity, and WPC/MCAPP performed better flame retardnacy and mechanical properties. POLYM. COMPOS., 38:2312–2320, 2017. © 2015 Society of Plastics Engineers     

Surface chemistry and mechanical property changes of wood‐flour/high‐density‐polyethylene composites after accelerated weathering

Although wood–plastic composites have become more accepted and used in recent years and are promoted as low‐maintenance, high‐durability building products, they do experience a color change and a loss in mechanical properties with accelerated weathering. In this study, we attempted to characterize the modulus‐of‐elasticity (MOE) loss of photostabilized high‐density polyethylene (HDPE) and composites of wood flour and high‐density polyethylene (WF/HDPE) with accelerated weathering. We then examined how weathering changed the surface chemistry of the composites and looked at whether or not the surface changes were related to the MOE loss. By examining surface chemistry changes, we hoped to begin to understand what caused the weathering changes. The materials were left unstabilized or were stabilized with either an ultraviolet absorber or pigment. After 1000 and 2000 h of accelerated weathering, the samples were tested for MOE loss. Fourier transform infrared (FTIR) spectroscopy was employed to monitor carbonyl and vinyl group formation at the surface. Changes in the HDPE crystallinity were also determined with FTIR techniques. It was determined that structural changes in the samples (carbonyl group formation, terminal vinyl group formation, and crystallinity changes) could not be reliably used to predict changes in MOE with a simple linear relationship. This indicated that the effects of crosslinking, chain scission, and crystallinity changes due to ultraviolet exposure and interfacial degradation due to moisture exposure were interrelated factors for the weathering of HDPE and WF/HDPE composites. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 2263–2273, 2004     

Influence of a stabilized cap layer on the photodegradation of coextruded high density polyethylene/wood‐flour composites

The effect of light stabilizer's addition method into wood‐plastic composites (WPCs), i.e., surface versus bulk, on their photostability was evaluated. Blends of ultraviolet absorbers (benzotriazole or hydroxyphenyltriazine) with a hindered amine light stabilizer were used as the stabilizing additives. Both unstabilized and photostabilized uncapped (control) samples, as well as coextruded WPCs counterparts, were exposed to up to 3000 h of accelerated artificial weathering. The light transmittance, surface morphology, and color of the samples before and after weathering were analyzed by UV‐vis spectroscopy, SEM, and Chroma Meter. The experimental results indicated that the method of adding the light stabilizer had a significant effect on the WPC photostability. While bulk addition reduced the degree of fading in uncapped composite, it did not suppress it completely. On the other hand, coextruded WPCs with photostabilized cap layers showed no visible signs of fading, thus clearly indicating that the stabilized cap layers blocked most of the UV radiation, and thereby prevent of UV light to reach the surface of the inner layer of coextruded composites. Cost‐analysis considerations indicated that 50 times more light stabilizer was needed when it was incorporated into the bulk of the composites rather than in the cap layer of coextruded samples. Clearly, these results suggest that adding light stabilizers at the surface of WPCs not only protects them against UV degradation, but also is a most efficient and cost‐effective method of photostabilization than bulk addition. J. VINYL ADDIT. TECHNOL., 19:239–249, 2013. © 2013 Society of Plastics Engineers     

Effects of material parameters on the diffusion and sorption properties of wood‐flour/polypropylene composites

Composites of wood in a thermoplastic matrix (wood–plastic composites) are considered a low maintenance solution to using wood in outdoor applications. Knowledge of moisture uptake and transport properties would be useful in estimating moisture‐related effects such as fungal attack and loss of mechanical strength. Our objectives were to determine how material parameters and their interactions affect the moisture uptake and transport properties of injection‐molded composites of wood‐flour and polypropylene and to compare two different methods of measuring moisture uptake and transport. A two‐level, full‐factorial design was used to investigate the effects and interactions of wood‐flour content, wood‐flour particle size, coupling agent, and surface removal on moisture uptake and transport of the composites. Sorption and diffusion experiments were performed at 20°C and 65 or 85% relative humidity as well as in water, and diffusion coefficients were determined. The wood‐flour content had the largest influence of all parameters on moisture uptake and transport properties. Many significant interactions between the variables were also found. The interaction between wood‐flour content and surface treatment was often the largest. The diffusion coefficients derived from the diffusion experiments were different from those derived from the sorption experiments, suggesting that different mechanisms occur. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 752–763, 2007