Wood Plastic Composites An Overview

Presentation Outline
Introduction to Wood Plastic Composites Historical Development Milestones in Commercialization Technology Status Benefits of wood plastic composites Applications Future markets & business opportunities

Definition
Wood Plastic Composite ( WPC )
Any composite that contains wood & thermoset or thermoplastic Thermoset : Epoxy , Phenolics Thermoplastics: PE, PP, PVC, PS

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

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

Plastic Lumber

Recycled Plastics Extruded profiles May / may not include wood flour Application Sleepers on rail roads

Historical Perspectives
1900 : Bakelite ( Gear shift knobs for Rolls Royce) 1920: Birth of the WPC industry

Marriage of plastic processing & forest products industry

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

Wood as a filler: Plastic Industrys 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

The Turn Around The 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

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

Milestones in The Commercialization Of WPCs

Year 1975 1983 Company G.O.R., Italy American Woodstock Lear Corporation Product Woodstock patent 50% WF/PP sheets for thermoforming for auto interiors

1990 1991

Strandex Corporation AERT Later TREX

Highly filled WPC extruded profiles& shapes 50 % WF/PE for deckboards, picnic tables etc
WF reinforced PVC sub sills for French doors & window lines

1993

Andersen Corporation

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

Technology Status Of WPCs Material Attributes

Thermoplastic
PE

Material
Virgin & recycled

End-Use
Exterior building components Automotive Profiles Building profiles & decking & windows

PP

Virgin

PVC

Virgin

Technology Status Of WPCs Polymer Attributes Selection of Thermoplastic matrix

* Inherent properties of polymer * Product requirements * Availability * Cost

Technology Status Of WPCs Attributes 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

Technology Status Of WPCs Manufacture & 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

Salient Features of Extrusion of WPCs

Two stage Process - compound & shaping

Two Extruders in tandem Twin screw Compounding and shaping

Extrusion of WPCs

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

Manufacturing Wood / PP Composites

Machinery For Wood PP Composites

Additive Developments Aid Growth of WPCs

Tailor-made lubricants Non stearate & compatibilizer package Special HALS Antimicrobials Blowing agents

Wood Filled PP

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

1.3 1.25 1.25 1.2

Weight

1.27

1.27

Conventional Fillers Vs Wood Filler

AWF Wood Flour Weight Savings Specific Gravity 40% Filled Resin Polypropylene

1.15 1.1 1.1 1.05 1 Wood Flour (AWF - 4020) Talc Calcium Carbonate Fillers Fiberglass

Flexural MOE (GPa)

Flexural MOE Versus % Wood Flour

5.0 4.0 3.0 2.0 2.0 1.0 0.0 20 30 40 50 2.2 3.8 3.2

4.5

60

% Wood Filler

Wood Filled PP Products

Wood Filled PP Products

Wood Filled PP Products

Foaming Expands Possibilities For Wood Fibre / PP Composites

Foaming Expands Possibilities For Wood Fibre / PP Composites

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 PP EOW PP Flexural Modulus ( M Pa ) 1800 7585

Plastics Steel Die Drawing Makes From Wood Filled PP

Material

Flexural Strength (MPa)

Flexural Modulus

PP Wood O-PP EOW-PP

48 96 276 138

1860 8946 7585 7585

Ram extrusion of PP / wood filled creates light weight wood-like material, even stronger than wood

Wood Fibre Adds Stiffness & Value To Tight Tolerance Tubes

Polypropylene Developments
Wood Filled Repol PP for Door Trims

PVC / Wood Composites

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

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 !