Graphene nanoplatelets (GNPs) were used to reinforce wood polymer composites (WPCs) in order to achieve multifunctionality. Multifunctionality could be achieved through the GNPs because of their excellent mechanical and electrical properties. The research consists of two parts: HDPE/GNP/WF composites and LLDPE/GNP composites. The HDPE part is a continuation of previous work. Here further mechanical characterisation was done (impact testing), impurities in the composites were identified, the manufacturing process that results in damaged wood particles was investigated and the Young's modulus of the composites were modeled. The impact strength was improved due to the addition of GNPs. WF composites exhibited more brittle behaviour and therefore a lower impact strength. The impurities were identified as some form of nanoclay introduced during the extrusion process. The particles were damaged during the extrusion processes. Little can be done about this as different shear configurations and/or screw speeds will result in a poor GNP dispersion and distribution. Modeling of the Young's modulus was the most accurate through applying the laminate analogy and rule of thumbs. The rule of mixtures does not represent the composites which have a preferred orientation. During the previous work done, it was found that the HDPE composite were not electrically conductive and therefore not multifunctional. The work was therefore continued with LLDPE and GNPs. LLDPE has more branches and is less dense, resulting in potential opportunities for the GNPs to form a network through the polymer. This could lead to a better conductivity. Mechanical and electrical characterisation was done of the LLDPE/GNP composites. Here multifunctionality could also not be achieved as the composites were highly electrically resistant. Mechanical testing indicated that the GNPs significantly enhance the LLDPE matrix. Here an increase of up to 170% could be seen in tensile modulus and an increase of 46% in tensile strength. Furthermore the GNPs improved the flexural properties and increase the resistance to viscoplastic deformation during residual strain testing. Overall the GNPs improve the mechanical properties significantly, but at 10wt.% GNP contents, multifunctionality could still not be achieved.

This doctoral thesis is focused on composites based on polypropylene and wood flour. Firstly, the experimental work deals with preparation of composites based on wood flour with various concentrations and isotactic polypropylene with various melt flow indexes. In terms of this study, one polypropylene, which can have also practical use, was chosen. Further, this polypropylene is investigated with various types and concentrations of wood flour. Also, the attention is devoted to the modification of polypropylene by a specific β-nucleating agent. The differences are compared and described between the composites with neat and nucleated polypropylene. Further, the work is focused on solvent extraction of wood flour. The effect of extraction and solvent of wood flour is also examined in composites with neat and nucleated polypropylene. On prepared composites, the rheological, structural and thermal properties are studied. These properties differ depending on specific type of wood flour, its concentration and specific type of polypropylene.

Thesis (PhD (Chemistry and Polymer Science))--University of Stellenbosch, 2010. / ENGLISH ABSTRACT: The effects of the macromolecular composition and content of different wood species on the properties of wood-polymer composites (WPCs) achieved when using poly(vinyl alcohol-co-ethylene) (EVOH) as a compatibiliser and linear low density polyethylene (LLDPE) as a matrix, were investigated. Four wood different species (A. cyclops (acacia), E. grandis (eucalyptus), P. radiata (pine) and Q. alba (oak)) with different macromolecular composition and contents and average particle lengths were used. WPCs filled with these species and WPCs filled with the same species but without extractives were prepared using 10% wood content and different amounts (0, 2, 5, 7 and 10%) of EVOH. An EVOH content of 7% was found to be optimum. Unextracted woods produced WPCs with higher mechanical properties and better resistance to ultraviolet (UV) degradation, while the extracted woods produced WPCs with lower water absorption (WA) rates and better thermal stability. Use of unextracted A. cyclops resulted in composites with superior mechanical and thermal properties compared with the other unextracted species, most probably due to its higher cellulose and lignin contents and a favourable average wood particle length (0.225 mm). A. cyclops composites also had higher WA and thickness swelling (TS) rates most likely due to the greater number of free hydroxyl groups present in these composites because of higher cellulose content. Composites containing wood species with a high lignin and extractive content, such as A. cyclops and Q. alba, exhibited higher resistance to UV degradation. Poly(vinyl alcohol-co-ethylenes) (EVOHs) with different ethylene content (27, 32, 38 and 44%) and A. cyclops with different particle sizes (180, 250 and 450 ìm) were used to prepare WPCs with 10% A. cyclops content. The effect of the contact area between the A. cyclops particles and LLDPE achieved when using EVOHs as compatibilisers on the properties of WPCs was also investigated. The greatest improvements in the mechanical and thermal properties of composites made with A. cyclops with particle size 180 ìm were obtained when EVOH with 44% ethylene content was used. The greatest improvements in the composites made with A. cyclops with particle size 250 ìm were achieved when EVOH with 38% ethylene content was used. Composites made with A. cyclops with particle size 450 ìm exhibited better properties when EVOH with 27% ethylene content was used. All the composites that had better mechanical and thermal properties, also exhibited better compatibility and interface adhesion. Two successful approaches were used to impart more attractive ecological and economical advantages to WPCs. In the first approach, (0, 2, 5 and 7%) degraded LLDPE was used as a compatibiliser in WPCs at levels of 10, 30 and 50% wood content. The resulting mechanical properties, such as tensile strength and hardness, thermal and morphological properties of the compatibilised composites were slightly higher than those of noncompatibilised composites and virgin LLDPE. Elongation at break and impact properties of the compatibilised composites were lower than in virgin LLDPE, but higher than in noncompatibilised composites. In the second approach, polyethylene (PE) and various functionalised polyethylenes (PEs) were synthesised by copolymerising ethylene and 10-undecen-1-ol using a soluble metallocene/methylaluminoxane catalyst at room temperature. The incorporation of functional groups increased with increasing comonomer content. WPCs with 10 and 30% wood content were prepared. The composites prepared with functionalised PEs had better mechanical, thermal and morphogical properties than the composites prepared with PE. Composites made with functionalised PE with higher hydroxyl groups content exhibited better properties than composites made with functionalised PE with lower hydroxyl groups content. Composites with 10% wood content exhibited better properties and performance than composites with 30% wood content. / AFRIKAANSE OPSOMMING: Die gevolg van die makromolekulere samestelling van verskillende houtspesies op die eienskappe van hout-polimeer saamgestelde materiale (HPS) wanneer poli(viniel alcohol-ko-etileen) (EVOH) as versoeningsmiddel gebruik word saam met linieere lae digtheid poli(etileen) (LLDPE) as matriks is ondersoek. Vier houtspesies (A. cyclops (acacia), E. grandis (eucalyptus), P. radiata (pine) and Q. alba (oak)) met verskillende makromolekulere samestelling and partikelgrootte-verspreiding is gebruik in die studie. HPS materiale is berei met hierdie vesels, beide voor en na ekstraksie van die houtpartikels met onderskeidelik warm water en oplosmiddels (alleen en in kombinasie). In hierdie HPS materiale is 10% hout gebruik en 0, 2, 5, 7 en 10% EVOH. 'n EVOH inhoud van 7% is as optimum bepaal. Houtpartikels voor ekstraksie het HPS materiale met beter meganiese eienskappe en beter weerstand teen UV bestraling, terwyle partikels wat ekstraksie ondergaan het HPS materiale met laer water-absorpsie en beter hitte-stabiliteit to gevolg gehad het. Die gebruik van ongeekstraheerde A. cyclops het samegestelde materiale met die beste meganiese en termiese eienskappe tot gevolg gehad in vergelyking met die ander houtspesies (voor ekstraksie), as gevolg van die hoer sellulose en lignien inhoud van die spesie, sowel as 'n voordelige partikelgrootte-verspreiding. A. Cyclops saamgestelde materiale he took hoer waterabsorpsie (WA) en dikte-swelling (DS) tempos gehad, weens die groter hoeveelheid vrye hidroksielgroepe teenwoording in die materiale, direk in verwantskap met die sellulose-inhoud. Saamgestelde materiale met 'n hoe hoevellheid lignien en ekstraheerbare materiale (A. cyclops and Q. alba) het beter weerstand teen UV-degradasie geopenbaar. Verskillende poli(viniel alkohol-ko-etileen) polimere (EVOHs) met wisselende etileen-inhoud (27, 32, 38 en 44%) en A. Cyclops met verskillende partikel-groottes (180, 250 en 250 µm) is gebruik om HPS materiale met 10% hout te vervaardig. Die gevolg van die kontak-area tussen die houtpartikels en die LLDPE wanneer EVOHs as versoeningsmiddel gebruik is, is ook ondersoek. Die beste verbetering in die meganiese en termiese eienskappe van die saamgestelde materiale met A. cyclops met partikel-grootte 180 µm is gekry met EVOH met 44% etileen-inhoud, terwyl die beste resultate met 250 µm partikels verkry is met 'n EVOH met 38% etileen, en met 27% etileen in die geval van die 450 µm partikels. Twee benaderinge om meer aantreklike ekologiese en ekonomiese eienskappe by die HPS materiale te bewerkstellig was suksesvol. In die eerste geval is gedegradeerde LLDPE as versoeningsmiddel gebruik. Die resulterende meganiese eienskappe van die HPS materiale met LLDPE as versoeningsmiddel was beter as die HPS mateirale daarsonder. Samegestelde materiale met 10, 30 en 50% hout is vervaardig. Die trekverlenging by die breekpunt sowel as die impaksterkte van die HPS materiale was laer as LLDPE alleen, maar beter as die nie-versoende HPS materiale. In die tweede benadering is polietileen (PE) en gefunksionaliseerde PE gesintetiseer deur etileen en 10-undekeen-1-ol te koplimeriseer met ‘n oplosbare metalloseen/metiel alumoksaan katalis. Die hoeveelheid funskionele (OH) groepe is verhoog deur toenemend ekomonommer-inhoud. HPS materiale met 10 en 30% hout is vervaardig. Die saamgestelde materiale met funksionele PE het beter maganiese eienskappe gehad as die met gewone PE. Hoe hoër die hidroksielgroep-inhoud, hoe beter die eienskappe van die HPS materiale, terwyl die materiale met 10% hout beter eienskappe openbaar het as materiale met 30% hout.

Ce travail porte sur l’étude des composites à base de polypropylène et de farine de bois. Seuls des composites à base d’une matrice polypropylène et de fibres végétales ont été mis en oeuvre sans aucun recours à quelque agent comptabilisant que ce soit. En premier lieu nous avons regardé l’influence de la viscosité initiale de la matrice polypropylène sur la processabilité des biocomposites en utilisant des polymères de grades variés. Puis nous avons étudié l’influence de la nature et de la concentration de la farine en utilisant des farines de pin (bois mou) et de chêne (bois dur). Enfin, une attention spécifique a été portée sur la possibilité de nucléation en phase Beta de la matrice polypropylène en présence de fibres végétales. Des polypropylènes β-Nucléés ainsi que des farines ayant subies des extractions par des solvants de leurs composés volatils ont été utilisées. Les mélanges obtenus ont été testés au moyen de la viscoélasticité à l’état fondu pour mettre en évidences les effets d’interaction charges-Matrices et par des mesures de diffraction aux rayons X ainsi que d’analyse thermique différentielle pour la caractérisation de leurs morphologies cristallines. / This doctoral thesis is focused on composites based on polypropylene and wood flour. Firstly, the experimental work deals with preparation of composites based on wood flour with various concentrations and isotactic polypropylene with various melt flow indexes. In terms of this study, one polypropylene, which can have also practical use, was chosen. Further, this polypropylene is investigated with various types and concentrations of wood flour. Also, the attention is devoted to the modification of polypropylene by a specific β-Nucleating agent. The differences are compared and described between the composites with neat and nucleated polypropylene. Further, the work is focused on solvent extraction of wood flour. The effect of extraction and solvent of wood flour is also examined in composites with neat and nucleated polypropylene. On prepared composites, the rheological, structural and thermal properties are studied. These properties differ depending on specific type of wood flour, its concentration and specific type of polypropylene. / Předložená doktorská práce je zaměřena na kompozity polypropylenu a dřevní moučky. V experimentální části práce jsou připraveny kompozity s různými koncentracemi plniva a izotaktických polypropylenů s různými indexy toku taveniny. Na základě této studie je vybrán jeden konkrétní polypropylen, který může mít v kombinaci s dřevní moučkou i praktické využití. Tento polypropylen je dále zkoumán s různými druhy a koncentracemi dřevní moučky. Pozornost je také kladena na úpravu vlastností izotaktického polypropylenu užitím specifického β-nukleačního činidla. Jsou porovnávány a popisovány rozdíly mezi kompozity s čistým a nukleovaným polypropylenem. Práce se dále zabývá extrakcí dřevní moučky v rozpouštědle. Je studován vliv extrakce a rozpouštědla dřevní moučky na vlastnosti připravených kompozitů. Byly studovány reologické, strukturální a tepelné vlastnosti, které se lišily v závislosti na zvoleném typu plniva, jeho koncentraci a typu polymerní matrice.

The objective of the study is to improve the interfacial adhesion between the wood fibers and thermoplastic matrix. Efforts were also directed towards improving manufacturing processes so as to realize the full potential of wood fibers as reinforcing fillers. Chemical coupling plays an important role in improving interfacial bonding strength in wood-polymer composites. A novel compatibilizer with isocyanate functional group was synthesized by grafting m-Isopropenyl –α –α –dimethylbenzyl-isocyanate (m-TMI) onto isotactic polypropylene using reactive extrusion process. The compatibilizer was characterized with respect to its nature, concentration and location of functional group, and molecular weight. There are two main process issues when blending polymers with incompatible filler: (1) creating and maintaining the target morphology, and (2) doing so with minimum degradation of fillers. A 28mm co-rotating intermeshing twin screw extrusion system was custom built and the design optimized for (1) blending biological fibers with thermoplastics, and (2) for melt phase fictionalization of thermoplastics by reactive extrusion. To assess the effect of inclusion of wood fibers in polypropylene composites, a series of polypropylene wood fiber/wood flour filled composite materials having 10 to 50 wt % of wood content were prepared using the co-rotating twin screw extrusion system. m-TMI-g-PP and MAPP were used as coupling agents. Addition of wood fibers, at all levels, resulted in more rigid and tenacious composites. The continuous improvement in properties of the composites with the increasing wood filler is attributed to the effective reinforcement of low modulus polypropylene matrix with the high modulus wood filler. Studies on were also undertaken to understand effect of particle morphology, type and concentration of coupling agent, and effect of process additives on mechanical properties. Composites prepared with m-TMI-grafted-PP were much superior to the composites prepared with conventionally used maleated polypropylene in all the cases. Non-destructive evaluation of dynamic modulus of elasticity (MoE) and shear modulus of wood filled polypropylene composite at various filler contents was carried out from the vibration frequencies of disc shaped specimens. The vibration damping behaviour of the composite material was evaluated. MoE and shear modulus were found to increase whereas damping coefficient decreased with the increasing filler content. Knowledge of moisture uptake and transport properties is useful in estimating moisture related effects such as fungal attack and loss of mechanical strength. Hence, a study was undertaken to asses the moisture absorption by wood filled polypropylene composites. Composites prepared with coupling agents absorbed at least 30% less moisture than composites without compatibilizer. Thermo-gravimetric measurements were also carried out to evaluate the thermal stability and to evaluate kinetic parameters associated with thermal degradation of wood fiber and wood flour filled polypropylene composites. The moisture absorption and thermal behaviour are described based on analytical models. High efficiency filler-anchored catalyst system was prepared by substituting of hydroxyl groups present on the cellulosic filler. The process involves immobilizing the cocatalyst onto the cellulosic filler surface followed by addition of metallocene catalyst and then polymerization of ethylene using this filler supported catalyst. The polymerization and composite formation takes place simultaneously. All the polymerization reactions were carried out in a high-pressure stirred autoclave. Effect of temperature, ethylene pressure, and cocatalyst to catalyst ratios (Al/TM ratios) were also studied. Studies on kinetics of polymerization showed that, higher Al/Zr ratio and higher temperature lead to higher polymerization rates but lower the molecular weight. A model incorporating effect of reaction parameter on polymerization rates has been developed.

Les travaux présentés dans ce manuscrit sont consacrés à l'élaboration et l’étude des propriétés physiques et thermiques d’une nouvelle génération de composites bois/polymère.Ils sont composés d’une matrice bio-sourcé le pebax®, qui est un thermoplastique élastomèreet de farine de bois de production locale, issue du pin maritime. La matrice pebax® a été choisie car elle présente plusieurs avantages, notamment, une élongation avant ruptureimportante, un point de fusion inférieur à 200°C pour éviter la dégradation du bois au coursde la mise en oeuvre et un caractère hydrophile améliorant l’affinité entre la matrice et lerenfort. Les composites ont été élaborés par extrusion bi-vis et injectés sous forme d’haltèresnormalisées pour les tests mécaniques. Au cours de ces travaux, nous avons montré la bonne qualité de l’interface entre le bois et la matrice, permettant de s'affranchir de l’utilisation d’agents compatibilisants. Nous avons aussi mis en évidence une forte amélioration de la stabilité thermique des composites sous atmosphère oxydante par rapport à celle de la matrice et du bois séparément. Les caractérisations mécaniques et rhéologiques effectuées sur les composites ont permis de montrer l’effet rigidifiant de la farine de bois avec un taux critique entre 20% et 30% de charges pour lequel le comportement des composites évolue d’un type élastomérique à celui de solide moins ductile. La dernière partie des travaux a été consacrée à l’évaluation de la prise en eau des composites. En accord avec les travaux de la littérature, nous avons montré une augmentation de la prise en eau avec le taux de bois. De plus, nous avons démontré que le début de l’absorption d’eau de nos composites suit un mécanisme de diffusion de type Fickien. / The physical properties and thermal stability of a new family of wood polymer composites (WPC) using a bio-based thermoplastic elastomer matrix (pebax® copolymers) were studied. The matrix is a polyether-b-amide thermoplastic elastomer which presents an important elongation at break, a melting point below 200°C which helps prevent degradation of wood fibres. The hydrophilic character of pebax® leads to a good interaction with wood fibres. We have chosen several types of wood flour as reinforcement agent, focusing on wood flour from maritime pine. Composites compounds were made using a laboratory twin screw extruder prior to injection molding to obtain tensile test samples. We have demonstrated the good quality of the interface between wood fibres and matrix, without using any specific compatibilizing agent. Most importantly, we have pointed out a strong improvement of thermal stability of composites under air atmosphere, compared with the behaviour of the matrix or wood separately. We have also characterized the mechanical properties of these composites. The resulting data show an improvement of the tensile modulus with increasing wood content and a decrease of elongation at break, with a behaviour change from elastomeric to less stretchable solid behaviour between 20% and 30% of wood content.The last part of our work was dedicated to the evaluation of water absorption of thecomposites at different wood content. We have shown an increase of water absorption withincreasing wood content and we demonstrated a Fickian diffusion process at the onset ofwater absorption.