Wood/plastic composites (WPCs) can absorb moisture in a humid environment due to the hydrophilic nature of the wood in the composites, making products susceptible to microbial growth and loss of mechanical properties. Co-extruding a poly(vinyl chloride) (PVC)-rich cap layer on a WPC significantly reduces the moisture uptake rate, increases the flexural strength but, most importantly, decreases the flexural modulus compared to uncapped WPCs. A two-level factorial design was used to develop regression models evaluating the statistical effects of material compositions and a processing condition on the flexural properties of co-extruded rigid PVC/wood flour composites with the ultimate goal of producing co-extruded composites with better flexural properties than uncapped WPCs. Material composition variables included wood flour content in the core layer and carbon nanotube (CNT) content in the cap layer of the co-extruded composites, with the processing temperature profile for the core layer as the only processing condition variable. Fusion tests were carried out to understand the effects of the material compositions and processing condition on the flexural properties. Regression models indicated all main effects and two powerful interaction effects (processing temperature/wood flour content and wood flour content/CNT content interactions) as statistically significant. Factors leading to a fast fusion of the PVC/wood flour composites in the core layer, i.e. low wood flour content and high processing temperature, were effective material composition and processing condition parameters for improving the flexural properties of co-extruded composites. Reinforcing the cap layer with CNTs also produced a significant improvement in the flexural properties of the co-extruded composites, insensitive to the core layer composition and the processing temperature condition. Copyright © 2009 Society of Chemical Industry

Wood/plastic composites co-extruded with multi-walled carbon nanotube-filled rigid poly(vinyl chloride) cap layer

This study was aimed at examining the effects of wood flour contents, wood species (softwood vs. hardwood), and particle size on the fusion characteristics (fusion time, fusion temperature, fusion torque, and fusion energy) of rigid PVC/wood-flour composites in a torque rheometer. Neat rigid PVC exhibited one fusion peak, whereas the addition of wood flour into the PVC matrix led to two fusion peaks. Increased wood flour content caused a significant increase in the time, temperature, and energy at which fusion between the primary particles started, thereby leading to increased fusion torque, irrespective of the wood flour species. These results implied that rigid PVC filled with wood flour must be processed at higher temperatures than neat resin. Although fusion characteristics of the composites were influenced by the wood species, a clear trend between softwood and hardwood species could not be established. However, finer particles fused more quickly and needed less energy than coarse ones. J. VINYL ADDIT. TECHNOL., 13:7–13, 2007. © 2007 Society of Plastics Engineers.

Fusion characteristics of rigid PVC/wood‐flour composites by torque rheometry

Fusion time, fusion temperature, and fusion torque of poly(vinyl chloride) (PVC) compounds with various components were studied in this article. Influences of chlorinated polyethylene (CPE), oxidized polyethylene (OPE), and calcium stearate on fusion characteristics of PVC compounds were illustrated. The synergistic reaction among CPE, OPE, and calcium stearate forms a powerful and effective processing aid that allows the PVC particles to fuse more quickly and uniformly. In PVC/CPE compounds, a higher concentration of CPE can function like a processing aid and help PVC particles to fuse together easily. Meanwhile, the interaction between a higher concentration of OPE and calcium stearate in PVC/OPE compounds can promote the PVC particles to fuse together easily in the beginning of the fusion process. However, the external lubricant property of OPE still exists and results in more intact PVC microparticles not fused. The fusion temperature of the PVC in a Haake mixing bowl increases as the fusion time increases. On the other hand, the fusion torque decreases as the fusion time increases. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 699–705, 1999

Influences of chlorinated polyethylene and oxidized polyethylene on the fusion of rigid poly(vinyl chloride) compounds

The shear level was increased during twin screw extrusion of PVC at different melt temperatures by inserting a hole plate in front of the screw tips. The variation of shear level did not significantly affect the capillary pressure in capillary viscometry at 135°C. However, the falling weight impact strength was markedly influenced. In internal water pressure tests at 60°C premature failure was obtained for pipes extruded at 198°C at the highest shear level.

The effect of shear on fusion and mechanical properties of rigid PVC pipes

A 50 mm twin screw extruder was used to study the melting profiles of various PVC formulations. Melt temperature and degree of flux are measured axially along various mixing paddle arrangements.

The viscous work is correlated with the rheology of the PVC mass and effective shear rate of the intermeshing co-rotating screws. The results of this investigation are used to develop a conceptual model of compounding PVC formulations.

The radial mixing patterns in paddle segments down the barrel length are analyzed by introduction of trace quantities of pigment added to the dry blend. The resulting residence time distributions coupled with localized shear rate distributions give a numerical evaluation of shear strain required to flux PVC particles into a continuous fluid mass.

By proper agitator design, compounding of PVC formulations can be accomplished with minimal thermal history.

Co-rotating twin screw compounding studies of PVC formulations

In this review of lubricants and how they function the lubrication mechanism is broken down into three stages: the heat absorption (onset of gelation), gelation (fusion process), and melt flow (postfusion) stages. The terms “internal” and “external” are used to describe the functionality of the lubricant at each stage. It is pointed out that these terms should not be used to label lubricants themselves, because most lubricants perform differently at each stage of processing. How the chemical and physical properties of various types of lubricants perform in each of the fusion stages is also discussed.

The function of lubricants in processing of rigid poly(vinyl chloride)

Standard PVC compounds containing various lubricant systems were fused in a Haake Torque Rheometer equipped with a torque integrator, holding the shear stress time value constant. The total work put into the system to fuse the compound was therefore held constant. The fused material was compression molded into sheeting for physical testing. The data will characterize the compounds for both rheological and physical properties at several processing conditions. Plotted curves will depict the lubricant systems and processing temperatures necessary to obtain maximum physical strength.

J. David Bower

Papers

The function of lubricants in processing of rigid poly(vinyl chloride)

Temperature and shear history effects on fusion of PVC