Optimizing the manufacture of bio-based composites and low temperature cure powder coating

Abstract

This study is based on evaluating several environmentally friendly aspects in processing and finishing fibre composites such as low-cost Medium Density Fibre (MDF) boards. These include, introducing sustainable materials to replace currently used toxic formaldehyde based binders and adding value to the composites with solvent-free powder coating with aesthetic finishes. The practicality of using conductive fillers, to enable uniform electrical conductivity on the surface of the panels to achieve uniform surface finish with powder coating is also looked into. This is a relatively new concept in composites to facilitate powder coating. The key properties investigated here in the manufacture of MDF include internal bond strength, modulus of rupture, modulus of elasticity and electrical conductivity. In finishing of the composites, a low-temperature powder coating formulation is evaluated using a thermal analysis method by Differential Scanning Calorimeter (DSC) to study the cure behaviour of powders during processing. In both investigations, full factorial design of experiments (DoE) was used as the most significant tool to detect the factors influencing to optimise the processing parameters to maximise the responses. The focus of this project includes mechanisms for preserving the technological knowledge through new business models funded by the NZ government to support the NZ manufacturing sector, for accelerating innovations and commercialization with targeted research into new products and markets