Hybrid Composites from Waste Materials

Hybrid composites of thermoplastic biofiber reinforced with waste newspaper fiber (NF) and poplar wood flour (WF) were prepared. The weight ratio of the lignocellulosic materials to polymer was 30:70 (w:w). Polypropylene (PP) and maleic anhydride grafted polypropylene (MAPP) were also used as the polymer matrix and coupling agent, respectively. The mechanical properties, morphology and thermal properties were investigated. The obtained results showed that tensile and flexural modulus of the composites were significantly enhanced with addition of biofibers in both types (fiber and flour), as compared with pure PP. However, the increasing in WF content substantially reduced the tensile, flexural and impact modulus, but improved the thermal stability. This effect is explained by variations in fiber morphological properties and thermal degradation. Increasing fiber aspect ratio improved mechanical properties. The effect of fiber size on impact was minimal compared to the effects of fiber content. Scanning electron microscopy has shown that the composite, with coupling agent, promotes better fiber–matrix interaction. The largest improvement on the thermal stability of hybrid composites was achieved when WF was added more. In all cases, the degradation temperatures shifted to higher values after addition of MAPP. This work clearly showed that biofiber materials in both forms of fiber and flour could be effectively used as reinforcing elements in thermoplastic PP matrix.     

Compatibilization Improves Performance of Biodegradable Biopolymer Composites Without Affecting UV Weathering Characteristics

With growing interest in the use of eco-friendly composite materials, biodegradable polymers and composites from renewable resources are gaining popularity for use in commercial applications. However, the long-term performance of these composites and the effect of compatibilization on their weathering characteristics are unknown. In this study, five types of biodegradable biopolymer/wood fiber (WF) composites were compatibilized with maleic anhydride (MA), and the effect of accelerated UV weathering on their performance was evaluated against composites without MA and neat biopolymers. The composite samples were prepared with 30 wt% wood fiber and one of the five biodegradable biobased polymer: poly(lactic) acid (PLA), polyhydroxybutyrate (PHB), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), Bioflex (PLA blend), or Solanyl (starch based). Neat and composite samples were UV weathered for 2000 h (hours), and characterized for morphological, physical, thermal, and mechanical properties before and after weathering. Compared to composites without MA, composites containing MA grafted polymers exhibited improved properties due to increased interfacial adhesion between the fiber and matrix. Upon accelerated weathering, thermal and mechanical properties of 70% of the samples substantially decreased. Surfaces of all the samples were roughened, and drastic color changes were observed. Water absorption of all the samples increased after weathering exposure. Even though the compatibilization is shown to improve composite properties before weathering, it did not affect weathering of samples, as there were no considerable differences in properties exhibited by the composites with MA and without MA after weathering. The results suggest that compatibilization improves properties of biodegradable biobased composites without affecting its UV degradation properties.     

Sustainable Use of Coffee Husks For Reinforcing Polyethylene Composites

The utilization of the coffee husk fiber (CHF) from the coffee industry as a reinforcing filler in the preparation of a cost-effective thermoplastic based composite was explored in this study. The chemical composition and thermal properties of the CHF were investigated and compared with those of wood fiber (WF). CHF proved to be mainly composed of cellulose, hemicellulose and lignin, and exhibited similar thermal behavior to WF. High density polyethylene (HDPE) composites with CHF loadings of from 40 to 70% were prepared using melt processing and extrusion. The processing properties, mechanical behavior, water absorption and thermal performance of these composites were investigated. The effect of maleated polyethylene (MAPE) used as a coupling agent on the composite was explored. The experimental results showed that increasing the CHF loading in the HDPE matrix resulted in an increase in the modulus and thermal properties of the composites, but resulted in poor water resistance. The addition of a 4% MAPE significantly improved the interfacial behavior of the hydrophilic lignocellulosic fiber and the hydrophobic polymer matrix.     

Aromatic/Aliphatic Polyester Blends

Blends of poly(3-hydroxybutyrate) (PHB) and poly(ethylene terephthalate-co-1,4-cyclohexenedimethanol terephthalate) (PETG) were prepared in a batch mixer and in a twin screw extruder and characterized by differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), field emission scanning electron microscopy (FE SEM), flexural tests, biodegradation tests in soil compost and in an enzymatic medium. The torque data showed that the addition of PETG to PHB improved its processability. DSC, DMA and FE SEM showed that the polymers are immiscible with morphology dependent on the processing conditions. A fine dispersion of PETG in the PHB matrix was observed for extruded and injection molded blends. Flexural modulus for blends was higher for blends in comparison with PHB, while the impact resistance of blends containing 20 wt% and 30 wt% of PETG is comparable to the value for PHB. PHB is biodegradable, while PETG did not degrade either in simulated soil or in the α-amylase medium. On the other hand, the PHB phase of the blends degrades under these aging conditions. Thus, the addition of PETG to PHB results in advantage such as improving of processability and Young′s modulus without significant changes in the impact resistance while keeping the biodegradability of PHB.     

Processing Stability and Biodegradation of Polylactic Acid (PLA) Composites Reinforced with Cotton Linters or Maple Hardwood Fibres

Polylactic acid (PLA) composites comprising up to 25 wt% cotton linter (CL) or up to 50 % maple wood fibre (WF) were prepared by compounding and injection moulding. A reduction of crystallinity in the PLA matrix was observed as a result of the thermal processing method. These PLACL and PLAWF composites provided excellent improvements in both stiffness (with increases in tensile and flexural modulus) and toughness (increases in notched impact strength) properties over the neat PLA resin, while the tensile and flexural strengths of the composites were generally unchanged, while the strain at break values were reduced in comparison to the neat PLA. DMA results indicated incorporating these fibres caused the mechanical loss factor (tan δ) to decrease, suggesting better damping capabilities were achieved with the composites. SEM analysis of the impact fractured surfaces of the PLACL composites showed debonding-cavitation at the matrix-fibre interface while the PLAWF composites showed good wetting along its matrix-fibre interface. The composting of these composites up to 90 days showed that the degradation onset time was increased when increasing the fibre loadings, but the maximum degree of degradation and the maximum daily rates of degradation were decreased compared to neat PLA. On a weight basis of fibre loading, the PLACL composites had a quicker onset of biodegradation, a higher maximum daily rate of biodegradation and, overall, a higher degree of biodegradation at 90 days than the PLAWF composites, possibly due to the quicker thermal hydrolysis observed in the PLA matrix of the PLACL composites during processing and composting.     

Renewable Resource-Based Composites of Acorn Powder and Polylactide Bio-Plastic: Preparation and Properties Evaluation

Renewable resource-based composites were prepared with acorn powder and Thermoplastic resin poly(lactic acid) (PLA) by twin-screw extrusion followed by injection molding processing or hot-compression molding processing. The study of the composites microstructure showed poor adhesion between acorn powder and PLA matrix. The hygroscopicity, mechanical properties and melt flow property of composites were promising even though the composites had a 70 wt% content of acorn powder. Silane coupling agent, 4,4′-Methylenebis (phenyl isocyanate) and PLA grafted with maleic anhydride did not show obvious effect on mechanical properties of composites. The impact resistance strength of reinforced composites with steel fiber webs were improved greatly in comparison with those having no steel fiber webs. Thermal properties results of DSC and DMA showed that the presence of acorn powder significantly affected the crystallinity, crystallization temperature (T_c), glass transition temperature (T_g) and melting temperature (T_m) of PLA matrix. The study results proved that composites had superior mechanical properties, enough to partially replace the conventional thermoplastic plastics.     

Effect of Nano-SiO<Subscript>2</Subscript> and Bark Flour Content on the Physical and Mechanical Properties of Wood–Plastic Composites

The aim of this study is to evaluate the impact of nano-SiO₂ and bark flour (BF) on the natural fiber–plastic composites engineering properties made from high density polyethylene (HDPE) and beech wood flour (WF). For this purpose, WF and BF in 60 mesh size and weight ratio of (50, 0 %), (30, 20 %), (10, 40 %) and (0, 50 %) respectively were mixed with HDPE. In order to increase the interfacial adhesion between the filler and the matrix, the maleic anhydride grafted polyethylene was constantly used at 3 wt% for all formulations as a coupling agent. The nano-SiO₂ particles with weight ratio of 0, 1, 2, and 4 % were also utilized to enhance the composites properties. The materials were mixed in an internal mixer (HAAKE) and then the bark and/or wood–plastic composite samples were made utilizing an injection molding machine. The physical tests including water absorption and thickness swelling, and mechanical tests including bending characteristics and un-notched impact strength were carried out on the samples based on ASTM standard. The results indicated that as the BF content increased in the composite, mechanical and physical properties were reduced, but the given properties were increased with the addition of nano-SiO₂. The addition of nano-SiO₂ had a negative impact on the physical properties, but when it was up to 2 %, it increased the impact strength.     

Characterization of composites based on expanded polystyrene wastes and wood flour

This paper aims to evaluate the potential for the use of recycled expanded polystyrene and wood flour as materials for the development of wood plastic composites. The effects of wood flour loading and coupling agent addition on the mechanical properties and morphology of wood thermoplastic composites were examined. In addition, a methodology for the thermo-mechanical recycling of expanded polystyrene waste was developed. The results show that the mechanical properties decreased as the wood flour loading increased. On the other hand, the use of poly(styrene-co-maleic anhydride), SMA, as a coupling agent improved the compatibility between the wood flour and polystyrene matrix and the mechanical properties subsequently improved. A morphological study revealed the positive effect of the coupling agent on the interfacial bonding. The density values obtained for the composites were compared with the theoretical values and showed agreement with the rule of mixtures. Based on the findings of this work, it appears that both recycled materials can be used to manufacture composites with high mechanical properties and low density.     

Characterization of Sorghum Bran/Recycled Low Density Polyethylene for the Manufacturing of Polymer Composites

The objective of the study was to investigate the suitability of using sorghum bran in recycled low density polyethylene (R-LDPE) composites manufacturing. In response to the disposal of environmental problematic agricultural and polymer waste, composite sheets using recycled low density polyethylene and sorghum bran of different loadings (5, 10, 15 and 20 wt%) were prepared by melt compounding and compression molding. The effects of sorghum bran loadings on the mechanical, thermal, water absorption, swelling and crystalline properties of the composites were determined. Characterization of composites was carried out using X-ray diffraction (XRD), differential scanning calorimetry (DSC), thermo gravimetric (TGA/DTG) and mechanical analyses. It was found that increasing fiber loadings resulted to increased moduli and tensile strength while hardness was decreased. XRD indicated that fiber addition to R-LDPE did not change characteristic peak position. DSC results showed that the R-LDPE had significantly larger peak heat flow during cooling run than the blank R-LDPE, showing higher crystallization rates for R-LDPE. The results obtained confirmed that sorghum bran particles showed some potential as a good reinforcement in polymer matrix composites and indicate its thermal stability for possibly future composite applications.     

Biodegradation of γ Irradiated Poly 3-hydroxybutyrate (PHB) Films Blended with Poly(Ethyleneglycol)

Poly(3-hydroxybutyrate) (PHB) was evaluated in blends with poly(ethyleneglycol) (PEG) of different weight average molecular weight (Mw = 300, 600, 1,000 and 6,000). Irradiation of the PHB/PEG films was carried out to different levels of irradiation doses (5 and 10 kGy) and the effects were investigated talking into consideration: thermal properties by differential scanning calorimetry (DSC), perforation resistance, water vapor transmission rate and biodegradation in simulated soil. The addition of plasticizer alters thermal stability and crystallinity of the blends. The improvement in perforation resistance due to irradiation was regarded to be a result of the crosslinking effect. Also, biodegradation assays resulted in mass retention improvements with increases in PEG molar masses, PEG concentration and irradiation dose. The irradiation process was shown to hamper the biodegradation mechanism.     

New Multi-Scale Hybrid System Based on Maple Wood Flour and Nano Crystalline Cellulose: Morphological,Mechanical and Physical Study

In the first part of this work, composites based on polypropylene (PP) and maple wood flour (MF) were prepared by melt compounding using twin-screw extrusion followed by compression molding. The morphological and mechanical properties of the composites were analyzed for three samples: PP, MF/PP and MF/PP containing maleic anhydride grafted polypropylene (MAPP) as coupling agent. The results showed that MF/PP composites have improved mechanical properties, especially tensile modulus (+33 %), with only 8 % increase in density. The addition of MAPP further improved the mechanical properties, in particular tensile modulus (up to 51 %), which could be related to better fiber/matrix adhesion. In the second step, nano crystalline cellulose (NCC) was added to all samples to produce NCC-MF/PP hybrid composites. From the mechanical analysis performed, the hybrid composites with MAPP have improved properties, especially tensile (+53 %) and flexural (+40 %) moduli. These results confirmed that multi-scale hybrid NCC-MF composites can substantially improve the mechanical properties of polyolefins with limited increase in density (14 %) leading to high specific properties.     

Influence of Filler Particle Size on Physical Properties and Biodegradation of Biocomposites Based on Low-Density Polyethylene and Lignocellulosic Fillers

This study examined biocomposites based on low-density polyethylene (LDPE) and lignocellulosic fillers [wood flour (WF) and oil flax straw (FS)] selecting four size fractions of each lignocellulosic material as fillers for the composites. The primary aim was to evaluate the influence of fraction size on the composites’ basic properties; to accomplish this, the composites’ mechanical properties, thermal oxidation, thermophysical characteristics, and water absorption capacity were examined. Then microphotographs of the samples were created and length-to-diameter (L/D) ratio of the fillers was calculated, finding that the L/D ratio increased with increasing particle size. The particle size influenced the oxidative degradation and water absorption processes in composites with oil flax but not in those with WF. Biodegradation tests performed on the recovered soil found that the loss of mass in composites based on LDPE and FS was higher than in the same composites with WF. Moreover, at the initial stage of composting, the biodegradation rate correlated with the size of filler particles (i.e., the larger the particles, the higher the degradation rate of the biocomposite).     

A Processing,Characterization and Marine Biodegradation Study of Melt-Extruded Polyhydroxyalkanoate (PHA) Films

A series of polyhydroxyalkanoates (PHA), all containing 1% nucleating agent but varying in structure, were melt-processed into films through single screw extrusion techniques. This series consisted of three polyhydroxybutyrate (PHB) and three polyhydroxybutyrate-valerate (PHBV) resins with varying valerate content. Processing parameters of temperature in the barrel (165–173 °C) and chill rolls (60 °C) were optimized to obtain cast films. The gel-permeation chromatography (GPC) results showed a loss of 8–19% of the polymer’s initial molecular weight due to extrusion processing. Modulated differential scanning calorimetry (MDSC) displayed glass transition temperatures of the films ranging from −4.6 to 6.7 °C depending on the amount of crystallinity in the film. DSC data were also used to calculate the percent crystallinity of each sample and slightly higher crystallinity was observed in the PHBV series of samples. X-ray diffraction patterns did not vary significantly for any of the samples and crystallinity was confirmed with X-ray data. Dynamic mechanical analysis (DMA) verified the glass transition trends for the films from DSC while loss modulus (E′) reported at 20 °C showed that the PHBV (3,950–3,600 MPa) had the higher E′ values than the PHB (3,500–2,698 MPa) samples. The Young’s modulus values of the PHB and PHBV samples ranged from 700 to 900 MPa and 900 to 1,500 MPa, respectively. Polarized light microscopy images revealed gel particles in the films processed through single-screw extrusion, which may have caused diminished Young’s modulus and tensile strength of these films. The PHBV film samples exhibited the greatest barrier properties to oxygen and water vapor when compared to the PHB film samples. The average oxygen transmission rate (OTR) and water vapor transmission rate (WVTR) for the PHBV samples was 247 (cc-mil/m²-day) and 118 (g-mil/m²-day), respectively; while the average OTR and WVTR for the PHB samples was 350 (cc-mil/m²-day) and 178 (g-mil/m²-day), respectively. Biodegradation data of the films in the marine environment demonstrated that all PHA film samples achieved a minimum of 70% mineralization in 40 days when run in accordance with ASTM 6691. For static and dynamic incubation experiments in seawater, microbial action resulting in weight loss as a function of time showed all samples to be highly biodegradable and correlated with the ASTM 6691 biodegradation data.     

Fiber from DDGS and Corn Grain as Alternative Fillers in Polymer Composites with High Density Polyethylene from Bio-based and Petroleum Sources

The steady increase in production of corn based ethanol fuel has dramatically increased the supply of its major co-product known as distiller’s dried grain with solubles (DDGS). Large amount of DDGS and corn flour are used as an animal feed. The elusieve process can separate DDGS or corn flour into two fractions: DDGS fraction with enhanced protein and oil content or corn flour fraction with high starch content, and hull fiber. This study investigated the feasibility of using fiber from DDGS and corn grain as alternative fillers to wood fiber in high density polyethylene (HDPE) composites made with two different sources of polymers. Two fiber loading rates of 30 and 50% were evaluated for fiber from DDGS, corn, and oak wood (control) to assess changes in various physical and mechanical properties of the composite materials. Two HDPE polymers, a bio-based HDPE made from sugarcane (Braskem), and a petroleum based HDPE (Marlex) were also compared as substrates. The biobased polymer composites with DDGS and corn fibers showed significantly lower water absorption than the Marlex composite samples. The Braskem composite with 30% DDGS fiber loading showed the highest impact resistance (80 J/m) among all the samples. The flexural properties showed no significant difference between the two HDPE composites.     

Characteristics of wood–fiber plastic composites made of recycled materials

This study investigates the feasibility of using recycled high density polyethylene (rHDPE), polypropylene (rPP) and old newspaper (rONP) fiber to manufacture experimental composite panels. The panels were made through air-forming and hot press. The effects of the fiber and coupling agent concentration on tensile, flexural, internal bond properties and water absorption and thickness swelling of wood–fiber plastic composites were studied. The use of maleated polypropylene as coupling agent improved the compatibility between the fiber and both plastic matrices and mechanical properties of the resultant composites compared well with those of non-coupled ones. Based on the findings in this work, it appears that recycled materials can be used to manufacture value-added panels without having any significant adverse influence on board properties. It was also found that composites with rHDPE provided moderately superior properties, compared with rPP samples.     

Effects of Waste Paper Sludge on the Physico-Mechanical Properties of High Density Polyethylene/Wood Flour Composites

The objective of this work was to determine some physical and mechanical properties of the high density polyethylene (HDPE) composites reinforced with various mixtures of the paper sludge and the wood flour, and to evaluate the coupling agent performance. The waste sludge materials originating from two different sources including paper making waste water treatment sludge (PS) and ink-eliminated sludge (IES) were characterized in terms of physico-chemical properties. In the experiment, four levels of paper sludge (20, 30, 40 and 60 wt%), three levels of wood flour (20, 40 and 60 wt%), and two levels of coupling agent (MAPE) content (2 and 3 wt%) were used. The flexural properties of the composites were positively affected by the addition of the sludge. Especially, tensile modulus improved with the increase of paper sludge content. With the addition of MAPE, flexural properties improved considerably compared with control specimens (without any coupling agent). The results showed that the water absorption (WA) and thickness swelling (TS) values of the samples decreased considerably with increasing sludge content in the composite, while they increased with increasing wood flour content. It is to be noted that with incorporation of MAPE in the composite formulation, the compatibility between the wood flour and HDPE was enhanced through esterification, which reduced the WA and TS and improved the mechanical properties. Composites made with IES exhibited superior physico-mechanical properties compared with the PS filled composites. Overall results suggest that the waste paper sludge materials were capable of serving as feasible reinforcing fillers for thermoplastic polymer composites.     

Thermal and mechanical properties of poly(lactic Acid) and poly(ethylene/butylene Succinate) blends

In this study, blends of poly (lactic acid) (PLA) with poly(ethylene/butylene succinate) (Bionolle) have been investigated for their thermal and mechanical properties as a function of the concentration of Bionolle. Differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), and tensile tests were used to characterize the blends. From the results of the DMA and DSC, it was found that this blend system was not miscible within the compositions studied. DSC results showed that adding Bionolle aids in crystallization of PLA. It was observed that increasing the Bionolle concentration led to a slight increase in the strain-at-break of the blends but a decrease in the Young’s modulus and ultimate tensile strength. Biaxially oriented films showed an increase in tensile strength, modulus, and strain-at-break.     

Injection Molded Biocomposites from Soy Protein Based Bioplastic and Short Industrial Hemp Fiber

Biocomposites from soy based bioplastic and chopped industrial hemp fiber were fabricated using twin-screw extrusion and injection molding process. Soy based bioplastics were prepared through cooking with plasticizer and blending with biodegradable poly(ester amide). Mechanical, thermal properties and fracture surface morphology of the “green”/biocomposites were evaluated with universal testing system (UTS), dynamic mechanical analysis (DMA), Environmental Scanning Electron Microscopy (ESEM). It was found that the tensile strength and modulus, flexural strength and modulus, impact strength and heat deflection temperature of industrial hemp fiber reinforced biocomposites significantly improved. The fracture surfaces showed no signs of matrix on the fiber surface suggesting poor interfacial adhesion.     

Enzyme-Retted Flax Fiber and Recycled Polyethylene Composites

Municipal solid wastes generated each year contain potentially useful and recyclable materials for composites. Simultaneously, interest is high for the use of natural fibers, such as flax (Linum usitatissimum L.), in composites thus providing cost and environmental benefits. To investigate the utility of these materials, composites containing flax fibers with recycled high density polyethylene (HDPE) were created and compared with similar products made with wood pulp, glass, and carbon fibers. Flax was either enzyme- or dew-retted to observe composite property differences between diverse levels of enzyme formulations and retting techniques. Coupling agents would strengthen binding between fibers and HDPE but in this study fibers were not modified in anyway to observe mechanical property differences between natural fiber composites. Composites with flax fibers from various retting methods, i.e., dew- vs. enzyme-retting, behaved differently; dew-retted fiber composites resulted in both lower strength and percent elongation. The lowest level of enzyme-retting and the most economical process produces composites that do not appear to differ from the highest level of enzyme-retting. Flax fibers improved the modulus of elasticity over wood pulp and HDPE alone and were less dense than glass or carbon fiber composites. Likely, differences in surface properties of the various flax fibers, while poorly defined and requiring further research, caused various interactions with the resin that influenced composite properties.     

Poly[(R)-3-hydroxy butyrate] Melt Processing: Strategy for Prevention of Degradation Reactions

Poly[(R)-3-hydroxy butyrate] (PHB) as well as all the components of the poly[(R)-3-hydroxy alkanoate]s (PHAs) family tend to degrade during processing at temperatures above their melting point via a hydrolytic mechanism induced by moisture attack and a concerted reaction mechanism induced by temperature. Therefore, the PHAs stabilization in the molten state is particularly important for production of biodegradable ecocompatible plastic items of commercial value. In order to refrain the indicated negative degradation effects, PHB was melt processed in a torque rheometer in the presence of a polymeric carbodiimide agent. Processed specimens were characterized by using FTIR, GPC, DSC, TGA and tensile properties. GPC analysis showed that the increase of the additive content in the formulation resulted in an increase of PHB molecular weight. However, decreasing in PHB thermal stability, glass transition temperature and mechanical properties, was observed with the increase of the additive amount. This behaviour most likely arises from the formation of new chemical structures promoted by the presence of the additive aimed at preventing the onset of hydrolitic processes.