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Feasibility of Manufacturing Paper-Plastic Laminates Using Waste Paper

Feasibility of Manufacturing Paper-Plastic Laminates Using Waste Paper. Chin-Yin Hwang. Taiwan Forestry Research Institute. 2007 IUFRO ALL DIVISION 5 CONFERENCE 11-02-2007 Taipei, Taiwan. Some Statistics. Waste Paper Recovery Rate in Taiwan. 69.7.

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Feasibility of Manufacturing Paper-Plastic Laminates Using Waste Paper

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  1. Feasibility of Manufacturing Paper-Plastic Laminates Using Waste Paper Chin-Yin Hwang Taiwan Forestry Research Institute 2007 IUFRO ALL DIVISION 5 CONFERENCE 11-02-2007 Taipei, Taiwan

  2. Some Statistics. . . . . Waste Paper Recovery Rate in Taiwan 69.7 (Taiwan Paper Industry Association, 2007) 1

  3. Paper Recycling Procedures. . . . • Collection • Classification • Disintegration • Washing • Deinking • Cleansing • Bleaching • Forming • Drying 1 2

  4. Some Questions. . . . . 3

  5. Some Questions. . . . . • Is there other options for Paper Recycling? 3

  6. Some Questions. . . . . • Is there other options for Paper Recycling? • Can other materials be reclaimed from the waste stream and combined with waste papers? 3

  7. Some Questions. . . . . • Is there other options for Paper Recycling? • Can other materials be reclaimed from the waste stream and combined with waste papers? • Is woodfiber plastic composites a possibility? 3

  8. Inherent H Bond Vigorous mixing Agglomeration of wood fibers Reduction in Composite Strength Reduced fiber aspect ratio Heterogeneous fiber dispersion Inferior interfacial adhesion Reduced fiber strength Some Problems with Woodfiber Plastic Composites 4

  9. Why Paper-Plastic Laminates? • Avoid elaborated paper recycling procedures…. • Reduce agglomeration b/w fiber and plastic • Preserve aspect ratio of fiber • Preserve H-bond of paper 5

  10. How PPL is Made? Interleaving + Hot Press Impregnation or Coating + Sheet Formation + 6

  11. How PPL is Made? Interleaving + Hot Press Impregnation or Coating + Sheet Formation + 6

  12. Material • Paper: office paper NP, Not-Printed P, Printed • Plastic: PE films, 0.03mm, 0.06mm, 0.09mm V, Virgin R, Recycled 7

  13. Factors of Interest. . . . . • Paper type (P, NP) • Plastic type (V, R) • Plastic film thickness (0.03, 0.06, 0.09 mm) 8

  14. NP-R-3 NP-R-6 NP-R-9 NP-V-3 NP-V-6 NP-V-9 Methods: preparation OVEN + HP IL P-R-3 P-R-6 P-R-9 P-V-3 P-V-6 P-V-9 9

  15. Typical Hot Press Scheme cool off 10

  16. Methods: Mechanical Properties • Flexural Properties (MORb, MOEb) • Tensile Properties (MORt, MOEt) • Notched Izod Impact Bending • Hardness (Shore D) • Heat Deflection Temperature 11

  17. Sample Preparation Scheme Flexural Hardness Izod Tensile HDT 12

  18. Resulting PPLs • Treatment combination: 12 • Replicate: 5 • Sp/Gr: 0.93 to 1.05 gm cm-3 • Compaction ratio: 1.17 to 1.23 • Fiber loading: 48, 60, and 72% 13

  19. Flexural Properties - MORb 44.8 ~ 69.8 MPa, overall avg 56.1 MPa 14

  20. Flexural Properties - MORb 44.8 ~ 69.8 MPa, overall avg 56.1 MPa Different trends with different plastic groups NP-R, P-R decreased with increasing plastic film thickness NP-V, P-V showed highest MORb at 0.06mm 14

  21. Flexural Properties - MORb 44.8 ~ 69.8 MPa 44.8 ~ 69.8 MPa, overall avg 56.1 MPa PPL 39.1~56.2 MPa (Michell et al. (1978) ) 14

  22. Flexural Properties - MORb 44.8 ~ 69.8 MPa 44.8 ~ 69.8 MPa, overall avg 56.1 MPa 5.9~39.6 MPa (Woodfiber-PE composites) 14

  23. 1.41 times Flexural Properties - MORb 44.8 ~ 69.8 MPa 44.8 ~ 69.8 MPa, overall avg 56.1 MPa 5.9~39.6 MPa (Woodfiber-PE composites) 14

  24. Flexural Properties - MOEb 4.2 ~ 7.3 GPa, overall avg 5.39 GPa 15

  25. Flexural Properties - MOEb 4.2 ~ 7.3 GPa, overall avg 5.39 GPa Similar trends with the corresponding MORb results, except that P-V remained unaffected at all PLFT levels. i.e.,NP-R, P-R decreased with increasing plastic film thickness NP-V showed highest MOEb at 0.06mm 15

  26. Flexural Properties - MOEb 4.2 ~ 7.3 GPa, overall avg 5.39 GPa PPL 5.8~7.6 GPa (Michell et al. (1978) ) 15

  27. Flexural Properties - MOEb 4.2 ~ 7.3 GPa, overall avg 5.39 GPa 0.8~3.6 GPa (Woodfiber-PE composites) 15

  28. 1.49 times Flexural Properties - MOEb 4.2 ~ 7.3 GPa, overall avg 5.39 GPa 0.8~3.6 GPa (Woodfiber-PE composites) 15

  29. Tensile Properties - MORt 30.4 and 56.9 MPa, overall avg 39.9 MPa 16

  30. Tensile Properties - MORt 30.4 and 56.9 MPa, overall avg 39.9 MPa Different trends with different paper types NP-V, NP-R decreased with increasing plastic film thickness P-V, P-R showed highest MORt at 0.06 mm 16

  31. Tensile Properties - MORt 30.4 and 56.9 MPa, overall avg 39.9 MPa 10.0~27.0 MPa (Woodfiber-PE composites) 16

  32. Tensile Properties - MORt 30.4 and 56.9 MPa, overall avg 39.9 MPa 10.0~27.0 MPa (Woodfiber-PE composites) 16

  33. 1.48 times Tensile Properties - MORt 30.4 and 56.9 MPa, overall avg 39.9 MPa 10.0~27.0 MPa (Woodfiber-PE composites) 16

  34. Tensile Properties - MOEt 45.6 ~86.2 GPa, overall avg 62.4GPa 17

  35. Tensile Properties - MOEt 45.6 ~86.2 GPa, overall avg 62.4GPa No specific trend was found 17

  36. Tensile Properties - MOEt 45.6 ~86.2 GPa, overall avg 62.4GPa 1.0~2.7 GPa (Woodfiber-PE composites) 17

  37. 23 times Tensile Properties - MOEt 45.6 ~86.2 GPa, overall avg 62.4GPa 1.0~2.7 GPa (Woodfiber-PE composites) ??? 17

  38. Notched Izod Impact Properties 139.2~371.0 J/ m 18

  39. Notched Izod Impact Properties 139.2~371.0 J/ m Different trends with different paper types NP-V, NP-R showed highest Izod at 0.06 mm P-V, P-R showed no specific trend 18

  40. Notched Izod Impact Properties 139.2~371.0 J/ m 14~27 J/m (Woodfiber-PE composites) 18

  41. >5 times Notched Izod Impact Properties 139.2~371.0 J/ m 14~27 J/m (Woodfiber-PE composites) 18

  42. 50 Shore D Commercial LDPE Hardness 64.2 ~72.6 19

  43. 50 Shore D Commercial LDPE Hardness 64.2 ~72.6 Different trends with different paper types NP-V, NP-R showed lowest hardness at 0.09 mm P-V, P-R seemed to converge at 0.06 mm 19

  44. Heat Deflection Temperature 121.6 ~130.0 HTD of LDPE: 47.0~50.0℃ 20

  45. Limitations • Size and shape (length, width, thickness) • Processability (higher stiffness, HDT) • Anisotropy • Durability unknown • Applications 21

  46. Conclusion • MORb, MOEb, MORt,and Izod of PPLs were better than reported WPCs. • The PPLs prepared in this study exhibited 1.5-times the flexural strength and stiffness and 5-times the notched Izod impact strength over extruded woodflour-plastic composites. • Except for tensile stiffness, all the other mechanical properties of the PPLs were affected by interactions among the 3 factors. 22

  47. Conclusion • PPLs with the same plastic type tended to show similar trends in flexural properties, whereas PPLs with the same paper type tended to exhibit similar trends in tensile strength at break, Izod impact strength, and hardness. 22

  48. Conclusion • These results indicate that PPLs may be a viable alternative method of paper recycling. However, further studies to address the long-term performance of PPLs under extreme conditions are recommended. • Feasibility of developing PPL as a paper recycling alternative seems to be encouraging. 22

  49. tHE eND Questions?

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