Injection molded hybrid composites based on corn fibers and poly(vinyl alcohol)

Ongoing research cooperation between USDA and the University of Pisa, Italy has yielded several composite blends of poly(vinyl alcohol) (PVA) and corn fibers (CF). The USA is the largest producer of ethanol from cereal grains. Composites based on natural fibers alone are extremely sensitive to water. Their mechanical properties deteriorated upon the absorption of water, thus suggesting a limited usefulness of such formulations in practical applications. In this study, corn-fibers produced during the wet milling process of corn for fuel ethanol were used to prepare composites. CF and PVA were processed in variable amounts in the presence of both dry/fluid plasticizers, such as glycerol and pentaerythritol. Composites prepared from CF in combination with PVA showed little change in their mechanical properties even after conditioning at variable relative humidities, as well as complete soaking in water. Composites tested after storage for one year under 50% relative humidity and 23°C exhibited mechanical properties similar to those of freshly prepared composites. Cornstarch was introduced in the formulation for the purpose of reducing the cost of the final product and to further increase the composition of natural components in the composites. Addition of starch moderately reduced the mechanical properties of the composites.