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FibreTuff FPS 12th

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FibreTuff ... a USDA BioPreferred intermediate resin

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FibreTuff FPS 12th

  1. 1. FibreTuffa low moisture, wood, cellulose flour composite pellet withimproved performance and cost structure for material replacementand share shift applications • By Robert Joyce of Innovative Plastics and Molding 66th FPS International Conference Innovative Plastics and Molding 1 Washington D.C. June 3-6
  2. 2. Innovative Plastics and Molding • Robert Joyce is a technical consultant for natural fiber composite processors and part producers. • Experience in calendaring, sheet and profile extrusion, injection molding, compounding and thermoforming. • Over 10 years of industry dedication, patented products and patent pending applications. 66th FPS International ConferenceInnovative Plastics and Molding 2 Washington D.C. June 3-6
  3. 3. Overview• Biomass Feedstocks / Wood , Cellulose flour.• BioPolymer Compounded Pellets including FibreTuff for Molding Parts.• Molded Parts with FibreTuff by Manufacturers.• FibreTuff application benefits.• Processing FibreTuff with advanced molding techniques.• Conclusion 66th FPS International Conference Innovative Plastics and Molding 3 Washington D.C. June 3-6
  4. 4. Biomass Feedstocks• Wood flour is the most abundant, lowest cost, lightest weight of feedstocks• Lowest carbon footprint..... wood flour is a bi product, not cultivated• Wood is primarily cellulose, hemi cellulose, lignins.• For every 2.2 tons input of wood chips, the process produces one ton of cellulose, 0.42 tons of lignin and 0.78 tons of sweet liquor. After fermentation the sweet liquor is converted to 0.25 tons of protein or can be used in the production of cellulosic ethanol. Pure Lignin Technology, Kelowna B.C. 66th FPS International Conference Innovative Plastics and Molding 4 Washington D.C. June 3-6
  5. 5. Cellulose, Wood flour characteristics• Wood flour is soft - not abrasive, compressible.• Tensile strength + (GPA) in agro based fibers * • Kenaf is 11.91, Hemp is 8.95 and Wood is 7.48• Wood is comprised of cellulose - 40 to 50%, plant species are about 33% .• Cellulose is odorless, has excellent strength, is compressible, good heat resistance, good adhesion.• Cellulose from wood flour is an organic compound, a white powder...not a food! *Lignocellulose-Plastic composites R.Powell 1997 ...GPA giga pascal 66th FPS International Conference Innovative Plastics and Molding 5 Washington D.C. June 3-6
  6. 6. History: Wood flour and polyolefin composite pellets • Wood flour, coupling, polyolefin - traditional. • Deficiencies in pellet include - inadequate distribution of coupling, high moisture, swell. • Wood flour, coupling, polyolefin, mineral - traditional. • Reduction in moisture, reduce strength & increase weight. • Minimal adhesion between fiber and polyolefin - In high filled fiber matrix and thin wall part separation in heat / cold thermal cycling.. 66th FPS International Conference Innovative Plastics and Molding 6 Washington D.C. June 3-6
  7. 7. Pelletized wood flour and polyolefin composite compound for molding• Less than a handful of compounders in North America producing a natural fiber polyolefin concentrate• Pelletizing process includes underwater, water ring, and strand cut• Underwater recommended - necessary pressure to compact and quickly solidify the fibers in the matrix.• 50 to 60% loading of natural fiber requires additional interfacial adhesion. 66th FPS International Conference Innovative Plastics and Molding 7 Washington D.C. June 3-6
  8. 8. An improved cellulose, wood flour and polyolefin composite pellet• FibreTuff...A low moisture cellulose, wood flour polyolefin alloy composite pellet for biopolymer part application. • Pellet has an increased adhesion, reduction in pellet swell (moisture) - promotes less fines. • FibreTuff pellets have been produced at less than .023% moisture. • Pellet can be compacted with high loadings with lower costs to customer. • Parts produced with FibreTuff, have significant improvement in performance...US Patent 7,994,241 66th FPS International Conference Innovative Plastics and Molding 8 Washington D.C. June 3-6
  9. 9. Injection Molding of cellulosic wood flour with polyolefin• Today’s Part Requirements for molding natural fiber composites. • Cost Competitive - process & material. • Performance - increase strength, better stiffness to weight ratio, improved thermal properties. • Functionality - consistent, low moisture content, minimize odor, ability to color. 66th FPS International Conference Innovative Plastics and Molding 9 Washington D.C. June 3-6
  10. 10. FibreTuff - superior adhesion for molded parts• Very important....Needed for biopolymer and polyolefin composite matrix.• FibreTuff has shown superior adhesion “Inside the polymer matrix and outside” • Mechanical, thermal and chemical bond...improved adhesion necessary for thin wall highly filled components• Automotive boil and dimensional stability test performed and passed by interior component supplier. Boil tested and passed by Injection Molded FibreTuff auto suppliers oversees - bonding strength 66th FPS International Conference Innovative Plastics and Molding 10 Washington D.C. June 3-6
  11. 11. Improved Thermal stability and part performance• Better thermal stability.......i.e. Heat deflection temperature. • Increase processing window - lower scrap rates. • Improved CLTE. Fibertuff / Basell Basell Test Units Method Profax Profax copolymer (40/60) Melt Index g/10min ASTM D1238 7.0 18.0 Specific Gravity - ASTM D792 1.03 0.90 20 28 Tensile Strength MPa ASTM D638 ( 3120 psi ) (4206 psi) Elongation @ yield % ASTM D638 2.2 5.0 Flexural Strength MPa ASTM D790 33 2820 1100 ( 415,000 ( 160,000 Flexural Modulus MPa ASTM D790 psi ) psi ) Izod Impact 23°C J/m ASTM D256 41 Izod Impact -10°C J/m ASTM D256 29 139.6 90 HDT (0.45 MPa) °C ASTM D648 ( 290 F ) ( 194 F ) Rockwell Hardness R ASTM D 785 85 Flammability mm/min FMVSS 302 49 66th FPS International Conference Innovative Plastics and Molding 11 Washington D.C. June 3-6
  12. 12. Molded part moisture uptake with FibreTuff• The molded part test data SAE J315 with the low moisture FibreTuff pellets shows very little moisture absorption in a 24 hr submersion at less than .4%. Nylon will soak up 1.2 % moisture with the same tests. The water absorption is approximately 2.5 percent after submersion for 18 days 66th FPS International Conference Innovative Plastics and Molding 12 Washington D.C. June 3-6
  13. 13. FibreTuff Performance Data with and unfilled PP • FibreTuff is a natural fiber alloy composition. • Increase natural fiber ..i.e. cellulose, wood flour isn’t a strength reinforcement. • Fiber size is important for wetting out. The compounded pellet is 20-120 mesh IPM woodfiber IPM woodfiber IPM woodfiber concentrate: concentrate: concentrate Properties Method Sunoco PP Sunoco PP Sunoco PP 70:30 60:40 50:50 Wood flour 43% 34% 28.50%Melt Flow (g/10min), 230C/2.16kg) ASTM D1238 9.33 13.05 15.06Specific Gravity ASTM D792 1.08 1.0588 1.0228Notched Izod @ 23°(ft-lbs/in) ASTM D256 0 0 0Gardner Impact (in.lbs) ASTM D5420 <10 <10 <10Tensile Strength @ Yield (psi) ASTM D638 5,110 5,280 5,170Tensile Elogonation @ Yield (%) ASTM D638 1.58 1.87 2.3Tensile Elongation @ Break (%) ASTM D638 1.63 2.59 3.36Flexural Modulus (psi) ASTM D790 604,000 545,000 456,000Flexural Strength (psi) ASTM D790 8,480 8,690 8,250 66th FPS International Conference Innovative Plastics and Molding 13 Washington D.C. June 3-6
  14. 14. A FibreTuff molded part “ Advantage” • Improved properties. i.e stiffness to weight ratio...Reduction in wall thickness • Improved part longevity • High resistance to molds, mildew, fungi attack and electrical resistance. • Coloring at the compounder or press or UV coated in line. • Heat aging has shown an increase in tensile strength and elongation • Lower concentration carbon residuals....end of life. 66th FPS International ConferenceInnovative Plastics and Molding 14 Washington D.C. June 3-6
  15. 15. Molded parts made from FibreTuffApplications include Transportation, Medical, Furniture, Electronics, Packaging, Toys, Recreation Parts 66th FPS International Conference Innovative Plastics and Molding 15 Washington D.C. June 3-6
  16. 16. Molded In Brass InsertsFinal Part is over Sample 1 Current Materialmolded with a soft touch 60% Fibre Tuff Material 30% GFPPmaterial 40% of 30% GFPP Robert Joyce – Fibre Tuff Material Gemini Group | Dan Rothe 66th FPS International Conference Innovative Plastics and Molding 16 Washington D.C. June 3-6
  17. 17. Injection Molding with Rapid thermal cycling• Part performance is increased by creating a polymer rich surface.• Achieve better impact, flexural strength....• Class A surface• Stain and moisture resistance, solid color at surface for better weather ability.• Cost advantages utilizing FibreTuff are increased performance - lower part weight and thinner parts. 66th FPS International Conference Innovative Plastics and Molding 17 Washington D.C. June 3-6
  18. 18. Fluid assist injection molded article• Art of mixing a fluid, preferably nitrogen and compressing natural fibers, specifically wood flour and polyolefin. • Benefits... • Lower machine tonnage required to produce parts - Energy savings • Faster part production - by as much as 50% • Improve flow - maintain high melt strength, improved processing performance - less scrap. • Material savings - Lower part density 66th FPS International Conference Innovative Plastics and Molding 18 Washington D.C. June 3-6
  19. 19. Benefits: Fluid assist injection with wood flour and polyolefin composite compound• Performance • Decrease cycle time - reduce degradation of fiber and minimize odor. • Prevent warpage, sink, no need for minerals, talcs, rice hulls - lighter bulk density.• Functionality • Improve strength - no knit lines, minimize porosity at surface - better weather ability • Producing a part with a cavity, non uniform cellular wall and impervious skin construction. • US Patent 7,214,240 and Canadian Patent 2,547, 623 66th FPS International Conference Innovative Plastics and Molding 19 Washington D.C. June 3-6
  20. 20. Applications with counter pressure and FibreTuff• Furniture coasters with FibreTuff composition and injection molded counter pressure by Caropreso and Associates.• No warp, very little shrink and polymer rich skin for excellent weather ability, stain and scratch resistance.• Foamed coaster with CP..Foam provided by Mike Reedy and Associates. 66th FPS International Conference Innovative Plastics and Molding 20 Washington D.C. June 3-6
  21. 21. Conclusion• New technology creates Improved Performance and Functionality with Cost benefits - parts cost less, eliminate secondary processes, energy savings, lower expenditure on tooling, less scrap, faster cycle times.....• FibreTuff, a natural fiber alloy composition provides improved adhesion and thermal performance...key word “adhesion” and “thermal” for injection molded biopolymers.• Applications and opportunities with FibreTuff • Processing is important, i.e. rapid thermal cycling, gas injection, counter pressure can help create new material replacements. 66th FPS International Conference Innovative Plastics and Molding 21 Washington D.C. June 3-6
  22. 22. Thank YouIllinois Valley Reedy CaropresoPlastics International Associates 72 Werden Road300 N Cummings Lane 25 East Front Street Becket, MA 01223Washington, IL 61571 Keyport, NJ 07735 413-243-9870Ph 309 444-8884 732-264-1777 caropresomh@msn.comCell 847 269-1830www.ivplastics.com www.reedyintl.comGemini Group175 Thompson RoadBad Axe, MI. 48413(989) 269-6272 - phone(989) 269-5137 - faxwww.geminigroup.net  Robert Joyce Innovative Plastics and Molding www.woodcompositesandmolding.com 66th FPS International Conference Innovative Plastics and Molding 22 Washington D.C. June 3-6

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