Waste-wood-derived fillers for plastics

F i l l ed thermop l a s t i c compos i t e s a re s t i f f e r ‚ stronger, and more dimensionally stable than their unfilled counterparts. Such thermoplastics are usually provided to the end-user as a precompounded, pelletized feedstock. Typical reinforcing fillers are inorganic materials like talc or fiberglass, but materials derived from wastewood, such as wood flour and recycled paper fiber, are also effective as fillers. The goal of this project was to generate commercial interest in using wastewood/paper-derived fillers (WPFs) English: Forest Products Technologist, USDA Forest Serv., Forest Prod. Lab., Madison, Wisconsin Clemons: Chemical Engineer. USDA Forest Serv., Forest Prod. Lab., Madison, Wisconsin Stark: Chemical Engineer, USDA Forest Serv., Forest Prod. Lab., Madison, Wisconsin Schneider: Materials Scientist. USDA Forest Serv., Forest Prod. Lab., Madison, Wisconsin to reinforce thermoplastics. The research strategy was two-fold: developmental research and outreach. Specific objectives were to: • improve wastepaper fiber preparation, feeding, and compounding methods, and optimize composite performance; and • communicate to end-product manufacturers the advantages of WPF thermoplastics. The research was led and supported by the Forest Products Laboratory (FPL), with input from a consortium of 15 fiber suppliers and plastics manufacturers. Additional funding was provided by the Wisconsin Department of Natural Resources. Equipment was leased and installed at the FPL. Eight generalpurpose formulations were developed including extrusionand injection-molding grades of both polyethylene and polypropylene reinforced with WPFs. An information packet containing performance data, appropriate processing conditions, sample pellets, sample parts, and a questionnaire was sent to nearly 500 commercial plastics manufacturers in Wisconsin, Illinois, and Michigan. In response to requests for in-house trials, FPL researchers conEnglish, Clemons, Stark, and Schneider · 309 ducted nearly 18 site visits. The researchers ensured proper handling of the material, provided consultation, and gathered information about processing and performance. The trials went very well, and parts were successfully manufactured at all facilities. Products included automobile tr im components and housings, vacuum cleaner parts, paint brush handles, bicycle parts, cosmetic cases, and other household items. Great interest has been shown in the use of WPF thermoplastics; one consortium member is establishing a 4-million kg/yr. (9-million lb./yr.) facility. Total market demand is conservatively expected to exceed 45 -million kg/yr. (100-million lb./yr.).