Abstract
Publisher Summary This chapter describes the unique advantages and applications of the Wood-Polymer Composite (WPC) foams, delineates the critical issues and processing strategies associated with the foaming of WPC, and then introduces the state-of-the-art technologies used to produce the WPC foams. WPCs made from wood fibers and polymers have been commercialized and are enjoying rapid growth in wood-replacement applications. Foaming of WPCs offers unique advantages. The physical and mechanical properties of the WPC foams are closely related to their cellular structure. Incorporating a fine-celled structure into WPCs typically is more desirable. However, a number of factors influence the WPC foam processing when WF is used. Increasing the WF content increases the apparent viscosity, which necessitates either the use of a higher Melt Flow Index (MFI) resin or the use of a lubricating additive. Use of coupling agents facilitates the dispersion and bonding of hydrophilic WF with hydrophobic resins. Suppression of the volatile emissions from the WF can be achieved by drying the WF; however, that places restrictions on the highest allowable processing temperatures, in conjunction with minimizing the residence times at those temperatures.
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