wood plastic composites
DESCRIPTION
The new generationTRANSCRIPT
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Wood Plastic Composites An Overview
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Presentation Outline
• Introduction to Wood Plastic Composites• Historical Development• Milestones in Commercialization• Technology Status• Benefits of wood plastic composites• Applications• Future markets & business opportunities
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Definition
Wood Plastic Composite ( WPC )
Any composite that contains wood & thermoset
or thermoplastic
Thermoset : Epoxy , Phenolics
Thermoplastics: PE, PP, PVC, PS
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Introduction
• First Generation WPCs Recycled woodchips / flour & binder
Designed for undemanding applications
• New Generation WPCs
High Performance products
Good mechanicals
High dimensional stability
Complex shapes
Extruded products with high dimensional tolerance
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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”
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Plastic Lumber
• Recycled Plastics
• Extruded profiles
• May / may not include wood flour
• Application – Sleepers on rail roads
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Historical Perspectives
• 1900 : Bakelite ( Gear shift knobs for Rolls Royce)
• 1920: Birth of the WPC industry
Marriage of plastic processing
&
forest products industry
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Initial Impediments to Growth
• Forest Product Industry Viewpoints– Alien to Plastic materials
– Few common material & equipment suppliers
– Only exposure to vinyl sidings
– Lack of Market Knowledge & application areas
• Plastic Industry Viewpoints– Conversant with mineral fillers & reinforcements
– Aversion to wood & natural fibers
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Wood as a filler: Plastic Industry’s Viewpoints
• Low bulk density of wood flour vis-a vis plastics
( 0.5)• Low specific gravity of wood• Low thermal stability of wood• Tendency to absorb moisture
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The Turn AroundThe last decade saw
• Greater awareness from both sides• Success of several WPC products• Greater understanding of wood filler• Developments in compounding equipments• Development in additives• Emerging opportunities in large volume building
application sector
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Forest Products Industry: Change in Perception
• WPCs :Products with little maintenance• Low maintenance : USP Of WPCs• Forest Product companies : Suppliers of WPCs
Synergize knowledge of wood flour & core competence in building products
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Milestones in The Commercialization Of WPCs
Year 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
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Technology Status of WPCs
Market Potential
• Global market size : 320,000MT in 2000
• Expected Volume : More than double in 2005
Wood Filled Composites Natural Fiber Filled Composites
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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
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Technology Status Of WPCsPolymer Attributes
Selection of Thermoplastic matrix
* Inherent properties of polymer
* Product requirements
* Availability
* Cost
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Technology Status Of WPCsAttributes of wood
• Wood flour : Particulate, l/d 2:1 to 4:1• Wood fiber : Reinforcing, l/d greater than 24:1• Commonly used species : Pine, Maple Oak• Typical particle size : 10 to 80 mesh• Price : Indian Rs. 15 to 20/- per Kg• Price : Imported Rs. 35 to 45/-per Kg
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Technology Status Of WPCsManufacture & Processing
• Two stage Process: Compounded pellets & shaping
• Commonly Used processing Techniques Sheets & profile extrusion Thermoforming Compression Molding Injection Molding• New Trend In-Line Compounding & Processing
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Salient Features of Extrusion of WPCs
• Two stage Process - compound & shaping
• Two Extruders in tandem Twin screw Compounding and shaping
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Extrusion of WPCs
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New Developments In Equipments
• American Maplan Corp : Counter rotating TSE, conical & parallel for direct extrusion
• 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
• Wilmington Machinery: 375 tons two stage injection molding for foamed WPCs
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Manufacturing Wood / PP Composites
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Machinery For Wood PP Composites
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Additive Developments Aid Growth of WPCs
• Tailor-made lubricants
• Non stearate & compatibilizer package
• Special HALS
• Antimicrobials
• Blowing agents
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Wood Filled PP
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Application Benefits
• Improved dimensional stability - increased strength
• Lower processing temperatures - less energy used
• Increased heat deflection temperature - reduced thermal expansion
• Up to 30% reduced cycle time for injection moulded products - increased productivity
• Approximately 10 - 20% lower specific gravity - lighter products
• Reduced shrinkage - lower internal shear in pultrusion application
• Low volumetric cost
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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
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Wood Filled PP Products
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Wood Filled PP Products
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Wood Filled PP Products
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Foaming Expands Possibilities For Wood Fibre / PP Composites
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Foaming Expands Possibilities For Wood Fibre / PP Composites
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Breakthrough Technology“Plastic Steel from Wood Filled PP”
• Expanded Oriented Wood filled PP• Low temperature die drawing • Synthetic Hardwood Technologies USA• Automotive side beams• Wood look – alike
Product Flexural Modulus ( M Pa )
PP 1800 EOW PP 7585
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‘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
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Wood Fibre Adds Stiffness & Value To Tight Tolerance Tubes
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Polypropylene Developments
Wood Filled Repol PPfor Door Trims
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PVC / Wood Composites
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Outlook For The Future
• USA: 50 % growth rate of WPCs for building products
• ASTM Standards for building products based on WPCs
• Automotive : 15 % growth rate
Innovation in processing & product performance
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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 !