WOOD-PLASTIC COMPOSITES | MATERIALS
Recent innovation in WPCs includes Chinese research to boost mechanical properties, combining PLA foam with beech plywood, and using reclaimed EPS as the basis for new materials
IMAGE: SHUTTERSTOCK
Research digs up new understanding in WPCs
Wood-plastic composites (WPCs) are now an established product, but research into improving them continues – as does the search for variants that combine the benefits of plastics and wood materials. For instance, Indian researchers recently found a way to upcycle expanded polystyrene (EPS) into WPCs for building insulation applications. WPCs are typically made from recycled PVC or polyolefins – and EPS is traditionally very difficult to recycle. The researchers, from the National Institute of
Technology Calicut, published their findings in Materials Research Express. “EPS is a better thermal insulator than concrete,
but lacks the minimum structural strength required for its use as a wall tile,” said the researchers. “This can be addressed by combining EPS with suitable wood and fibre reinforcements to fabricate WPCs.” Here, post-consumer EPS was dissolved in a
mixed solvent of acetone and ethyl acetate and reinforced with a bamboo pulp fibre mixture. Composite panels with varying EPS content (40–70 wt%) and fibre-pulp ratios (30:70 and 40:60) were fabricated using compression moulding. In addition, a foaming agent (sodium bicarbonate) was added at concentrations of 2.5%, 5%, and 7.5%
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in 60% EPS composite to evaluate the pore size effect on thermal and mechanical properties. Mechanical testing showed that the sample containing 60 wt% EPS had superior flexural strength, compressive strength and thermal conduc- tivity. WPCs with 60% EPS with 2.5% pore foaming agent showed controlled pore formation, resulting in the lowest thermal conductivity, which was 7% less than that without foaming agent. The 60% EPS formulation with controlled porosity emerged as a balanced solution – offering good mechanical integrity while lowering thermal conductivity. “Using EPS to fabricate WPCs can address two critical sustainability challenges: diverting EPS waste from landfills; and reducing building energy demands through reduced thermal conductivity,” the researchers concluded.
Product improvement Meanwhile, researchers at the University of Bologna in Italy have described how they helped Iperwood – which makes WPCs – to optimise its Novowood product over several years. Iperwood initially used tropical woods to make
its products – such as decking for lake or river environments. However, rising prices led the
Winter 2025 | PIPE & PROFILE EXTRUSION 27
Main image: WPCs have become widely used in products such as outdoor decking
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