Novel Thermoplastic Composites from Commodity Polymers and Man‐Made Cellulose Fibers

Abstract

AbstractSummary: A new class of fibre reinforced commodity thermoplastics suited for injection moulding and direct processing applications has been developed using man‐made cellulosic fibres (Rayon tire yarn, Tencel, Viscose, Carbacell) and thermoplastic commodity polymers, such as polypropylene (PP), polyethylene (PE), high impact polystyrene (HIPS), poly(lactic acid) (PLA), and a thermoplastic elastomer (TPE) as the matrix polymer. For compounding, a specially adapted double pultrusion technique has been employed which provides composites with homogeneously distributed fibres. Extensive investigations were performed with Rayon reinforced PP in view of applications in the automotive industry. The Rayon‐PP composite is characterized by high strength and an excellent impact behaviour as compared with glass fibre reinforced PP, thus permitting applications in the field of engineering thermoplastics such as polycarbonate/acrylonitrile butadiene styrene blends (PC/ABS). With the PP based composites the influence of material parameters (e.g. fibre type and load, coupling agent) were studied and it has been demonstrated how to tailor the desired composite properties as modulus and heat distortion temperature (HDT) by varying the fibre type or adding inorganic fillers. Man‐made cellulose fibers are also suitable for the reinforcement of further thermoplastic commodity polymers with appropriate processing temperatures. In case of PE modulus and strength are tripled compared to the neat resin while Charpy impact strength is increased five‐fold. For HIPS mainly strength and stiffness are increased, while for TPE the property profile is changed completely. With Rayon reinforced PLA, a fully biogenic and biodegradable composite with excellent mechanical properties including highly improved impact strength is presented.