Kompetenzzentrum Holz GmbH
Wood Polymer Composites – Applications for natural fibres, wood, cellulose and biomass as
reinforcement or filler for thermoplastic polymersDr. Claudia Pretschuh, Dr. Andreas Haider
What are Wood-Polymer Composites (WPC)?
What are Wood-based Polymers?What is known?
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..are polymers (plastics, biopolymers or recycling polymers) combined with cellulosic materials (wood particles, cellulose fibers, plant fibers…), which act as filler and reinforcing material.
Wood Polymer Composites
Source: www.northstarrecycling.comwww.prontoaerospace.comwww.jrs.eu
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WPC - DeckingsPortugal: Kork basierte WPC
http://www.pinuform.de
Source: TCKT
http://www.holzdenzel.de/publish/afe1ba6c_7e90_43c1_79c6811ccf16cb41.cfm
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Raw MaterialsPossible Polymers
Polyethylene (PE), Polypropylene (PP), Polyvinylchloride (PVC), Biopolymers, Thermosets, recycled Polymers
Additives for Plasticslubricant, coupling agent, inorganic filler, pigments, UV-stabilizer, biocide, algaecide, flame retardant, …
Bioplasticsnews.com
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Raw MaterialsWood / Natural fibres
wood flour and natural fibres (hemp, flax), Kraft-pulp fibres, regenerated-cellulose, alternative resources: wood-”waste”, rice hulls, paper/-”waste”, cork, biomass…
Requirements:• dry materials• good pourability
Hemp Soft wood Pulp
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Why “Natural” Composites?
http://gtms1317.wordpress.com/2013/04/09/damping-characteristics-flax-fiber-composites/http://www.flaxwood.com/mo
dels/2hb-h+2hb-t+rautia/
4) “Natural” designCombination of natural look with polymer processing every shape and surface ideas are possible
5) Special acoustic properties and vibration absorptione.g. loud speaker cases, music instruments, bicycle frames (flax fibers)
1) Improved mechanical properties compared with pure polymers
Stiffness and strength, heat deflection, toughness (crash behavior)2) Ecological advantage
Use of sustainable raw materials3) Weight reduction
Reduction of density by replacement of high-density mineral fillers (talcum, glass fibers)
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…are polymers derived from woodLignin and celluloseTecnaro is using Lignin as polymer in their Arboform® materials – fully biobased, called “Liquid Wood”.
Wood Based Polymers
Tecnaro and „Liquid Wood“ as Case Study
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Tecnaro Profile at Agriforvalor Page
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Tecnaro Profile at Agriforvalor Page
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• Successful – serial production for many specialized products– 2006: serial production for automotive industry (founded 1998)– 2008: 40% growth in sales– more than 40 household articles from Arbofill®
• Focus in sustainability (100% biobased, multiple/cascading use of wood)• Services
– material production and development – consulting – continually research on new formulations and improve of processing
Tecnaro: Case Study for Good Practice
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3 Product Lines (4000 different compounds)
Based on lignin “liquid wood” Based on biopolymer blends (reinforced)Combining plastic and natural materials
Wood K plus–leading Research Institute in the
area wood and wood-related renewable resources
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Wood K plus in AustriaHeadquarter + WPC Science Park Linz
WCC at Lenzing
• R&D Institute for Wood Composites & Wood Chemistry
• Founded in 2001• 110 scientific
employees• 4 business units
and one cross sectional areaMarket analysis and Innovation Research
WMT at UFT Tulln
W3C in St. Veit a.d. Glan
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Division WPC – Projects & ServicesDevelopment of innovative bio(based)-materialsProcess Development
Trials in own pilot plants forCompounding, Profile-Extrusion and Injection Moulding
Material CharacterizationRaw materials: Wood, Natural Fibres and PolymersCompoundComposite
Consulting and Technical Support
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R & D – ExtrusionPortugal: Cork based WPC for
outdoor and maritime applications
http://www.pinuform.de
Thailand: Development of a PVC-based formulation with customer related wood fibres for outdoor usage
Green body, C-Template and C/Si/SiC-ceramic
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FIBROMER® Prototypes
Automotive
Quelle: http://www.mondigroup.com/products/desktopdefault.aspx/tabid-1913/
Salad bowl
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References – 100% bio-based
http://www.releva.at/
Regional 3D-FFF-printing
Application Samples -for Wood Polymer or Natural Fiber Reinforced Composites
Mehrwerk design, 2007Werzalit
Staedtler
Hiendl NFC®
Application Samples
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dishes etc., www.tecnaro.de
www.edding.com
http://www.dm.de/de
Application Samples
23Kareline Composite used by Kupilka, Flaxwood and Fenron
Tecnaro used by Gucci, ECO PUMP, 2010 Babel Pico, 2010
Application Samples
GRENADILL-COMPOSITE Fa. Rödel, 2010
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Wood- / NF-filled Filaments for 3D Printing
http://www.3ders.org/articles/20141214-jelwek-launches-3d-printed-wood-filament-watch-collection.htmNew corkFill Wood pulp stick filament
Issues in Material andProcess Development for
WPC
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Fiber-Matrix-Adhesion
without and with coupling agent
Coupling agentas additive isnecessary if high material strengthis required
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Fiber Length
0
5
10
15
20
25
30
0 100 200 300 400 500 600 700 800 900 1000
Frequ
ency
[%]
Fiber length [µm]
FCP 300
SC 500
SC 700
02468
101214161820
0 100 200 300 400 500 600 700
Frequ
encyl
[%]
Fiber length [µm]
PP-FCP 300 / TSE20PP-SC 500 / TSE20PP-SC 600 / TSE20PP-SC 600 / TSE95
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Processing TemperatureHigher injection mould temperatures (>200 °C) leads to: odour change in colour lower mechanical properties
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Material Homogeneitydepending on compounding equipment
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Manifold applications possible, performance is customizable but often niche products
Different production processes possible (different polymer processing) adaption/optimization of standard procedures always necessary
Marketing is often inadequate Awareness for biobased/biogenic non-fossil materials
SustainabilityUse of sustainable biobased raw materials, recycling possibleSustainable processing (low temperatures, fast cycle times,
sustainable additives) is important
Conclusions
New Applications for Wood-related Materials
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Biogenic SiC-ceramics based on WPC
Green body, C-Template and C/Si/SiC-ceramic (green body / left: 3 mm wall thickness and inner cross, right: 4 mm)
Developed at Wood K plus
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Activated carbon: porous carbon materialsMain application: adsorption (waste water purification, gas purification)
New application: electrode material for supercapacitors (current raw material: coconut shell fibres, cellulose materials), necessary for E-mobility
Issues: cheaper raw materials and production ways (carbon yield)
Activated Carbon from Biomass
Prof. Cao, University of Washington Example for AC: Zorflex® by Chemviron Carbon Wood K plus developed
carbon cell inserted in outer measuring setup
Kompetenzzentrum Holz GmbH
Andreas Haider Area Manager
Division Wood Polymer CompositesAltenbergerstrasse 69
4040 Linz, AustriaTel.: +43 (0)732 2468-6771
mobile: +43 (0)664 964 9806E-mail: [email protected]
… to achieve sustained success
