new engineering-grade wpc and its potential in...
TRANSCRIPT
New Engineering-grade WPC and its Potential in Automobile
Industry
Yousoo Han, PhD. Univ. of MaineDoug Gardner, PhD. Univ. of Maine
Duncan Mayes, Stora EnsoJanne Pynnonen, Stora Enso
2017 SPE ACC&E, Novi, MI, USA. Sept 6-8, 2017
INTRODUCTION TO WOOD PLASTIC COMPOSITES
Thermally formed profiles made of natural fibers and conventional thermoplastics
www.teknowpcboards.com
http://www.duofuse.com
INTRODUCTION TO WOOD PLASTIC COMPOSITES
BETTER THAN WOOD
BETTER THAN PLASTIC
Environmental Friendly High ModulusLow CostMachining Ease (Sawn, Plane, Cut, etc.)Thermal Stability
Dimensional Stability Superior Water ResistanceDecay ResistanceFreedom in Engineered Shapes
(Hollow, I-Beam, etc.)
WORD MARKETS OF WOOD PLASTIC COMPOSITES
2014 Global WPC market sizeUSD $2.6 ~ 3.5 Billion USA
(48%)Asia(31%)
EU(15%)
6%
USA$1.3B
Asia$0.85B
EU$0.39B
$0.15B
2019 Global WPC market sizeUSD $4.6 Billion
CAGR12.2%
* Estimated and projected by RnR Market Research Inc. & Freedonia Consulting.
2018 US Markets of Plastic lumber + WPCUSD $5.5 Billion
In total US decking market of $6.6 Billion(Projected by Freedonia Consulting)
percentage USD
WPC VS. STRUCTURAL?
No thermoplastic composites available for structural applications so far.
Structural timbers
TimbersAlaska cedarAspenDouglas Fir-SouthGlued LamPWPlywood (Falk, etc. 1999)OSBOriented Strand boardOPBOriented particle board
Glued Lam-flat Glued Lam-edge PW OSB OPB PE-based SMA-basedWood plastic composites
Generic design valuefor structural applications
PP-COMPOSITES IN AUTOMOBILES?
CNF improves PP but not much as GF that is much heavier than WPC.
PP composites filled with cellulose nanofibers [5 ~15% by wt.]
PP composites filled with glass fiber/talc [20% by wt.]
WPC LIMITATIONS IN STRUCTURAL/AUTOMOBILE
MECHANICAL Low stiffness Low strength Low impact strength
DIMENSIONAL CREEP Moisture-induced Heat-induced Weight-induced
PHYSICAL Weak water resistance
WPC LIMITATIONS IN FORMULATIONS
FORMULATIONS Weak matrices
[PP, PE] Low Tm required Low heat resistance
INTERFACES Not strong bonding between
wood & plastics Coupling agent helps but
limited (2~5% by weight)
STRATEGIC APPROACHES
New polymer matrices Engineering polymers or blends:
PA, PET, SMA, HIPS etc.
New strength enhancers & Additives
Moisture-resistant fibers Hybrids with GF or CF fiber, etc.
New interfaces Chemical linkages Optimal compatability
NEW HPTP-MW-WPC
Research conceptAdoption of a new polymer system
Use of ThermoWood for better performanceStrong interfaces between wood & polymer
High performanceTechnical polymer
[HPTP]
Styrene Maleic AnhydrideCopolymer
[SMA]
Cellulose-richWood fiber
=Best compatibility
by same backboneAffordable plasticGood properties
+
Strong chemical bonding
SMA IN NEW HPTP-MW-WPC
Polymer blends with SMA & HPTP Styrene Maleic Anhydride copolymer [SMA]
SMA has been a popular polymer in automobiles because of its novel thermal, physical, & mechanical properties.
It is being used now as a metal replacement in EU automobiles.
Low CTE, heat performance, high surface energy, moldable for injection, compression, extrusion, etc.
Brittleness can be improved by polymer blends.
XIRAN SMA sunroof frame for Citroen DS3 Cabrio
NEW HPTP-MW-WPC
Research conceptAdoption of a new polymer to SMA-WPC lumberUse of novel modified wood fiber (MW)
Creation of strong interfaces
Stora Enso developed and introduced a novel modified wood fiber for:
Superior dimensional stability Superior biological durability Good compatibility to polymer matrices
NEW HPTP-MW-WPC with 50% WF by weight
Production of lumber samples
NEW HPTP-MW-WPC LUMBERS
500% stiffer
Results : Flexural properties
HPTP-MW-WPC with various formulations CommercialWPC lumber
NEW HPTP-MW-WPC LUMBERS
Results : Flexural properties
250% stronger
HPTP-MW-WPC with various formulations CommercialWPC lumber
NEW HPTP-MW-WPC LUMBERS
Results : CTE (coefficient of thermal expansion)
500% less
HPTP-MW-WPC with various formulations HPTP[Without MW]
NEW HPTP-MW-WPC LUMBERS
Results : Moisture resistance
Commercial WPCAfter 24 h
24 times less
HPTP-Pine
HPTP-MW
NEW HPTP-MW-WPC LUMBERS
Results : Stora Enso’s fiber vs. Pine50% stiffer &60% stronger than pine
HPTP[Without MW]
HPTP-Pine HPTP-MW
NEW HPTP-MW-WPC LUMBERS Vs. STRUCTURAL?
New HPTP-MW-WPC lumbers
NEW HPTP-MW-WPC FOR AUTOMOBILES?
Properties comparisons of PP-based composites in automobiles
NEW HPTP-MW-WPC FOR AUTOMOBILES?
Properties comparisons of PP-based composites in automobiles
?
APPLICATIONS OF NEW HPTP-MW-WPC LUMBERS
Application example: Ocean farms
Global Market valued at USD $135 B in 2012 & USD $203 B in 2020 Growing at a CAGR 5.1% until 2020 Aquaculture is 40% of the total fish marketplace Global 2013 production: 70 MT with CAGR 2.3%
APPLICATIONS OF NEW HPTP-MW-WPC LUMBERS
Application example: Ocean farms- Collaboration with UMaine, Stora Enso, & InnovaSea
Recycled HDPE plastic lumbers reinforced with GF or bar inserts
Current lumber
APPLICATIONS OF NEW HPTP-MW-WPC
Not for automobiles? Why not!Splinterhttp://jalopnik.com/5870797/the-ten-coolest-wooden-cars-of-all-time/
1924 Hispano Suiza H6C Tulipwood Torpedo by Nieuporthttp://www.carstyling.ru/ru/entry/Hispano_Suiza_H6C_Tulipwood_Torpedo_by_Nieuport_1924/images/2573//
New HPTP-MW-WPC shows Excellent properties For structural/automobile.
New fish cage is now being built Using HPTP-MW-WPC lumbers For its 1st commercialization.
You have a new applicationFor automobile/structural? Contact to UMaine & Stora Enso!
