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Twin-Screw Extrusion Process to Produce Renewable Fiberboards

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Published on: January 27, 2021

Solvent infusion processing of all-cellulose composite materials.

Tim Huber¹, Simon Bickerton², Jörg Müssig³

¹Department of Mechanical Engineering, University of Canterbury, Private Bag 4800, 8140 Christchurch, New Zealand.

Carbohydrate Polymers

|April 23, 2014

Summary

Continuous fibre-reinforced all-cellulose composites (ACCs) were created using solvent infusion processing (SIP). This method produces thick, stable ACC laminates with high fibre content, overcoming limitations of thin-film materials.

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Area of Science:

Materials Science
Polymer Science
Green Chemistry

Background:

All-cellulose composites (ACCs) offer sustainable material alternatives.
Conventional methods often yield thin ACC films, limiting applications.
Developing methods for thicker ACC production is crucial for broader material use.

Purpose of the Study:

To develop and investigate a solvent infusion processing (SIP) pathway for producing thick, continuous fibre-reinforced all-cellulose composites (ACCs).
To analyze the impact of processing parameters on the microstructure and properties of ACC laminates.
To demonstrate SIP's capability in overcoming limitations of existing thin-film ACC production.

Main Methods:

Utilizing rayon (Cordenka™) textiles and the ionic liquid 1-butyl-3-methylimidazolium acetate for ACC fabrication.
Employing solvent infusion processing (SIP) involving partial cellulose fibre dissolution and in-situ matrix regeneration via solvent exchange.
Applying pressure during regeneration and drying to enhance fibre compaction and minimize voids.

Main Results:

Successfully produced dimensionally thick (>1 mm) ACC laminates with high continuous fibre volume fractions (>70 vol.%).
Demonstrated homogeneous and controlled partial fibre dissolution, crucial for matrix formation.
Showcased effective fibre compaction through applied pressure, preventing void formation and ensuring dimensional stability.
Examined the influence of inlet/outlet positioning and applied pressure on ACC macro- and microstructure.

Conclusions:

Solvent infusion processing (SIP) is an effective and easy-to-use method for manufacturing thick, dimensionally stable all-cellulose composites (ACCs).
SIP overcomes the limitations of conventional thin-film ACCs by enabling the production of robust, high-fibre-content laminates.
This advancement expands the potential applications of all-cellulose composites in various industries.