Continuous cellulose fiber-reinforced cellulose ester composites III. Commercial matrix and fiber options

Thermoplastic composites were prepared using two continuous regenerated cellulose fiber types, rayon and lyocell, and with several different commercially-available thermoplastic cellulose esters as matrix. Matrix options included cellulose acetate propionate (CAP), and several cellulose acetate butyrates (CAB) with different butyryl content, having different molecular weights and different methods of plasticization (adipates and very low molecular weight cellulose ester fractions). Choice of cellulose ester type was generally found to have little or no effect on mechanical properties. A significant effect, however, was revealed for fiber type. The lyocell-based composites thereby were reflective of the greater stiffness of a fiber produced from anisotropic solution state. Their modulus consistently exceeded 20GPa whereas the rayon fiber-based composites had moduli between 6 and 8GPa. The latter, however, possessed failure strains that were 3 to 4 times greater than their stiffer counterparts.     

Continuous cellulose fiber-reinforced cellulose ester composites. II. Fiber surface modification and consolidation conditions

We prepared thermoplastic composite panels using solution impregnation of continuous lyocell (regenerated cellulose) fibers with a cellulose mixed-ester (cellulose acetate butyrate) matrix. We examined both fiber-matrix adhesion and melt consolidation in an effort to produce uniform panels having low void content and high mechanical strength. We characterized the effect of surface modification by acetylation on interfacial adhesion between the cellulose fiber and cellulose ester. Whereas wood fiber acetylation had previously been observed to result in significant strength gains in (discontinuous) wood fiber- reinforced composites (with the same matrix material), we did not observe a similar increase in strength in the continuous lyocell cellulose fiber system. This suggests that interfacial stress transfer is not a limitation in this system. This was confirmed by microscopic examination of the fracture surfaces, which indicated that fiber-matrix adhesion was considerable in the absence of fiber surface modification. We then systematically varied melt consolidation conditions (temperature, pressure and time) in an attempt to define optimum consolidation parameters by using design of experiments (DOE) methodology. We measured both interlaminar shear strength (ILSS) and composite void volume. We found that a minimal void content (ca. 2.83 vol. %) occurred at moderate temperatures (200°C), low consolidation pressures (81.4kPa) and long press times (13min). This was also where we maximized the interlaminar shear strength (ILSS) at a value of 16.3MPa. This agrees with the regression model predictions. We observed the highest tensile properties at the ILSS and void-volume optimal-consolidation condition: a tensile modulus of 22GPa and tensile strength of 246MPa were obtained.     

Computer simulation of crystallization kinetics and morphology in fiber-reinforced thermoplastic composites. I. Two-dimensional case

A body of experimental evidence suggests that reinforcing fibers influence both the crystallization kinetics and morphology of those composite materials that are based on crystallizable thermoplastics. The absence of an analytical model to predict the effect of fibers on crystallization has hindered data analysis. A new approach, using computer simulation of polymer crystallization, makes it possible to study the influence that reinforcing fibers have on the crystallization kinetics and morphology of semicrystalline polymers. Fibers depress the crystallization rate relative to an unreinforced polymer since they constrain spherulitic growth by an impingement mechanism. On the other hand, reinforcing fibers can also enhance crystallization rate by providing added surface nucleation sites. This work describes a two-dimensional simplification of the crystallization process that occurs in bulk materials. It is demonstrated that the relative bulk and fiber nucleation densities, in addition to the fiber fraction, fiber diameter, and spherulitic growth rate control the crystallization kinetics and also the spherulitic and transcrystalline morphologies that develop in reinforced thermoplastic composites. © 1993 John Wiley & Sons, Inc.     

Banana fiber-reinforced biodegradable soy protein composites

Banana fiber, a waste product of banana cultivation, has been used to prepare banana fiber reinforced soy protein composites. Alkali modified banana fibers were characterized in terms of density, denier and crystallinity index. Fourier transformed infrared spectroscopy (FTIR), scanning electron microscopy (SEM) and thermogravimetric analysis (TGA) were also performed on the fibers. Soy protein composites were prepared by incorporating different volume fractions of alkali-treated and untreated fibers into soy protein isolate (SPI) with different amounts of glycerol (25%–50%) as plasticizer. Composites thus prepared were characterized in terms of mechanical properties, SEM and water resistance. The results indicate that at 0.3 volume fraction, tensile strength and modulus of alkali treated fiber reinforced soy protein composites increased to 82% and 963%, respectively, compared to soy protein film without fibers. Water resistance of the composites increased significantly with the addition of glutaraldehyde which acts as cross-linking agent. Biodegradability of the composites has also been tested in the contaminated environment and the composites were found to be 100% biodegradable.     

Sugar beet cellulose nanofibril-reinforced composites

Cellulose was isolated from sugar beet chips, a by-product of sugar production, by wet chemistry. Further processing of the cellulose with a high-pressure homogeniser led to the disruption of cell walls into nanofibrils. Cellulose sheets obtained by casting and slow evaporation of water showed higher strength and stiffness when homogenised cellulose was used compared to unhomogenised cellulose. These cellulose sheets showed significantly better mechanical performance than Kraft paper tested for reference. The addition of cellulose nanofibrils to a polyvinyl alcohol and a phenol-formaldehyde matrix, respectively, demonstrated excellent reinforcement properties. The best mechanical performance was achieved for a composite with a phenol-formaldehyde resin content of 10%, which showed a tensile strength of 127 MPa, a modulus of elasticity of 9.5 GPa, and an elongation at break of 2.9%.     

Computer simulation of crystallization kinetics and morphology in fiber-reinforced thermoplastic composites. III. Thermal nucleation

A computer simulation has been used to predict crystallization kinetics and crystalline morphology in composite materials based on thermally nucleated crystallizable matrices. As demonstrated for athermally nucleated composites, the presence of reinforcing fibers increases the complexity of the system. Fibers are shown to have a dual effect on the spherulitic crystallization process. The influence that fibers have depends on the interplay between the enhancing effects that fibers have on nucleation and the depressing effects that fibers have on spherulitic growth. Fibers that do not provide additional nuclei to the system depress the rate of crystallization relative to an unreinforced polymer, while fibers that add nuclei to the system increase the rate of crystallization. The transcrystalline morphologies that develop in thermally nucleated fiber-reinforced polymers are controlled primarily by the relative numbers of bulk and fiber nuclei. The extent of transcrystalline regions can be suppressed either by increasing the rate of bulk nucleation, or by decreasing the rate of fiber nucleation. Finally, the qualitative appearance of the morphology in the transcrystalline region was found to be indicative of the mode of fiber nucleation. © 1995 John Wiley & Sons, Inc.     

Computer simulation of crystallization kinetics and morphology in fiber-reinforced thermoplastic composites. II. Three-dimensional case

A three-dimensional computer simulation has been used to predict crystallization kinetics and crystalline morphology in composite materials that are based on crystallizable thermoplastics. Reinforcing fibers in three-dimensional simulations show similar behavior to those in two-dimensional simulations; fibers suppress crystallization relative to an unreinforced polymer since they constrain spherulitic growth by an impingement mechanism, and also enhance crystallization by providing added surface nucleation sites. The effects of varying controlling parameters on crystallization kinetics and morphology are qualitatively the same as those observed in the two-dimensional case. The relative bulk and fiber nucleation denisities, in addition to the fiber volume fraction, fiber diameter, and spherulitic growth rate control the crystallization kinetics and crystalline morphology that develop in reinforced thermoplastic composites. It is more difficult to achieve the transcrystalline morphology in slices of three-dimensional composites than it is in two-dimensional composites because nuclei in 3-D systems are not constrained to positions in or near a 2-D plane. © 1993 John Wiley & Sons, Inc.     

Thermal behavior of cellulose fibers with enzymatic or Na<Subscript>2</Subscript>CO<Subscript>3</Subscript> treatment

Summary New regenerated cellulose fibers were developed during the last decades as environmentally friendly systems. In this work, three fibers: lyocell, modal and viscose were subjected to an enzymatic treatment. Likewise, different lyocell fibers were washed in a Na₂CO₃ solution under severe conditions. Analysis was performed by means of differential scanning calorimetry, thermogravimetry and scanning electron microscopy. In all samples, at low temperature, water desorption was detected. Furthermore, thermal analysis shows wide exothermic processes that began between 250 and 300°C corresponding to the main thermal degradation and it is associated to a depolymerization and decomposition of the regenerated cellulose. It is accompanied with mass more than 60% mass loss. Kinetic analysis was performed and activation energy values 152-202 kJ mol^-1 of the main degradation process are in agreement with literature values of cellulose samples.     

Changes in the Inter- and Intra- Fibrillar Structure of Lyocell (TENCEL®) Fibers after KOH Treatment

Lyocell fibers were treated with KOH up to 8 M which was demonstrated to distribute homogeneously at the outer zones of fiber cross section compared to NaOH which accesses more deeply but less homogenously. Both NaOH and KOH solutions can be used to lower significantly the fibrillation of lyocell fibers. However, due to intrafibrillar swelling together with deep penetration ability of alkali seen for NaOH treatments results in great fiber tensile strength loss which is not observed for KOH treatments due to its inability to penetrate the fiber completely. The porous structure of fibers was studied by inverse size exclusion chromatography (ISEC) to identify mean pore diameter, total pore area and accessible pore volume (APV). Mean pore diameter of fibers decreased after KOH treatments which did not change after NaOH treatments. Wide angle X-ray diffraction analyses (WAXD) were applied to identify the crystallinity index and crystallite size. In general, fiber properties such as water retention value, carboxyl content using methylene blue sorption method, depth of color measured after dyeing with C.I. Direct Red 81 and weight loss were distinctly different in the ranges up to 2 M, 2-5 M and 5 to 8 M KOH. KOH treatment suggests new possibilities for the pretreatment of lyocell fibers to lower fibrillation while slightly lowering elongation at break without a distinct loss in tensile strength and with less decrease in carboxyl content and weight loss without changing dyeing properties of fibers compared to NaOH treatment.     

Novel cellulose derivatives. II. synthesis and characteristics of mono-functional cellulose propionate segments

Mono-functional cellulose propionate segments for use in ter- or star-block polymers have been prepared by the depolymerization (step 1) of cellulose propionate in homogeneous phase using a mixture of HBr and propionic anhydride in methylene chloride solution. The anomeric mixture of glycosyl bromide has subsequently (step 2) been hydrolyzed in aqueous acetone. Functionality was determined by H-NMR spectroscopy of triethyl silane derivatives in combination with gel permeation chromatography. The cellulose ester segments were semi-rigid, highly crystalline materials with melting points between 180° and 250°C. The lowest useful segment size, based on crystallinity and Mark-Houwink-Sakurada exponential factor, appeared to be DP 20, with an optimum around DP 40 to 50.Part I has been published in theJ. Appl. Polym. Sci.,49, 1671 (1993).     

Self-reinforced composites obtained by the partial oxypropylation of cellulose fibers. 2. Effect of catalyst on the mechanical and dynamic mechanical properties

This work describes the partial oxypropylation of filter paper cellulose fibers, employing two different basic catalyst, viz., potassium hydroxide and 1,4-diazabicyclo [2.2.2] octane, to activate the hydroxyl groups of the polysaccharide and thus provide the anionic initiation sites for the “grafting-from” polymerization of propylene oxide. The success of this chemical modification was assessed by FTIR spectroscopy, X-ray diffraction, scanning electron microscopy, differential scanning calorimetry, thermogravimetric analysis and contact angle measurements. The study of the role of the catalyst employed on the extent of the modification and on the mechanical properties of the ensuing composites, after hot pressing, showed that both the Brønsted and the Lewis base gave satisfactory results, without any marked difference.     

The adhesion coefficient of fiber-reinforced polymers evaluated by dynamic measurements

A theoretical model, consisting of a series of infinite concentric cylinders surrounding a fiber in a composite material, was introduced in this paper to give a quantitative account of interface phenomena, already experimentally observed. A series of specimens, conveniently designed to represent the theoretical model, were subjected to dynamic modes of loading to measure the amount of adhesion between fibers and matrices by means of an adhesion coefficient developed in the theory. It was found that theoretical results for the adhesion between matrix and filler were compatible with the structural characteristics of the specimens tested.     

Thermal degradation of lyocell,modal and viscose fibers under aggressive conditions

Lyocell, modal and viscose fibers were subjected to mercerization or to solar degradation. The ulterior thermal degradation was analyzed by means of differential scanning calorimetry (DSC). Thermal analysis shows wide exothermic processes that began between 250 and 300°C corresponding to the main thermal degradation and are associated to a depolymerization and decomposition of the regenerated cellulose. Thermal degradation was analyzed as a function of concentration and time. Lyocell fiber is the most stable under thermal degradation conditions. Furthermore, mercerized samples are initially more degraded and present a lower thermal stability.     

Studies on the Stabilization of Modified Lyocell Solutions

Additives with functional properties makes the Lyocell process a versatile tool for the creation of new innovative materials beyond the textile sector. Occupying functional groups or active surfaces the additives emphasize the suitability of Lyocell fibers, but simultaneously enhance the complexity of chemical reactions in cellulose/N-methylmorpholine-N-oxide (NMMO) solutions, respectively. Concerning to the concentration acidic ion exchange resins, activated charcoals, carbon black etc. shift the start of decomposition to lower temperatures, decrease the viscosity, enhance the formation of amines as the main degradation products or cause autocatalytic reactions. New routes in stabilization of modified Lyocell solutions applying a polymeric stabilizer system are described. Using calorimetric, UV/VIS, ESR and HPLC analysis the degradation processes and thermal stability of modified Lyocell solutions compared to the unstabilized were studied. Moreover, as kinetic investigations show a distinguished behavior for modified solutions autocatalytic reactions can be suppressed by the stabilizing system. ESR kinetic study of radicals reveals that formation and recombination rates of radical reactions depend on cellulose concentration in Lyocell solutions and additional ingredients.     

Surface treated cellulose fibres in flame retarded PP composites

Polypropylene-based composites were prepared containing non-treated and various treated cotton fibre and wood flakes. A correlation was observed among the fibre treatment and compounding parameters, mechanical and discoloration properties. The structural changes in fibres were demonstrated by Raman spectroscopic and DSC measurements. The possibility for forming cellulose fibre containing flame retardant composites was also investigated. The efficiency of various treatments on compounding, discoloration and mechanical properties enhance in the following order: no treatment < non ionic surfactant < reactive silicone segment containing non ionic surfactant < special silylation treatment. The best results obtained with the special silylation treatment were explained with the more organophilic character and by the thermal stability of the treated fibres. Cellulose fibre as a polyol-charring component and ammonium-polyphosphate together constitute a high performance intumescent flame retardant system in the PP matrix.     

Basic studies on gas solubility in natural rubber–cellulose composites

This work reports sorption processes of oxygen, carbon dioxide, methane, ethylene, and propylene in films of both vulcanized natural rubber and vulcanized rubber–regenerated cellulose composites. The curves representing the pressure dependence of the concentration of carbon dioxide in the composites clearly exhibit a slight concavity with respect to the abscissa axis as a result of adsorption processes taking place in Langmuir sites located in the glassy cellulose component. Adsorption processes are also detected in the sorption curves of ethylene at low pressures. The concavity with respect to the ordinate axis of the curve concentration of propylene versus pressure at high pressure is pretty well described by the Flory‐Huggins formalism. The solubilities of the other gases mainly obey Henry's behavior, adsorption processes in the glassy component being in most cases negligible. Values of the interaction χ parameter for gas–natural rubber and gas–natural rubber composites are obtained from the comparison of the experimental solubility coefficients with those predicted by the Flory‐Huggins theory. The theory suggests that Henry's constant is a linear function of the boiling temperature of the gases. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 2131–2140, 2005     

Novel cellulose derivatives. V. Synthesis and thermal properties of esters with trifluoroethoxy acetic acid

Esters of cellulose with trifluoroethoxy acetic acid (TFAA) were prepared in homogeneous phase using a mixed anhydride with p‐toluenesulfonic acid. Esters with low degree of substitution (DS), and with DS rising from 0 to 3, had hydrophobic character that prevented the usual association with moisture, which is otherwise typical of cellulose esters with low DS. Cellulose trifluoroethoxy acetate (CT) had T_g's declining by about 40 °C per DS‐unit (from 160 to 41 °C) as DS rose from 1 to 3. Mixed esters, cellulose derivatives with acetate and trifluoroethoxy acetate substituents (CAT), exhibited glass‐to‐rubber and melting transitions by DSC. A linear relationship between both T_g and T_m with respect to DS was recorded with the T_g and T_m separated by 30° to 40 °C. This is consistent with cellulose esters described elsewhere. Surprisingly, the T_g's of CT and CAT were found to be identical when the DS was equivalent to the DS of the fluoro substituents (DS_F). © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 486–494, 2000     

Determination of tensile strength of UHMWPE fiber-reinforced polymer composites

Quasi-static tensile test of UHMWPE fiber-reinforced composite laminate is challenging to perform due to low interlaminar shear strength and low coefficient of friction. Tensile tests proposed in the literature were conducted and limitations associated with each method led to the evolution of a new method. Tensile test of single-ply was realized as the best representative of tensile strength of a composite than tensile test of UHMWPE laminate. A fixture was developed for single-ply tests which increased friction and provided the mechanical constraint to slipping. The fixture is easy to fabricate and has provided repeatable results for eight grades of UHMWPE fiber-based (0/90) fabrics. Reported tensile strengths are in quite high range of 900–1500 MPa.     

Ultrafine fibrous cellulose membranes from electrospinning of cellulose acetate

Three solvents, that is, acetone, acetic acid, and dimethylacetamide (DMAc), with a range of solubility parameter δ, surface tension γ, viscosity η and boiling temperature were used to generate mixtures for electrospinning cellulose acetate (CA) (degree of substitution, DS = 2.45). Although none of these solvents alone enables continuous formation of fibers, mixing DMAc with either acetone or acetic acid produced suitable solvent systems. The 2:1 acetone:DMAc mixture is the most versatile mixture because it allows CA in the 12.5–20% concentration range to be continuously electrospun into fibrous membranes. These CA solutions have η between 1.2 and 10.2 poise and γ around 26 dyne/cm and produce smooth fibers with diameters from 100 nm to ～1 μm. Fiber sizes generally decrease with decreasing CA concentrations. The nature of the collectors affects the morphology as well as packing of fibers. Fibers collected on paper have more uniform sizes, smooth surfaces, and fewer defects, whereas fibers collected on water are more varied in size. Electrically conductive solid collectors, such as Al foil and water, favor more tightly packed and less porous membranes. Porous collectors, like paper and copper mesh, produce highly porous membranes. The pores in membranes collected on the Al foil and paper are much better interconnected in the planar directions than those in membranes collected on water. There is evidence that electrospinning induces order in the fibers. Deacetylation of CA membranes is more efficient and complete in NaOH/ethanol than in aqueous NaOH, producing DS values between 0.15 and 2.33 without altering fiber surfaces, packing, or organization. The fully regenerated cellulose membranes are similarly hydrophilic as commodity cellulose fibrous matrices but absorb nearly 10 times as much water. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2119–2129, 2002     

Thermoplastic Cellulose-Based Compound for Additive Manufacturing

The increasing environmental awareness is driving towards novel sustainable high-performance materials applicable for future manufacturing technologies like additive manufacturing (AM). Cellulose is abundantly available renewable and sustainable raw material. This work focused on studying the properties of thermoplastic cellulose-based composites and their properties using injection molding and 3D printing of granules. The aim was to maximize the cellulose content in composites. Different compounds were prepared using cellulose acetate propionate (CAP) and commercial cellulose acetate propionate with plasticizer (CP) as polymer matrices, microcellulose (mc) and novel cellulose-ester additives; cellulose octanoate (C8) and cellulose palmitate (C16). The performance of compounds was compared to a commercial poly(lactic acid)-based cellulose fiber containing composite. As a result, CP-based compounds had tensile and Charpy impact strength properties comparable to commercial reference, but lower modulus. CP-compounds showed glass transition temperature (Tg) over 58% and heat distortion temperature (HDT) 12% higher compared to reference. CAP with C16 had HDT 82.1 °C. All the compounds were 3D printable using granular printing, but CAP compounds had challenges with printed layer adhesion. This study shows the potential to tailor thermoplastic cellulose-based composite materials, although more research is needed before obtaining all-cellulose 3D printable composite material with high-performance.