FibreTuff ... a USDA BioPreferred intermediate resin

1. FibreTuff
a low moisture, wood, cellulose flour composite pellet with
improved performance and cost structure for material replacement
and 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. 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 Conference
Innovative Plastics and Molding 2 Washington D.C. June 3-6

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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 15.06
Specific Gravity ASTM D792 1.08 1.0588 1.0228
Notched Izod @ 23°(ft-lbs/in) ASTM D256 0 0 0
Gardner Impact (in.lbs) ASTM D5420 <10 <10 <10
Tensile Strength @ Yield (psi) ASTM D638 5,110 5,280 5,170
Tensile Elogonation @ Yield (%) ASTM D638 1.58 1.87 2.3
Tensile Elongation @ Break (%) ASTM D638 1.63 2.59 3.36
Flexural Modulus (psi) ASTM D790 604,000 545,000 456,000
Flexural 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. 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 Conference
Innovative Plastics and Molding 14 Washington D.C. June 3-6

15. Molded parts made from FibreTuff
Applications 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. Molded In Brass Inserts
Final Part is over Sample 1
Current Material
molded with a soft touch 60% Fibre Tuff Material
30% GFPP
material 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. 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. 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. 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. 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. 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. Thank You
Illinois Valley Reedy Caropreso
Plastics International Associates
72 Werden Road
300 N Cummings Lane 25 East Front Street Becket, MA 01223
Washington, IL 61571 Keyport, NJ 07735 413-243-9870
Ph 309 444-8884 732-264-1777 caropresomh@msn.com
Cell 847 269-1830
www.ivplastics.com www.reedyintl.com
Gemini Group
175 Thompson Road
Bad Axe, MI. 48413
(989) 269-6272 - phone
(989) 269-5137 - fax
www.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