Valorization of waste thermoset material as a filler in thermoplastic: Mechanical properties of phenolic molding compound waste‐filled PP composites

Bernardeau, Fabien; Didier, Perrin; Caro, Anne-Sophie; Bénézet, Jean‐Charles; Ienny, Patrick

doi:10.1002/app.45849

Cited by 15 publications

(10 citation statements)

References 25 publications

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“…Similar or higher values than talc-filled PP can be obtained, showing that PMC can be used as semi-reinforcing filler [62]. This work, published in 2017 by Bernardeau et al, showed that this thermoset material can be recycled as functional filler in a thermoplastic matrix, improving its mechanical properties in a similar way as conventional semireinforcing filler such as talc.…”

Section: Resultsmentioning

confidence: 72%

Development of a recycling solution for waste thermoset material: waste source study, comminution scheme and filler characterization

Bernardeau

Didier

Bénézet

et al. 2018

J Mater Cycles Waste Manag

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End of life electrical equipment is a continuously increasing source of waste in our modern society, and constitute an environmental problem. Understanding this type of waste flow is important to devise proper dismantlement and sorting strategies, and to maximize the material recovery rate and valorization. In this work, a waste pool constituted of electrical meter was studied. The specificities of this equipment in term of design were enlightened, and the overall material composition was determined. An emphasis was put on the characterization of the plastic fraction, both in term of plastic type and presence of regulated substances. It revealed that this fraction is mostly composed of phenolic molding compound (PMC), a thermoset material, which is troublesome in term of recycling. A material valorization solution through mechanical recycling is proposed , consisting in using PMC as functional filler in a thermoplastic matrix. A comminution scheme to obtain such filler is presented in this work, and the comminuted products are characterized. Through 2 or 3 steps of comminution, particle size below 50 µm can be obtained, which is expected to be a sufficient size for incorporation in a thermoplastic matrix.

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Section: Resultsmentioning

confidence: 72%

Development of a recycling solution for waste thermoset material: waste source study, comminution scheme and filler characterization

Bernardeau

Didier

Bénézet

et al. 2018

J Mater Cycles Waste Manag

Self Cite

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“…It was found in a previous research that this resin was reinforced with various fillers and additives such as calcium carbonate, silica, magnesium carbonate and wood. Bakelite densities is between 1.31 and 1.39 g/L [2].…”

Section: Bakelitementioning

confidence: 99%

“…The polydispersity of PMC filler size distribution was quantified by laser diffraction Particle Sizing Technique (PSD) ( Figure 1). The procedure is fully described in [2].…”

Section: Bakelitementioning

confidence: 99%

“…The method used a minimization algorithm based on that of Levenberg Marquardt leading to a set of parameters (given in Table 3) that conduct to a good accordance between simulated and experimental stress/strain (Figure 8 (a) As a first result, flexural tests were used for Bakelite TM mechanical properties [2].…”

Section: Pp Matrixmentioning

confidence: 99%

“…As most thermoset materials, phenolic molding compound (PMC) wastes generate environmental problems and very few recycling solutions have been proposed for this type of material. In a previous paper, authors consider the possibility to use PMC as fillers in a polymer matrix [1], [2]. Mineral fillers such as calcium carbonate, talc, silica, clay, etc., are usually used to reduce costs, to give some flame-retardancy and/or in some cases to enhance mechanical material properties.…”

Section: Introductionmentioning

confidence: 99%

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Computational modelling of void growth in Phenolic Molding Compounds filled PolyPropylene from optical measurements

Caro-Bretelle¹,

Bernardeau²,

Didier³

et al. 2018

Polymer Testing

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Phenolic molding compounds (PMC), also known as Bakelite TM , are the first synthetic plastics ever produced. They are still in use today in electrical, household and automotive applications. However, one major drawback of PMC is their lack of recycling option. Indeed, landfilling is still the main route of disposal, which constitutes a serious environmental burden. A new alternative recycling method is the use of comminuted PMC as filler in a thermoplastic matrix, in order to improve its mechanical and thermal properties. Several key parameters of the manufactured composite structure are the fillers size distributions, their loading percentage, and the adhesion at the filler/matrix interface. These parameters are related to mechanical properties of the composites, such as tensile strength. In this work, a polypropylene matrix is filled with 20% by weight of comminuted PMC (d 50 = 24μm) functionalized with 3% by weight of PP-g-MA to improve matrix/fillers compatibility. A FE model was developed from the mechanical behavior of each component. PP matrix and PMC fillers are individually characterized from tensile tests instrumented with photomechanics for the matrix characterization and their behaviors were modelled through a set of numerical parameters (elasto-visco-plasticity with a Gurson criterion behavior for the matrix and damage elasticity for the fillers). Numerical simulations at several strain rates were conducted on representative volume element with various microstructures. Comparison between the determinist model results and the experimental data (strength, volumetric variation) shows that this type of modelling could be a predictive tool in order to design particulate composites with optimized mechanical properties. Hence, it is an adequate way to understand micromechanisms of deformation (damage, cavitation).

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Closed‐loop recycling of thermoset composites from electric motor assembly process into flexible polyurethane foams

et al. 2022

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Polyurethane foams (PU) are used in many automotive applications due to their durability and sound absorption properties. This paper examines the effects of reusing predominantly silica-filled thermoset composites as a reinforcing agent when ground to a particle size less than 106 μm (0%, 2.5%, 5%, 7.5% by wt%) on mechanical, physical, thermal, and sound absorption properties of PU foam. Young's modulus improved by 27%, and tensile strength increased by 18% with 7.5% reinforcement. Compression stress improved at 25%, 50%, and 65% strain by 37%, 41%, and 44%, respectively, with the 7.5% filler. Com-

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Valorization of waste thermoset material as a filler in thermoplastic: Mechanical properties of phenolic molding compound waste‐filled PP composites

Cited by 15 publications

References 25 publications

Development of a recycling solution for waste thermoset material: waste source study, comminution scheme and filler characterization

Development of a recycling solution for waste thermoset material: waste source study, comminution scheme and filler characterization

Computational modelling of void growth in Phenolic Molding Compounds filled PolyPropylene from optical measurements

Closed‐loop recycling of thermoset composites from electric motor assembly process into flexible polyurethane foams

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