Effect of Starch and Paperboard Reinforcing Structures on Insulative Fiber Foam Composites.

Single-use plastic foams are used extensively as interior packaging to insulate and protect items during shipment but have come under increasing scrutiny due to the volume sent to landfills and their negative impact on the environment. Insulative compression molded cellulose fiber foams could be a viable alternative, but they do not have the mechanical strength of plastic foams. To address this issue, a novel approach was used that combined the insulative properties of cellulose fiber foams, a binder (starch), and three different reinforcing paperboard elements (angular, cylindrical, and grid) to make low-density foam composites with excellent mechanical strength. Compression molded foams and composites had a consistent thickness and a smooth, flat finish. Respirometry tests showed the fiber foams mineralized in the range of 37 to 49% over a 46 d testing period. All of the samples had relatively low density (Dd) and thermal conductivity (TC). The Dd of samples ranged from 33.1 to 64.9 kg/m3, and TC ranged from 0.039 to 0.049 W/mk. The addition of starch to the fiber foam (FF+S) and composites not only increased Dd, drying time (Td), and TC by an average of 18%, 55%, and 5.5%, respectively, but also dramatically increased the mechanical strength. The FF+S foam and paperboard composites had 240% and 350% higher average flexural strength (σfM) and modulus (Ef), respectively, than the FF-S composites. The FF-S grid composite and all the FF+S foam and composite samples had equal or higher σfM than EPS foam. Additionally, FF+S foam and paperboard composites had 187% and 354% higher average compression strength (CS) and modulus (Ec), respectively, than the FF-S foam and composites. All the paperboard composites for both FF+S and FF-S samples had comparable or higher CS, but only the FF+S cylinder and grid samples had greater toughness (Ωc) than EPS foam. Fiber foams and foam composites are compatible with existing paper recycling streams and show promise as a biodegradable, insulative alternative to EPS foam internal packaging.

Polyhydroxybutyrate Rice Hull and Torrefied Rice Hull Biocomposites.

Raw and torrefied rice hulls (RRH and TRH) were incorporated into polyhydroxybutyrate (PHB) as fillers using extrusion and injection molding to produce biomass-polymer composites. Filler and composite materials were characterized by particle size analysis, thermomechanical analysis, thermogravimetric analysis, differential scanning calorimetry, FTIR analysis, CHNSO analysis, and mechanical testing. Heat distortion temperature of the RRH composites were 16-22 °C higher than TRH composites. The RRH composite samples showed a 50-60% increase in flexural modulus and 5% increase in stress at yield compared to PHB, while TRH composite samples showed nearly equal flexural modulus and a 24% decrease in stress at yield. The improved mechanical properties of the RRH composites in comparison to TRH composites were due to better particle-matrix adhesion. FTIR analysis showed RRH particles contained more surface functional groups containing oxygen than TRH particles, indicating that RRHs should be more compatible with the polar PHB plastic. SEM images showed space between filler and plastic in TRH composites and better wetted filler particles in the RRH composites.

Redispersion and structural change evaluation of dried microfibrillated cellulose.

Commercializing dried microfibrillated cellulose (MFC) has always been a challenge mainly due to the tendency of MFC to aggregate. In this study MFC samples were submitted to drying/redispersion cycles at different temperatures. Morphology, crystallinity and mechanical performance of films were analyzed throughout the cycles. Microscopy images, particle size and stability in water showed that aggregation happens more severely with 5 drying/redispersion cycles and at drying temperatures of 75 and 100 °C. Particles once-dried at 20 °C formed the same size and web-like structure as the MFC-control. Crystallinity and crystallite sizes increased with drying/redispersion cycles especially when dried at 75 and 100 °C, however drying/redispersion cycles also led to a reduction in mechanical performance due to aggregation. While oven-drying is not the most suitable method, milder action at room temperature once-drying led to suspension stability in water, morphology and mechanical properties close to never-dried MFC, which makes this treatment a feasible option to maintain cellulose quality.