Novel cellulose fibre reinforced thermoplastic materials

Spun cellulose fibres from the viscose, lyocell and carbamate processes have been used to reinforce thermoplastic commodity polymers, such as polypropylene (PP), polyethylene (PE) and (high impact) polystyrene (HIPS) as well as poly(lactic acid) (PLA) and a thermoplastic elastomer (TPE) for injection moulding applications. A specially developed double pultrusion technique has been employed for compounding. Fibres were analysed in single fibre tensile tests. Strength, stiffness, impact strength, and heat distortion temperature (HDT) were determined for injection-moulded standard test specimen and structural features were revealed by scanning electron microscopy. A strong reinforcing effect was observed in all cases. In particular, high tenacity tyre cord rayon gives excellent composite strength and impact strength, often doubling or tripling the pristine matrix values. In the case of PP, Lyocell type fibres provide enhanced stiffness and HDT, and thus the combination of both fibre types leads to a balanced composite property profile. The PE case is very similar to PP. For HIPS mainly strength and stiffness is increased, while for TPE the property profile is changed completely. With PLA, a biogenic and biodegradable composite with excellent mechanical properties is presented.     

Effects of Water and Chemical Solutions Ageing on the Physical,Mechanical, Thermal and Flammability Properties of Natural Fibre-Reinforced Thermoplastic Composites

Biocomposites comprising a combination of natural fibres and bio-based polymers are good alternatives to those produced from synthetic components in terms of sustainability and environmental issues. However, it is well known that water or aqueous chemical solutions affect natural polymers/fibres more than the respective synthetic components. In this study the effects of water, salt water, acidic and alkali solutions ageing on water uptake, mechanical properties and flammability of natural fibre-reinforced polypropylene (PP) and poly(lactic acid) (PLA) composites were compared. Jute, sisal and wool fibre- reinforced PP and PLA composites were prepared using a novel, patented nonwoven technology followed by the hot press method. The prepared composites were aged in water and chemical solutions for up to 3 week periods. Water absorption, flexural properties and the thermal and flammability performances of the composites were investigated before and after ageing each process. The effect of post-ageing drying on the retention of mechanical and flammability properties has also been studied. A linear relationship between irreversible flexural modulus reduction and water adsorption/desorption was observed. The aqueous chemical solutions caused further but minor effects in terms of moisture sorption and flexural modulus changes. PLA composites were affected more than the respective PP composites, because of their hydrolytic sensitivity. From thermal analytical results, these changes in PP composites could be attributed to ageing effects on fibres, whereas in PLA composite changes related to both those of fibres present and of the polymer. Ageing however, had no adverse effect on the flammability of the composites.     

Cellulose man-made fibre reinforced polypropylene—correlations between fibre and composite properties

A series of viscose fibres from the tyre cord type varying in mechanical parameters and titre were compounded with polypropylene to produce fibre reinforced composites. Single fibre strength is analysed in detail and conclusions are drawn with respect to effective strength values in composite applications. Composites were analysed in terms of tensile and impact properties. Correlations between single fibre and composite properties are studied. High fibre elongation leads to favourable composite impact properties via high composite elongations at break. Using water as a plastisizing agent increasing fibre elongation, notched Charpy impact strength can be improved by more than 50%. Using a modified rule of mixtures and a shear lag model for the composite modulus it was shown how a titre reduction improves the composite stiffness by an increased interfacial area. A direct fibre-composite strength correlation was not found.     

High-performance polyolefin composites by chemical modification

The paper will give a short introducing survey on the present state of polyolefin and copolyolefin cross linking. The combination of high-density polyethylene (PEHD) and polypropylene (PP) with elastomers, particularly with ethylene-propylene terpolymer (EPDM), results in high-impact strength PP (HI-PP) and in thermoplastic elastomers (TPE) considered as high-performance polyolefin composites (HP-POC). By filling of PEHD and PP, HP-POCs with increased stiffness, modulus, and abrasion resistance can be produced. They are cost - advantageous substitutes for construction materials as, for example, ABS. Possibilities and limits are demonstrated by own investigations in this field. Best mechanical properties are obtained by reinforcement with fibres, particularly with glass fibres. Requirement for superior parameters is a chemical coupling between glass-fibre surface or glass-fibre size, respectively, and the PP matrix. A new adhesive agent on the basis of siloxane allows to reach high strength and toughness of the composites. The effect seems to be due to a better mutual penetration of the adhesive agent, the size, and the PP matrix. Outlooks will be given on the further development of HP-POC in the field of reinforcement and reactive combination with other polymers.     

New PP/PLA/cellulose composites: effect of cellulose functionalization on accelerated weathering behavior (accelerated weathering behavior of new PP/PLA/cellulose composites)

Polylactic acid (PLA) was used as partial replacement for conventional thermoplastic matrix, new composites comprising cellulose, polypropylene (PP), and PLA being realized. In order to obtain a compatible interface between cellulosic pulp and polymeric matrix, two chemical modifications of cellulose with stearoyl chloride and toluene di‐isocyanate (TDI) were performed, structural changes being evidenced by X‐ray photoelectron spectroscopy and Fourier transform infrared spectroscopy. The composite materials were characterized by Fourier transform infrared spectroscopy, scanning electron microscopy, dynamic scanning calorimetry, impact, tensile and melt rheological tests, surface tension, and dynamic vapor sorption. Because promising results for impact strength and Young modulus were recorded when replacing 15% of PP with PLA in blends of PP with the same cellulosic pulp load, the aim of our study was to assess the behavior to accelerate weathering of composites comprising PP, cellulosic pulp, and PLA. Although the slight decrease in the mechanical properties was recorded after accelerated weathering, the use of functionalized cellulose successfully prevented the deterioration of surface materials, especially for composite comprising stearoyl chloride treated cellulose pulp. Copyright © 2015 John Wiley & Sons, Ltd.     

Research progress in the heat resistance,toughening and filling modification of PLA

Due to its high strength, high modulus, excellent clarity, good biodegradability and biocompatibility, poly(lactic acid) (PLA), a bio-based thermoplastic polyester, has evolved into a competitive commodity material with potential to replace conventional petrochemical-based polymers. However, the wide applications of PLA have been hampered by its native drawbacks, such as low heat distortion temperature (HDT), inherent brittleness and relatively high cost. In recent years, researchers have devoted to breaking above-mentioned bottleneck and attempted to extend the application of PLA. This review will summarize recent work about the modification of PLA, especially focusing on enhancing HDT, toughening and reducing cost.     

The influence of pre-treatment of Spartium junceum L. fibres on the structure and mechanical properties of PLA biocomposites

Different chemical pre-treatments of Spartium junceum L. fibres using alkali (NaOH), nanoclay (MMT) and Citric acid (CA) with the aim of producing biodegradable composite material are discussed. As environmental requirements in processing technologies have been higher in recent years, the Polylactic acid (PLA) is used in this research as a matrix, due to its renewability, biodegradability and biocompatibility. Biocomposites are prepared by reinforcing PLA with randomly oriented, short Spartium junceum L. fibres in order to increase material strength. The effects of different pre-treatments of Spartium junceum L. fibres on the mechanical properties of final biocomposite material are examined. Fibre tenacity is studied using Vibroscop and Vibrodyn devices. Tensile strength of biocomposite material was measured on the universal electromechanical testing machine Instron 5584. The results indicate that biocomposites reinforced with fibres modified with MMT and CA show upgraded mechanical properties of the final composite material in comparison with the composite materials reinforced with referenced (nontreated) fibres. Infrared spectra of tested fibres and biocomposites were determined with Fourier transform infrared spectroscopy using Attenuated total reflection (FT-IR ATR) sampling technique and the influence of fibre modifications on the fibre/polymer interfacial bonding was investigated. The interface of Spartium/PLA composites was observed with scanning electron microscope (SEM) and it was clearly visible that biocomposites reinforced with fibres modified by MMT and CA showed better interaction of fibres and matrix.     

What is the technical and environmental interest in reusing a recycled polypropylene-hemp fibre composite?

The integration of the environmental problem in the design of industrial products leads us to incorporate vegetal fibres and recycled polymers into composite materials. The aim of this work is to study the behaviour and the environmental interest of a recycled PP/hemp fibre after several injection cycles. The mechanical and rheological behaviour of recycled PP/hemp composite was first studied by using tensile, dynamical mechanic analysis and rheological measurements. Then, to better understand the influence of the recycling, a morphology study was carried out on composites by using optical and electron microscopy. Finally, we investigated the environmental advantages of our composite thanks to a simplified environmental assessment. Our results highlighted the environmental interest of using a recycled matrix to prepare composites reinforced with vegetal fibres and the interesting properties of this material after recycling.     

Kapok/cotton fabric–polypropylene composites

Kapok/cotton fabric has been used as reinforcement for conventional polypropylene and maleic anhydride grafted polypropylene resins. Treating the reinforcement with acetic anhydride and sodium hydroxide has modified the fabric (fibres). Thermal and mechanical properties of the composites were investigated. Results show that fibre modification gives a significant improvement to the thermal properties of the plant fibres, whereas tests on the mechanical properties of the composites showed poor tensile strength. Mercerisation and weathering were found to impart toughness to the materials, with acetylation showing slightly less rigidity compared to other treatments on either the fibre or composites. The modified polypropylene improved the tensile modulus and had the least toughness of the kapok/cotton reinforced composites. MAiPP reinforced with the plant fibres gave better flexural strength and the same flexural modulus at lower fibre content compared with glass fibre reinforced MAiPP.     

The Case for Polylactic Acid as a Commodity Packaging Plastic

Abstract

Polylactide, sometimes called polylactic acid (PLA), meets many requirements as a packaging thermoplastic and is suggested as a commodity resin for general packaging applications. Its general physical properties and melt processing ease are similar to conventional packaging resins. PLA slowly degrades by hydrolysis in even a slightly moist environment over a period of several months to a year to environmentally-friendly products, which, in turn, biodegrade to carbon dioxide, methane, and water. PLA is a clear, colorless thermoplastic when quenched from the melt and is similar in many respects to polystyrene. When plasticized with its own monomers, PLA becomes increasingly flexible so that a continuous series of products can be prepared that can mimic PVC, LDPE, LLDPE, PP, and PS. Degradation is increased with increasing plasticizer, and shelf life is favored by decreasing plasticizer content and/or orientation. Orientation also substantially improves tensile strength, modulus, and heat stability. A general rationale for the commercial development of PLA is presented.     

Accelerated weathering of unbleached and bleached Kraft wood fibre reinforced polypropylene composites

In this paper, combined moisture/ultraviolet (UV) weathering performance of unbleached and bleached Kraft wood fibre reinforced polypropylene (PP) composites was studied. Composites containing 40 wt% fibre with 3 wt% of a maleated polypropylene (MAPP) coupling agent were fabricated using extrusion followed by injection moulding. Composite mechanical properties were evaluated, before and after accelerated weathering for 1000 h, by tensile and impact testing. Differential scanning calorimetry (DSC), X-ray diffraction (XRD), thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) were also carried out to assess the changes occurring during accelerated weathering. Bleached fibre composites initially showed higher tensile and impact strengths, as well as higher thermal stability and greater crystallinity. During accelerated weathering, both unbleached and bleached fibre composites reduced tensile strength (TS) and Young's modulus (YM), with the extent of the reduction found to be similar for both unbleached and bleached fibre composites. Evidence supported that the reduction of TS and YM was due to PP chain scission, degradation of lignin and reduced fibre-matrix interfacial bonding.     

Analysis of moisture sorption in lyocell-polypropylene composites

The preparation of composites by thermoforming of intermingled fibre slivers is an efficient method to receive high performance and lightweight materials. Cellulosic fibres have benefits like low density and sustainability but the sorption of water due to the high hydrophilicity of the cellulose requires attention. The swelling of the wet fibres changes the fibre-matrix adhesion and as a consequence, the mechanical strength of the composite is influenced negatively. In this study, the thermoplastic polypropylene was combined with lyocell fibres as reinforcement. Moisture sorption isotherms of cellulose/polypropylene composites were recorded as function of relative humidity. Additionally, the specific surface area was analysed by the Brunauer–Emmett–Teller model. It has been found, that the moisture sorption is influenced by the polypropylene (PP) ratio in the composites. At 60% relative humidity the moisture uptake of the lyocell fibres was reduced from 10.8 to 5.8% for lyocell embedded in a composite with 50% polypropylene. Besides the hysteresis between moisture sorption/desorption cycles was found to be proportional to the increased content of PP. The “Parallel Exponential Kinetics” (PEK) model was used to analyse the kinetics of moisture sorption of these composites in more detail. With the help of the PEK model the sorption/desorption kinetics were described by a fast and slow moisture sorption/desorption process. The capacity for rapid moisture sorption is reduced by the formation of PP layers on the lyocell surface. The share of slow moisture sorption increased with increasing PP content in the composite. The results support understanding of the interaction of water with cellulose containing composites.     

Low velocity impact response of flax/polypropylene hybrid roving based woven fabric composites: Where does it stand with respect to GRPC?

Flax-PP based thermally bonded roving (TBR) has a unique structure where the flax fibres remain twist-free and fully aligned along the roving axis. The present study describes an experimental investigation on the low velocity impact (LVI) behaviour of the TBR based woven fabric composites and compares the same with plain woven glass fabric reinforced PP composites (GRPC). Two different fabric architectures namely plain woven (PW) and unidirectional (UD) are fabricated using flax/PP based TBR. These TBR based woven fabrics and the glass fabric/PP sheets are consolidated in a compression moulding machine and the resultant composite-laminates are tested for their LVI behaviour. The impact test results revealed that the glass/PP composites absorb more energy and exhibit a higher peak load than both TBR based PW and UD fabric composites. However, the specific load and energy of all flax/PP composites are higher than the glass/PP composite. The damage tolerance of all composite laminates are evaluated by comparing their flexural strength before and after the impact. It is observed that the proportionate loss in flexural strength due to impact thrust is larger in case of glass/PP composites than all flax-PP composites.     

Date palm fibre filled recycled ternary polymer blend composites with enhanced flame retardancy

Flammability of recycled polypropylene (PP)/low density polyethylene (LDPE)/high density polyethylene (HDPE) ternary blends containing date palm fibres is investigated in this study. Melt blending is used for the composite preparation and the palm fibres induce good mechanical strength to the blend composites. The effect of flame retardant magnesium hydroxide, is studied through the limiting oxygen index analysis and cone calorimeter studies. Morphology of the palm fibres in presence of fire retardant reveals interesting facts of base hydrolysis. Since the polymers used are recycled ones and the fibres are obtained from the date palm leaves, the whole composite manufactured stands as low cost, less energy consuming and environmental friendly. Though the flame retardant reduced the mechanical properties, the palm fibres strengthened the whole composite thus helping to achieve the flame retardancy and mechanical properties simultaneously. Flame retardancy is correlated with the thermal degradation and thermal conductivity of the blend fibre composites as well.     

IFSS, TG, FT-IR spectra of impregnated sugar palm (Arenga pinnata) fibres and mechanical properties of their composites

This study aimed to investigate the effect of resin impregnation on the interfacial shear strength (IFSS), thermogravimetric (TG) and fourier transform infrared (FT-IR) of sugar palm (Arenga pinnata) fibres. In addition, the effect of resin impregnation on the mechanical properties of sugar palm fibre reinforced unsaturated polyester (UP) composites was also studied. The fibres were impregnated with UP via vacuum resin impregnation process at a pressure of 600 mmHg for 5 min. Composites of 10, 20, 30, 40 and 50 % fibre loadings were fabricated and tested for tensile and flexural properties. It was observed that the impregnation process caused the fibres to be enclosed by UP resin and this gave a strong influence to the increase of its interfacial bonding by the increase of its IFSS from single fibre pull-out test. It was also observed with TG and FT-IR spectra that the impregnated fibre had lower moisture uptake than the control and there was no significant increase in thermal stability of the impregnated fibre. The sequence of fibre decomposition started from the evaporation of moisture, hemicelluloses, cellulose, lignin and finally ash content and the presence of these components were proven by FT-IR spectra. For the composite specimens, due to the high interfacial bonding of the impregnated fibre and the matrix, the impregnated composites showed consistently higher tensile strength, tensile modulus, elongation at break, flexural strength, flexural modulus and toughness than the control samples. It was also observed that 30 % fibre loading gave optimum properties.     

Biodegradation of sequentially surface treated lignocellulose reinforced polylactic acid composites: Carbon dioxide evolution and morphology

Maple fibres were treated with a variety of sequential treatments, namely sodium hydroxide (NaOH), NaOH followed by acetylation, or NaOH followed by silanation. These fibres were incorporated into a polylactic acid (PLA) composite and the biodegradation effects were investigated. After 124 days, all composites had exceeded 90% biodegradation with most close to 100%. The PLA composite with the NaOH-treated fibres had the quickest onset of degradation (4.9 days) and highest peak rate of degradation (1.77% biodegradation/day) of all composites studied. Neat PLA had a similarly high peak rate of degradation at 1.85% biodegradation/day, but had a later onset of 11 days. Gel permeation chromatography (GPC) analysis showed the earlier onset of degradation of the composites was caused by increased hydrolysis during composite fabrication as well as composting. GPC showed the formation of up to three molecular weight bands in the PLA during composting which were hypothesised to be occurring by surface hydrolysis, bulk hydrolysis and hydrolysis at the fibre interface. Analysing the remaining composite revealed the NaOH treatment not only caused an increased rate of degradation in the PLA through increase fibre porosity, but also caused an increased rate of degradation in the fibre from the lack of surface waxes and hemicellulose. Similar, yet slower, behaviours were also seen in the NaOH followed by acetylation and NaOH followed by silane treated composites with all composites degrading more rapidly than the neat PLA and neat maple fibre samples.     

Thermoplastic composites based on flax fibres and polypropylene: Influence of fibre length and fibre volume fraction on mechanical properties

Natural-fibre-mat-reinforced thermoplastic (NMT) composites based on flax fibre mats and a Polypropylene (PP) matrix were manufactured using (i) a film-stacking method and (ii) a paper making process. The influence of fibre length and fibre content on stiffness and strength is reported and compared with data for glass-mat-reinforced thermoplastic (GMT) composites, including the influence of using maleic-anhydride grafted PP. The data is also compared with existing micromechanical models like Kelly-Tyson and Cox-Krenchel for strength and stiffness, respectively. A good agreement was found between theory and experiment in case of stiffness while in case of strength the experimental values fall well below the theoretical predictions. Results indicated that NMTs are of interest for low-cost engineering applications and can compete with commercial GMTs, especially when a high stiffness per unit weight is desirable. Results also indicated that the key area for future development lies not only in improved adhesion but mainly in improving the fibre strength.     

Damping analysis of nonwoven natural fibre-reinforced polypropylene composites used in automotive interior parts

The aim of this work is to evaluate the dynamic properties of nonwoven flax, hemp, kenaf and glass fibre-reinforced polypropylene (PP) composites. Also, the influence of some parameters, such as the type of reinforcement, the fibre/matrix weight ratio, the fibre orientation and the porosity content, on the damping behaviour of these nonwoven composites is investigated. To this end, a free flexural vibrations analysis was conducted to experimentally identify their natural frequencies and their associated loss factors. The obtained results show that the nonwoven composites reinforced by natural fibres present higher loss factors compared with those of the glass-PP composite. These interesting damping properties make these nonwoven composites very attractive for automotive applications where the dissipation of vibrations is highly requested.     

Factors and processes influencing the reinforcing effect of layered silicates in polymer nanocomposites

The analysis of the tensile yield stress of a large number polymer/layered silicate composites showed widely differing mechanical properties. The composition dependence of yield stress can be described and evaluated quantitatively by a simple model developed earlier for particulate filled polymers. The comparison of data produced in our laboratory or taken from the literature indicated that several processes may take place during the preparation of the composites and a considerable number of factors influence composite properties. Quite a few of these are often neglected and percentage increase in modulus, strength or other properties is reported in published papers instead. The most important of such effects are changing matrix properties when a functionalized polymer is used to promote adhesion (PE, PP), modification of crystalline structure due to nucleation (PA, PP), plasticization or lubrication (PVC), decreased interaction (PA, PVC, PET, rubbers) or chemical reactions (PVC, PP, PET). Using a few simple assumptions, most of which are supported by previous experience, the extent of exfoliation can be estimated quantitatively in nanocomposites. The analysis of the tensile yield stress of more than 80 composites with various matrices indicated that the extent of exfoliation is very low in most composites; it reaches maximum 10% in the best case, which corresponds to about 10 silicate layers per stack. Although the approach has limitations and several factors were neglected during analysis, this result is in agreement with observations indicating that complete exfoliation rarely can be reached in thermoplastic/clay composites. In order to achieve larger reinforcement, silicates must be exfoliated more perfectly in the future.     

Mechanical properties of hybrid glass/sugar palm fibre reinforced unsaturated polyester composites

A research has been carried out to investigate the mechanical properties of composites made by hybridizing sugar palm fibre (Arenga pinnata) with glass fibre into an unsaturated polyester matrix. Hybrid composites of glass/sugar palm fibre were fabricated in different weight ratios of strand mat glass fibres: sugar palm fibres 4:0, 4:1, 4:2, 4:3, 4:4, and 0:4. The hybrid effects of glass and sugar palm fibre on tensile, flexural and impact properties of the composites were evaluated according to ASTM D5083, ASTM D790 and ASTM D256 respectively. Results have been established that properties of hybrid glass/sugar palm composites such as tensile strength, tensile modulus, elongation at break, toughness, flexural strength, flexural modulus and impact strength are a function of fibre content. The failure mechanism and the adhesion between fibres/matrix were studied by observing the scanning electron micrographs of impact fracture samples. In general, the incorporation of both fibres into unsaturated polyester matrix shows a regular trend of increase in the mechanical properties.