K.ARAVIND KUM 201 Wood Plastic Composites An Overview
Oct 24, 2015
BY K.ARAVIND KUMAR 2012250002
BY K.ARAVIND KUMAR 2012250002
Wood Plastic Composites An Overview
Presentation Outline
O Introduction to Wood Plastic Composites
O Historical DevelopmentO Milestones in CommercializationO Technology StatusO Benefits of wood plastic compositesO ApplicationsO Future markets & business
opportunities
Definition
Wood Plastic Composite ( WPC )
Any composite that contains wood & thermoset
or thermoplastic
Thermoset : Epoxy , Phenolics Thermoplastics: PE, PP, PVC, PS
Introduction
O First Generation WPCs Recycled woodchips / flour & binder Designed for undemanding
applicationsO New Generation WPCs High Performance products Good mechanicals High dimensional stability Complex shapes Extruded products with high
dimensional tolerance
Introduction
“The new generation WPCs are
produced by mixing wood flour or fiber & plastics to produce a material that can be processed like a conventional plastic & has the best features of wood & plastic”
Plastic Lumber
O Recycled PlasticsO Extruded profilesO May / may not include wood flourO Application – Sleepers on rail roads
Historical Perspectives
O1900 : Bakelite ( Gear shift knobs for Rolls Royce)
O1920: Birth of the WPC industry
Marriage of plastic processing &
forest products industry
Initial Impediments to Growth
O Forest Product Industry ViewpointsO Alien to Plastic materialsO Few common material & equipment
suppliersO Only exposure to vinyl sidingsO Lack of Market Knowledge &
application areasO Plastic Industry Viewpoints
O Conversant with mineral fillers & reinforcements
O Aversion to wood & natural fibers
Wood as a filler: Plastic Industry’s Viewpoints
OLow bulk density of wood flour vis-a vis plastics
( 0.5)OLow specific gravity of woodOLow thermal stability of woodOTendency to absorb moisture
The Turn AroundThe last decade saw
OGreater awareness from both sidesOSuccess of several WPC productsOGreater understanding of wood
fillerODevelopments in compounding
equipmentsODevelopment in additivesOEmerging opportunities in large
volume building application sector
Forest Products Industry: Change in Perception
O WPCs :Products with little maintenanceO Low maintenance : USP Of WPCsO Forest Product companies : Suppliers of
WPCs
Synergize knowledge of wood flour
& core competence in
building products
Milestones in The Commercialization Of
WPCsYear Company Product
1975 G.O.R., Italy Woodstock patent
1983 American Woodstock
Lear Corporation
50% WF/PP sheets for thermoforming for auto interiors
1990 Strandex Corporation Highly filled WPC extruded profiles& shapes
1991 AERT Later TREX 50 % WF/PE for deckboards, picnic tables etc
1993 Andersen Corporation WF reinforced PVC sub sills for French doors & window lines
Technology Status of WPCs
Market Potential O Global market size : 320,000MT in 2000O Expected Volume : More than double in 2005
Wood Filled Composites Natural Fiber Filled Composites
Technology Status Of WPCsMaterial Attributes
Thermoplastic Material End-Use
PE Virgin & recycled Exterior building components
PP Virgin Automotive
Profiles
PVC Virgin Building profiles & decking & windows
Technology Status Of WPCsPolymer Attributes
Selection of Thermoplastic matrix
* Inherent properties of polymer * Product requirements * Availability * Cost
Technology Status Of WPCsAttributes of wood
O Wood flour : Particulate, l/d 2:1 to 4:1
O Wood fiber : Reinforcing, l/d greater than 24:1
O Commonly used species : Pine, Maple Oak
O Typical particle size : 10 to 80 meshO Price : Indian Rs. 15 to 20/- per KgO Price : Imported Rs. 35 to 45/-per Kg
Technology Status Of WPCsManufacture & Processing
O Two stage Process: Compounded pellets & shaping
O Commonly Used processing Techniques
Sheets & profile extrusion Thermoforming Compression Molding Injection MoldingO New Trend In-Line Compounding &
Processing
Salient Features of Extrusion of WPCs
O Two stage Process - compound & shaping
O Two Extruders in tandem Twin screw Compounding and shaping
Extrusion of WPCs
New Developments In Equipments
O American Maplan Corp : Counter rotating TSE, conical & parallel for direct extrusion
O Woodtruder American Davis Standard ( Crompton): First Stage drying extruder & side arm extruder for injection of polymer melt into the main extruder. Up to 80 % wood flour
O Wilmington Machinery: 375 tons two stage injection molding for foamed WPCs
Manufacturing Wood / PP Composites
Machinery For Wood PP Composites
Additive Developments Aid Growth of WPCs
O Tailor-made lubricantsO Special HALSO AntimicrobialsO Blowing agentsO ColorantsO UV stabilizersO Foaming agents
Wood Filled
PP
Application BenefitsO Improved dimensional stability - increased
strengthO Lower processing temperatures - less energy usedO Increased heat deflection temperature - reduced
thermal expansionO Up to 30% reduced cycle time for injection
moulded products - increased productivityO Approximately 10 - 20% lower specific gravity
- lighter productsO Reduced shrinkage - lower internal shear in
pultrusion applicationO Low volumetric cost
ConventionalFillers Vs Wood Filler
AWF Wood Flour Weight Savings
Specific Gravity40% Filled Resin -
Polypropylene
Flexural MOE Versus %
Wood Flour2.0 2.2
3.23.8
4.5
0.0
1.0
2.0
3.0
4.0
5.0
20 30 40 50 60
% Wood Filler
Fle
xu
ral M
OE
(G
Pa
)
1.1
1.251.27 1.27
1
1.05
1.1
1.15
1.2
1.25
1.3
Wood Flour(AWF - 4020)
Talc CalciumCarbonate
Fiberglass
Fillers
We
igh
t
Wood Filled PP Products
Wood Filled PP Products
Wood Filled PP Products
Foaming Expands Possibilities For
Wood Fibre / PP Composites
Foaming Expands Possibilities For
Wood Fibre / PP Composites
Breakthrough Technology“Plastic Steel from Wood
Filled PP”O Expanded Oriented Wood filled PPO Low temperature die drawing O Synthetic Hardwood Technologies USAO Automotive side beamsO Wood look – alike
Product Flexural Modulus
( M Pa ) PP 1800 EOW PP 7585
‘Plastics Steel’ Die Drawing Makes From Wood
Filled PP
Material Flexural Strength Flexural Modulus
(MPa)
PP 48 1860
Wood 96 8946
O-PP 276 7585
EOW-PP 138 7585
Ram extrusion of PP / wood filled creates light weight wood-like material, even
stronger than wood
Wood Fibre Adds Stiffness & Value
To Tight Tolerance Tubes
Polypropylene Developments
Wood Filled Repol PPfor Door Trims
PVC / Wood Composites
Outlook For The Future
O USA: 50 % growth rate of WPCs for building products
O ASTM Standards for building products based on WPCs
O Automotive : 15 % growth rate
Innovation in processing &
product performance
Summary
The future of wood plastic composites will ultimately
depend on many factors; including new product
identification, product quality, consumer perception
& performance of these materials !
REFERENCEO http://wpc-composite-
decking.blogspot.com/p/what-is-wood-plastic-composite-wpc.html
O Clemons, C. (2002) "Wood-plastic Composites in the United States: The interfacing of two Industries" Forest Products Journal 52(6)
O http://www.wpcextruder.com/news_show-13.html Introduction of WPC Wood Plastic Composite Products
REFERENCE Stark, N. (2001) “Influence of Moisture Absorption on Mechanical Properties of Wood Flour-Polypropylene Composites.” Journal of Thermoplastic Composite Materials 14O Hamel, S. (2011) Modeling the Time-dependent Flexural Response of Wood-plastic Composite Materials Dissertation, University of Wisconsin–MadisonOMorrell, J et al.(2006) “Durability of wood-plastic composites.” Wood Design Focus 16(3)
REFERENCEO http://
www.decksandfencesbyryan.com/articles/21-composite-vs-wood.html
O http://fencedeck.ca/decks/mississauga-composite-deck/
O http://wpcinfo.org/techinfo/Fire_Studies.html Washington State University Wood Plastic Composites Information Center, "Fire Issues in Engineered Wood Composites for Naval Waterfront Facilities", 46th International SAMPE Symposium and Exhibition, Long Beach, California, May 2001
REFERENCEO http://www.enn.com/business/article/
24261 Environmental News Network, "California Fire Codes Put Focus on Plastic Decking Concerns" 5 Nov 2007
O BibliographyO Anatole A. Klyosov. Wood-Plastic Composites.
John Wiley & Sons, Hoboken, New Jersey, 2007, 698 pp.
O Asta Eder, Andreas Haider: Marktchancen für Wood Polymer Composites im deutschsprachigen Raum. In: Holztechnologie. 52 (2011), S. 44-49, (online)
O Retrieved from "http://en.wikipedia.org
USEFUL ???????? ANY WAY
THANK YOU