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ORIGINALS ORIGINALARBEITEN
Processing and flexural properties of surface reinforced flatpressed WPC panels
Henrik Schmidt • Jan T. Benthien •
Heiko Thoemen
Received: 24 August 2012 / Published online: 5 July 2013
� Springer-Verlag Berlin Heidelberg 2013
Abstract While extrusion and injection molding are the
common technologies to produce wood-plastic composites
(WPC), pressing may be an alternative, particularly when
flat products are striven for. In this study, flat pressed WPC
panels were surface-reinforced by two different types of
thermoplastic face layers to improve flexural properties. The
two face materials applied were a commingled fabric made
of glass and polypropylene filaments (TWINTEX�) and a
glass fabric reinforced polypropylene laminate (S-TEX�).
Combination of face layers and WPC panels was achieved in
a single and a two stage flat pressing process. Besides
studying the effects of reinforcing material and number of
process stages, the influence on flexural properties of the
reinforced panels was identified. Unreinforced WPC panels
were tested for comparison. The reinforced WPC panels
exhibited greatly improved flexural properties, with MOE
(MOR) values up to nearly 10,000 N/mm2 (90 N/mm2).
Herstellung und Biegeeigenschaften von flachgepressten
WPC-Platten mit verstarkten Deckschichten
Zusammenfassung Holz-Kunststoff-Verbundwerkstoffe
(wood-plastic composites) (WPC) werden uberwiegend im
Extrusions- oder Spritzgießverfahren hergestellt. Alternativ
hierzu konnen plattenformige WPCs mit Hilfe der
Flachpresstechnologie hergestellt werden. In dieser Studie
wurden flachgepresste WPC-Platten mit zwei verschiedenen
thermoplastischen Deckschichtmaterialien verstarkt, um so
deren Biegeeigenschaften zu verbessern. Als Deckschicht-
materialien wurden TWINTEX�, eine kombinierte Glasfa-
ser-Polypropylenfaser-Matte, sowie S-TEX�, eine dunne
glasfaserverstarkte Polypropylenplatte, verwendet. Die
Verbindung zwischen Deckschicht und WPC-Platte wurde
in einem ein- und einem zweistufigen Verfahren realisiert.
Erganzend zum Einfluss des Verstarkungsmaterials und der
Anzahl der Prozessschritte, wurden die Biegeeigenschaften
der verstarkten Platten bestimmt. Als Referenzmaterial dien-
ten unverstarkte WPC-Platten. Durch die Verstarkung der
Deckschichten wurde ein Anstieg der Biegeeigenschaften
auf einen Wert von fast bist zu 10.000 N/mm2 (MOE) und
90 N/mm2 (MOR) erzielt.
1 Introduction
Wood–plastic composites (WPC) are mainly processed into
profiles or 3-dimensional form parts by extrusion and
injection molding techniques. In building applications,
dimensions of WPC profiles and also extruded sheets are
restricted to the limitations of the extruders; therefore only
limited widths and thicknesses can be achieved. Aside from
extrusion and injection molding, flat pressing technology, in
reference to the wood-based panel production, may be seen
as a promising method to manufacture large dimensioned
WPC panels. Various scientific papers deal with the devel-
opment of WPC panels in laboratory scale (Benthien and
Thoemen 2012; Philipp 2005; Wolcott 2003; Boeglin et al.
1997; Falk et al. 1999; Chaharmahali et al. 2008). WPC
panels offer a good alternative to lumber or wood-based
panels because of their durability and low maintenance cost
H. Schmidt � J. T. Benthien (&)
Department of Wood Science, Mechanical Wood Technology,
Hamburg University, Leuschnerstrasse 91c, 21031 Hamburg,
Germany
e-mail: [email protected]
H. Thoemen
Department of Architecture, Wood and Civil Engineering,
Bern University of Applied Sciences, Solothurnstrasse 102,
2500 Biel, Switzerland
123
Eur. J. Wood Prod. (2013) 71:591–597
DOI 10.1007/s00107-013-0719-y
(Rizvi and Semeralul 2008). While the water resistance
properties are advantageous, flexural properties should be
further improved. According to Falk et al. (1999) maximum
bending modulus of elasticity (MOE) of WPC panels is
similar to the lower MOE-ranges of particleboard and
medium-density fiberboard. Maximum bending MOR of flat
pressed WPCs is comparable to the lower modulus of rup-
ture (MOR) range of oriented strand board (OSB). There
have been different attempts to improve the mechanical
properties of flat pressed WPC panels and other WPC
products such as extruded profiles. The properties of WPC
depend on many parameters such as the amount of wood
filler, fiber aspect ratio of the wood particles and the adhe-
sion between wood and polymer (Jiang et al. 2007).
One option to increase the strength and toughness of WPC
products is the addition of glass fiber reinforcement to the
compound. Rizvi and Semeralul (2008) added 5 % glass fibers
to WPC specimen with varying amounts of wood fiber content
and found significant improvement in strength and modulus.
By using an integrated pressing and cooling device and
pretend infrared heating (fusion bonding) Jiang et al. (2007)
applied commingled glass and polypropylene filaments
(TWINTEX�) in form of an unidirectional tape to WPC
deck boards. Arrangements with and without additional
polypropylene tie-layer between the WPC and the thermo-
plastic reinforcement were carried out. Improvement of
MOE and MOR up to 60 % was achieved by applying the
reinforcement on both surfaces of the WPC deck boards.
Commingled glass and polypropylene filaments
(TWINTEX�) have also been used to design a wood–
polypropylene composite. Dai et al. (2004) applied the
thermoplastic reinforcement to a wood floor structure and
reported an improvement in bending strength of 40 %
compared to the unreinforced deck board.
The aim of this study was to determine chances and
limitations of enhancing flexural properties of flat pressed
WPC panels. Reinforced WPC panels were manufactured
with two different thermoplastic fiber-reinforced face
materials using a one-step and a two-step flat pressing
process. The flexural properties of the reinforced panels
were examined and compared to those of unreinforced flat
pressed WPC panels to detect the potential of the different
reinforcement systems to improve flexural properties. The
density of the WPC middle layer was modified to investi-
gate the influence on the properties of the reinforced panels.
2 Materials and methods
2.1 Materials
The polypropylen (PP) (HP 500 V) used for the WPC pro-
vided by Basell Polyolefine GmbH (Lyondell Basell
Industries), Wesseling, Germany, was pulverized by (kryo-)
milling to ensure fine spreading using dry blending as
mixing method. The melt flow rate (MFR) of the polymer is
120 g/10 min (230 �C/2.16 kg).
Soft wood flour JELUXYL WEHO 500S was provided
by JELU-WERK, Rosenberg, Germany. The main mass
fraction of \0.3 mm was determined by sieve analysis.
Before mixing the raw materials, the wood flour (WF) was
ovendried at 105 �C to a moisture content of about 1 %. As
Stark (2001) stated, using WF with high moisture content
adversely affects mechanical properties of the WPCs.
Two different types of thermoplastic reinforcement
materials were used as surface layers. TWINTEX� is a
reinforcement fabric of commingled thermoplastic and
glass filaments provided by Schilgen, Emsdetten, Ger-
many. The material is commonly used in 3-dimensional
and sandwich structures in building, automotive and mar-
ine application. Consolidation of the commingled fibers is
done by heating the fabric above melting temperature of
the polypropylene. The fabric is woven in a 2/2 twill pat-
tern. S-TEX� is a glass fabric reinforced polypropylene
laminate with randomly oriented glass fibers. The ortho-
tropic laminate is commonly used for large semi-structural
applications in a sandwich structure and has a thickness of
approx. 1.5 mm. The material was kindly provided by
Quadrant Plastics, Lenzburg, Switzerland. Properties of the
reinforcement materials are shown in Table 1.
2.2 Methods
The size of all manufactured WPC test panels was 420 mm
in length and 380 mm in width. The WF was manually
mixed with the polymer powder at room temperature (dry
blending method) and placed into a frame made of poly-
urethane (PU) foam to inhibit a lateral yielding of the
dryblend while pressing. When producing a reinforced
panel, the facing material was cut to size and placed within
the PU frame underneath and above the WPC. The target
thickness of all panels was 10 mm. The amount of WPC
material in a reinforced panel was calculated by estimating
Table 1 Properties of S-TEX� and TWINTEX�
Tab. 1 Eigenschaften von S-TEX� und TWINTEX�
S-TEX TWINTEX
Nominal weight (g/m2) 2,178 985
Glass content by weight (%) 40 60
Glass weight (g/m2) 871 591
Tensile strength (N/mm2) 125a 50b
Tensile modulus (N/mm2) 10,200a 4,700b
a Longitudinal directionb Transverse direction
592 Eur. J. Wood Prod. (2013) 71:591–597
123
the thickness of the facing material and the WPC middle
layer in the finished panel.
The pressing of the panels was conducted on a com-
puter-controlled laboratory hot press, whereas cooling took
place in a separate press while keeping the panel thickness
constant by using distance bars. The hot press was operated
in plate position control mode, with the pressure limited to
a maximum of 700 N/cm2. WPC reference panels without
reinforcement and WPC middle layers to be reinforced in a
second process step were hot-pressed for 500 s at 210 �C.
Surface reinforced panels manufactured in a one-step
process were pressed with a pressure of 45 N/cm2 for
400 s, before a specific pressure of 700 N/cm2 was
implemented for another 100 s. The same pressing pro-
gram was used when applying a surface layer to a previ-
ously made WPC middle layer. By applying low pressure
for 400 s, the polymer in the thermoplastic surface lami-
nates and in the WPC-layer plasticized before compression
to the target thickness.
2.3 Experiment design
The WPC consisted of 70 % WF and 30 % PP powder. In
order to identify the influence on the flexural properties of
surface reinforced flat pressed WPC panels, three series (A,
B, C) with altering modifications (type of reinforcement,
density of WPC-layer, number of process stages) were
designed (Table 2). Three test panels for each modification
were pressed and four bending specimens were cut from
each panel.
2.4 Characterization of flexural properties
Three-point bending tests according to DIN EN 310:1993
were carried out to investigate MOE and MOR. For
homogeneous materials such as unreinforced WPC panels,
three-point bending leads to constant results independent of
panel thickness. In multilayered panels of different thick-
nesses, changing amounts of shear strain lead to inconsis-
tent values of MOE and MOR (Gupta 2007). Therefore, the
experimental values only apply to the specific panel setup
and thickness. To be able to compare the panels and
evaluate the influence of the different types of reinforce-
ment, density of WPC layer and number of process stages,
a consistent panel thickness for all manufactured panels
was of great importance.
3 Results and discussion
3.1 Influence of surface reinforcement type
Table 3 summarizes the average values of MOE and MOR
of the reinforced panels and unreinforced reference panels
(series A). The reinforced WPC panels show greatly
improved flexural properties in comparison to the unrein-
forced reference panels. The reinforcement with TWIN-
TEX� in a single step process leads to a 2.4 (4.0) times
higher MOE (MOR) compared to the unreinforced refer-
ence panel. Surface reinforced panels using S-TEX� show
3.4 (5.6) times higher MOE (MOR). For comparision,
Boehme (1976) found for glass fiber/polyester resin rein-
forced particleboards with a thickness of 10.7 mm (8 mm
core layer thickness) flexural properties of 6,011 N/mm2
(61.3 Mp/cm2) (MOE) and 81.2 N/mm2 (MOE/
MOR = 74) (MOR), and Cai (2006) found for glass fiber/
phenol resin reinforced medium-density fiberboards,
respectively flakeboards (12.7 mm core layer thickness)
flexural properties of 3,310 N/mm2 (3.31 GPa) (MOE) and
33.4 N/mm2 (33.4 MPa) (MOR), respectively 7,140 N/
mm2 (7.14 GPa) (MOE) and 51.3 N/mm2 (51.3 MPa)
(MOR).
S-TEX� reinforced WPC panels show higher values
than panels reinforced with TWINTEX� due to the higher
glass fiber content and the higher nominal weight of the
Table 2 Test set-up with different modifications of materials, den-
sities and process parameters
Tab. 2 Versuchsaufbau mit Blick auf Material, Dichte und
Prozessparameter
Series Type of
reinforcement
WPC density
(g/cm3)
Number of
process steps
A Unreinforced 0.8 1
TWINTEX� 0.8 1
S-TEX� 0.8 1
B Unreinforced 0.65 1
Unreinforced 0.8 1
TWINTEX� 0.65 1
TWINTEX� 0.8 1
S-TEX� 0.65 1
S-TEX� 0.8 1
C TWINTEX� 0.8 1
TWINTEX� 0.8 2
S-TEX� 0.8 1
S-TEX� 0.8 2
Table 3 Mean values of flexural properties of the different rein-
forced panels and unreinforced panels (n = 12)
Tab. 3 Mittelwerte der Biegeeigenschaften der unterschiedlich
verstarkten bzw. unverstarkten Platten (n = 12)
Unreinforced TWINTEX� S-TEX�
MOE (N/mm2) 2,828 ± 215.3 6,677 ± 148.5 9,694 ± 736.6
MOR (N/mm2) 15.6 ± 3.0 62.2 ± 4.1 89.7 ± 9.4
Eur. J. Wood Prod. (2013) 71:591–597 593
123
material. S-TEX� shows 40 % glass content by weight
which calculates to 871 g glass fibers, while the TWIN-
TEX� fabric contains 591 g of glass fibers per square
meter. Because S-TEX� surface layer is estimated to have
a thickness of 1.7 mm after pressing, the WPC panel is
correspondingly thin to form a panel with the overall
thickness of 10 mm. This leads to a predominant influence
of the reinforcing material on the properties of the whole
reinforced panel. TWINTEX� is estimated to have a
thickness of 0.7 mm in the manufactured composite panel.
For further characterization of the surface materials as
reinforcement for flat pressed WPC panels, fracture char-
acteristics of the composites in addition to absolute
strength values are analyzed.
In Fig. 1 exemplary load-displacement curves for two
different reinforced panels and an unreinforced panel
obtained from three-point bending are presented. It can be
seen that the unreinforced panel failed with a brittle frac-
ture while both surface reinforced WPC panels showed
ductile fracture behavior after reaching the maximum load.
Hereby the TWINTEX� reinforced WPC panel showed a
more extensive ductility and flexibility than the S-TEX�
reinforced panel, as can be seen in the bigger displacement.
Since the testing machine was set up to stop bending when
the load-level of the decreasing load curve reached a value
of 90 % of the maximum load, the testing procedure for the
TWINTEX� panels was often stopped manually, because
the 10 % drop of the load took several minutes and total
failure of the specimen did not occur.
In Fig. 2 the fracture patterns of exemplary bending
specimens are presented. In Fig. 2a, wrinkling on the top-
side of a TWINTEX� reinforced panel can be observed.
All specimens of this type showed wrinkling on the top-
side. Total failure never occurred and the bottom of the
specimen which was exposed to tensile strain stayed
visually intact. Figure 2b shows the tensile fracture of an
S-TEX� reinforced WPC panel. These types of reinforced
panel failed mostly by tensile fracture or to a lesser extent
by shear fracture in the middle of the WPC-layer (Fig. 2c).
Shear failure or tensile fracture occurs in the S-TEX�
reinforced WPC panels, because the STEX� laminates
show high compressive strength. Therefore, no stress is
compensated by local wrinkling on the topside of the
composite. Consequently tensile and shear stress increases
and leads to failure. In the TWINTEX� reinforced panel no
shear fracture is observed. The TWINTEX� layers are thin
and wrinkle when exposed to pressure. Thus TWINTEX�
reinforced panels show smaller flexural strengths but no
total failure by tensile fracture, whereas S-TEX� rein-
forced panels reach higher values but fail with tensile or
shear fracture. Both reinforced panel types show no
delamination of the surface layer while exposed to bending.
Strong interfacial adhesion and a good compatibility
between the matrix polymers of the face materials and the
thermoplastic in the WPC are indicated.
3.2 Influence of the WPC layer density
The density of the WPC layer was regulated by the weight
of the raw materials. Pressing parameters were kept con-
stant for both target densities. The panels included in the
investigation on the influence of the density of the WPC-
layer were all manufactured in a single stage process. As
can be seen in Fig. 3, the increase in density of 0.15 g/cm3
leads to about two times higher MOE and MOR values for
the unreinforced panels. Benthien et al. (2009) state that the
density of the WPC panels is the strongest influencing
factor on physical and mechanical properties. For the
reinforced panels improvements of flexural values with
increasing density of the WPC-layer are less extensive.
MOE of the TWINTEX� reinforced panel increases by
13 %, MOR by 30 % when WPC density rises from 0.65 to
Fig. 1 Load-displacement curves of the different types of reinforced
panels
Abb. 1 Kraft-Wegdiagrammkurven der unterschiedlichen verstark-
ten Platten
Fig. 2 Fracture-characteristics of the WPC panels reinforced with
a TWINTEX� and b, c S-TEX�
Abb. 2 Bruchcharakteristiken der mit a TWINTEX� und b, c S-
TEX� verstarkten WPC-Platten
594 Eur. J. Wood Prod. (2013) 71:591–597
123
0.80 g/cm3. 0.15 g/cm3 raise in density leads to an increase
of MOE by 10 % and MOR by 27 % for S-TEX� rein-
forced panels. Fracture pattern of the reinforced panels
with low density core layers is mainly wrinkling on the top
side of TWINTEX� reinforced panels, while S-TEX�
reinforced panels all fail by shearing in the middle of the
WPC layer. Unlike the S-TEX� reinforced panels with
higher WPC density, no tensile fracture of the bottom
S-TEX� surface layer occurred. Increase of MOR with
rising WPC density is stronger than the increase of MOE
for both reinforced panel types. This can also be observed
by looking at the correlation between overall density of the
reinforced panels with MOE and MOR in Fig. 4. Properties
of TWINTEX� and S-TEX� reinforced panels increase in
a similar linear manner with rising WPC density. The
effect of the MOE of the WPC is less influential on the
MOE of the reinforced panels than the MOR of the WPC
on the MOR of the reinforced panels.
The reason for this behavior can be found in the rela-
tionship between MOE and MOR (MOE/MOR) of the
different materials. While the ratio in unreinforced WPC
panels is very high (170…200), the ratio between MOE
and MOR for the S-TEX� material itself is rather low (30).
The reinforced panels show a ratio between 85 and 120.
Therefore, the reinforcement generally shows a stronger
influence on MOR than on MOE. Albers and Plath (1970)
and also Boehme (1976) found the same phenomena for
surface reinforced wood-based panels.
3.3 Influence of number of process stages
Besides the obvious economic differences of a single stage
and a two-step process to manufacture surface reinforced
WPC panels, properties also change with the number of
process steps. As can be seen in Fig. 5, MOE is higher for
the reinforced panels, which are manufactured in a single
process step, while MOR is higher for the panels which are
manufactured in a two step process.
This behavior can be explained by the different density
profiles over the cross section of the panels, which develop
in the progression of the pressing process. It can be
examined that the single stage process leads to a region of
very high density of the WPC directly beneath the rein-
forcing S-TEX� material. This may be caused by a prec-
edent densification of this region due to a higher specific
pressure. The additional reinforcement supplies more
material which needs to be compressed. The pressure is at
first transmitted to the WPC layer until the polymer of the
laminate plasticizes. The density profiles shown in Fig. 6
further indicate that the single stage process leads to a
redistribution of the polymer of the reinforcement layers.
Especially the S-TEX� reinforced panels show a dis-
similar density distribution on the surface of the reinforced
panels. In the single stage process the reinforcement is
plasticized by the heat of the press plates before the plas-
ticization of the polymer in the WPC layer starts. A part of
the polymer of the reinforcement flows into the not yet
Fig. 3 Influence of core density
on MOE and MOR of the
reinforced panels
Abb. 3 Einfluss der
Kernschichtdichte auf MOE und
MOR der verstarkten Platten
Fig. 4 Correlation between
panel density and flexural
properties
Abb. 4 Korrelation zwischen
Plattendichte und
Biegeeigenschaften
Eur. J. Wood Prod. (2013) 71:591–597 595
123
plasticized WPC layer parallel to the direction of the heat
transfer. Consequently, because a part of the polymer of the
face material flows to the middle, the reinforcing glass
fabric in the surface material moves further to the surface
of the panels. The higher density values on the surface of
the S-TEX� may be caused by the accumulation of the
glass fibers due to the flow-off of the polymer. This mod-
ification as well as the oriented structure (woven) and the
Fig. 5 Flexural properties
depending on the number of
process steps
Abb. 5 Biegeeigenschaften in
Abhangigkeit der Anzahl der
Prozessschritte
Fig. 6 Density profiles of the
reinforced panels manufactured
in a single and two stage
process, left TWINTEX, right
S-TEX�
Abb. 6 Rohdichteprofile der
verstarkten Platten, die im
einstufigen und zweistufigen
Prozess hergestellt wurden.
Links: TWINTEX�, rechts:
S-TEX�
Fig. 7 Cross-sections of the
differently manufactured panels,
a S-TEX�: single stage process,
b S-TEX�: two stage process,
c TWINTEX�: single stage
process, d TWINTEX�: two
stage process
Abb. 7 Querschnitte der
unterschiedlich hergestellten
Platten. a S-TEX�: einstufiger
Prozess, b S-TEX�:
zweistufiger Prozess,
c TWINTEX� einstufiger
Prozess, d TWINTEX�:
zweistufiger Prozess
596 Eur. J. Wood Prod. (2013) 71:591–597
123
higher amount of glass fibers (see Table 1) lead to higher
MOE. The reinforced panel on the other hand, which is
manufactured in a two stage process, shows a broader
range of high density over the width of the reinforcement
layer. No flow-off into the WPC-layer takes place, since
the reinforcing material is pressed on an intact WPC sur-
face that does not draw in plasticized polymer as much as
the unconsolidated dryblend. These panels show higher
MOR. In Fig. 7 images of the cross sections of the dif-
ferently manufactured reinforced panels are displayed. It is
well recognizable that the S-TEX� and TWINTEX�
reinforcement layers are thinner when combined with the
WPC layer in a single stage process (Fig. 7a, c), while the
reinforcement layers in panels manufactured in a two stage
process stay intact with no flow-off of the matrix-polymer
(Fig. 7b, d).
4 Conclusion
Two different types of thermoplastic reinforcement-sys-
tems were used to enhance the flexural properties of flat
pressed WPC panels. The utilized materials were a com-
mingled fabric made of glass and polypropylene filaments
(TWINTEX�) and a glass fabric reinforced polypropylene
laminate (S-TEX�). The compatibility of the polymer-
systems of both reinforcement materials with the WPC was
found to be very satisfying. Delamination between the
layers did not occur for both types of reinforced panels. Up
to 5.6 times higher MOR and 3.4 times higher MOE were
achieved in comparison to unreinforced WPC panels.
S-TEX� reinforced panels showed higher flexural proper-
ties than TWINTEX� reinforced panels because of higher
nominal weight and glass content. Fracture behavior of the
reinforced panels was dissimilar. S-TEX� panels failed
either by tensile break or by shear fracture, caused by the
high compressive strength of the reinforcing layer.
TWINTEX� panels showed wrinkling on the compressed
top side of the panel, which was promoted by the minor
thickness of the layer and therefore did not fail by tensile
fracture or shear fracture. The different fracture patterns
and the related ductile fracture behavior visualized by the
slowly decreasing load displacement curves (Fig. 1)
obtained by three-point bending indicate another advantage
of the reinforced panels. Besides the extensively increased
flexural properties the fracture behavior changed from a
brittle manner to a distinct ductility, which further pro-
motes the suitability of the reinforced WPC panels in
structural applications.
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