Byk Tp-A1 WPC Modifiers en 1
Byk Tp-A1 WPC Modifiers en 1
Byk Tp-A1 WPC Modifiers en 1
Modifiers for
Wood Plastic Composites (WPC)
Application Information TP-A 1
Background
Wood Plastic Composites (WPC) belong Manufacture filled compounds and heating /cooling
to a group of natural fiber-reinforced WPC profiles, which are produced in a mixer combinations are also used. Other
compounds in which wood fibers (or single or two-stage extrusion process, mixing methods are pellet mills and
wood flour) are used as reinforcing are the most commonly manufactured special grinding methods in which the
fillers in amounts generally ranging from form of WPC (figure 1). wood and the plastic are ground at the
50 to 80 %. A number of other natural melting point range of the plastic. The
fibers can be used for comparable Single-stage Extrusion: This is a profile is then usually produced using
applications, for example, hemp, flax, so-called direct extrusion process. single-screw extruders.
sisal, and coconut fibers. However, The mixing of the wood fibers with
wood fibers are used most frequently on the plastic granules (compounding) If a WPC is manufactured according to
a volume basis. Polymeric materials such and the extrusion of the profile are the two-stage extrusion compounding
as polyethylene (PE), polypropylene (PP) performed in one step. Usually conical, process described above, it must not
and PVC are used as binders. counter-rotating double screw extruders necessarily be extruded, but can also be
are employed that are able to both further processed using other methods.
thoroughly mix the wood and plastic Injection molding is mentioned here in
and generate the pressure required for particular because it is a technique that
extruding the specified profile. allows the manufacture of complex
shapes. Other possibilities include
Two-stage Extrusion: In this rotational molding and the plate press
method, compounding and extrusion method. In principle, WPC compounds
of the profile occur in two separate can be processed by almost all
processes. In this case, the compound conventional techniques used in plastics
can be prepared using different types engineering. The limiting factor is
of extruders. Most often parallel, usually the flow properties of the WPC,
co-rotating double screw extruders are which are primarily determined by the
Advantages used. Planetary gear extruders for the wood content.
WPC products are generally more particularly gentle preparation of highly
expensive to produce than conventional
wood materials, but have a number of
advantages. Alongside much simpler
forming and the variety of diversified Manufacture of WPC
shapes, they are more durable due to
their better weather resistance. Because
of their high wood content, WPC are
significantly more attractive, both Plastic Natural
on a cost and technical basis, than Granule Fibers WPC
products made of pure plastic. They
are frequently used as a replacement Single-stage Extrusion
for tropical timber on account of their
longevity, thereby contributing to the Compounding & Extrusion
preservation of ecologically important Profiles
tropical forests.
Two-stage Extrusion
Applications
Wood plastic composite materials are Compounding Extrusion
used wherever wood has traditionally Injection Molding
been employed. First and foremost,
Rotational Molding Other
WPC is employed as a flooring material Shapes
(decking) mainly outdoors, but also Plate Press
indoors. WPC is also used as railing,
privacy fencing, exterior wall cladding,
furniture and much more.
figure 1
2
Application Information TP-A 1
In figure 2, E-modulus and Charpy Influence of Wood Content on the Mechanical Properties of a WPC
impact strength values are used to
illustrate the dependence of the
mechanical properties of a wood 4,000 120
E-Modulus (MPa)
0 0
Through the use of SCONA coupling 0 10 20 30 40 50 60 70
agents, which significantly enhance
Wood Content (% w/w)
the bonding of wood fibers with the
polymer matrix, mechanical properties
such as bending strength and impact figure 2
strength of the composite material are
also greatly improved (figure 3).
Improvement in the Mechanical Properties through Coupling Agents
Furthermore, the ability to withstand
higher temperatures and surface quality
are enhanced. SCONA modifiers also 70 14
Bending Strength (MPa)
3
Application Information TP-A 1
temperature causes less damage to the Combined Solid Phase Grafting and Melt Grafting
base polymer and the resulting higher
molecular weight is reflected in the
improved mechanical properties of the
“SCONA TP…” products are SCONA Mechanism of Action As a result, the fibers are optimally
modifiers that are manufactured by The maleic acid anhydride groups of the incorporated into the polymer matrix,
the solid-phase process only. “SCONA modifier react with the OH groups of which significantly improves the
TS…” products are modifiers that are the wood fibers to produce a chemically mechanical properties and increases the
manufactured by the combined process. stable compound (figure 6). weather resistance of the compound.
Reaction of the Coupling Agent with Natural Fibers Incorporation of the Fibers into the
Polymer Matrix
O O
C C O
H O
O H O
H O
C C
O H
PP PP
O O
figure 6
4
Application Information TP-A 1
MFR (230 °C, 2.16 kg): X PP-1: 40 g /10 min. X PP-2: 1.5 g/10 min figure 8
Source: IFA-Tulln Institut für Naturstofftechnik, Tulln, Austria
It is very important to adjust the amount of a coupling agent with The modifier with the greater degree
dosage in an existing formulation when 1.72 % MAH is used instead, the of grafting attains this value at a
replacing a coupling agent with low bending strengths of the product are concentration of as little as 2 %, while
MAH content for a product with a almost identical. If the amount of the a much higher concentration (approx.
higher MAH content. Otherwise, the latter coupling agent is reduced to 2 %, 5 %) is logically needed for the modifier
expected improvement in mechanical the resulting product has improved with lower MAH content. The exact
properties after the substitution may mechanical properties. values vary for each specific application
not materialize or may even result in and with the raw materials used. Thus,
a decline in the properties. Figure The critical factor is always the MAH it is always advisable to determine the
10 illustrates this: a coupling agent content in the composite. The optimum optimal concentration by testing a series
with 0.74 % MAH was used at a in this case lies between 0.03 and 0.04 % of concentrations.
concentration of 3 %. If the same MAH.
70 70
Bending Strength (MPa)
60 60
55 55
50 50
45 45
40 40
0 1 2 3 4 5 6 0 0,01 0,02 0,03 0,04 0,05
Comparison of the effect of LLDPE- and HDPE-based Coupling Agents on Applications in Polyethylene
Mechanical Strength At the outset of developing WPC for
wider applications in Europe, the focus
was primarily on using polypropylene as
Parallel, Co-Rotating Extruder Conical, Counter-Rotating Extruder the matrix material. In contrast, HDPE
50 50 was the preferred matrix polymer in the
Tensile Strength (MPa)
6
Application Information TP-A 1
Two very highly grafted SCONA HDPE-based SCONA TSPE 2102 GAHD LLDPE. In units that are able to achieve
modifiers that are produced through produces very good results in all a more thorough mixing, for example
the combination of solid-phase grafting systems with respect to improvement a parallel, co-rotating extruder, this
and melt grafting are extremely suitable in mechanical properties and reduction coupling agent does produce somewhat
for this application. The base polymer is of water uptake. LLDPE-based SCONA lower strength values (due to the lower
either LLDPE or HDPE. Which product is TSPE 1112 GALL is not recommended inherent strengths), yet attains extremely
used in a specific case is very dependent for use in mixing units that do not work good values for the reduction of water
upon the mixing units available and the material so intensely, such as a uptake.
the specific objectives of the respective conical counter-rotating extruder, due
customer (figures 11 and 12). to the limited miscibility of HDPE and
7 7
Water Absorption after 14 Days (%)
6 6
5 5
4 4
3 3
2 2
1 1
0 0
0,0 1,0 2,0 3,0 4,0 0 0,5 1 1,5 2 2,5 3 3,5
Amount of Coupling Agent (%) Amount of Coupling Agent (%)
SCONA TSPE 2102 GAHD HDPE Solid Phase + Melt > 5 g/10 min. 1.7 %
7
Application Information TP-A 1
BYK Additives
[email protected]
www.byk.com/additives
BYK Instruments
BYK offers a complete line of testing instruments BYK-Gardner GmbH
to meet your needs in many application areas: P.O. Box 970
• Gloss/Appearance 82534 Geretsried
• Color Germany
Tel +49 8171 3493-0
Portable or stationary laboratory equipment – +49 800 427-3637
including easy-to-use quality control software. Fax +49 8171 3493-140
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AQUACER®, AQUAMAT®, AQUATIX®, CERACOL®, CERAFAK®, CERAFLOUR®, CERAMAT®, CERATIX®, HORDAMER®, and MINERPOL® are registered
trademarks of BYK-Cera.
SCONA® is a registered trademark of BYK Kometra.
This information is given to the best of our knowledge. Because of the multitude of formulations, production, and application conditions, all the
above-mentioned statements have to be adjusted to the circumstances of the processor. No liabilities, including those for patent rights, can be
derived from this fact for individual cases.
This issue replaces all previous versions – Printed in Germany
07/2013