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Three-dimensional (3D) forming of fibre-based materials has been a topic of growing interest over recent years and 3D forming processes using hydroforming, press forming and deep drawing processes have been widely explored. Thermoforming as a potential alternative method for forming these materials remains, however, relatively understudied. This research attempts to provide a fundamental understanding of the thermoforming limitations of plastic-coated paperboards. In the work, a variety of commercial paperboards are subjected to experimental tests with different forming parameters and moulding depths. Shape accuracy, maximum acquired depth, thickness distribution behaviour and damage mechanisms are used to evaluate thermoformability, and the results linked to the material properties and forming conditions. The research findings indicate that the plastic-coated paperboards studied are thermoformable but only in simple geometric shapes and with low mould depths.Unlike plastic, thermoforming can result in thickness increase in plastic-coated paperboards, which is thought to be a result of out-of-plane auxetic behaviour of paperboards. Paperboard thermoforming was also found to be hindered by rupture, blistering and curling defects. Tensile strain at break is the key factor determining thermoformability. Additionally, the density of the paperboard can impact the heating step and the rate at which the moisture content of the material changes during the forming process. Furthermore, it was observed that changes in process parameters affected materials differently, with the direction and rate of change differing based on the material being used.

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Three‐dimensional forming of plastic‐coated fibre‐based materials using a thermoforming process

Afshariantorghabeh

Kärki

Leminen

2022

Packag Technol Sci

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Fiber Evolution during Alkaline Treatment and Its Impact on Handsheet Properties

et al. 2018

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Hemicellulose Removal in Curaua (Ananas erectifolius) Fibers for Polyester Composites

Rodrígues

García

Leão

et al. 2018

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Introduction: Alkaline treatments extract hemicellulose from the fibers, which can be reused in the manufacture of other materials, and the cellulosic portion can be applied as reinforcement in a composite. This way, all components of the fibers are utilized.Method: In this work, curaua fibers (Ananas erectifolius) were treated with potassium hydroxide (KOH) to solubilize part of the hemicellulose and lignin, and the cellulose-rich fibers were used to manufacture composites with unsaturated polyester, which were characterized to investigate the effect of the treatment on their properties.Results: The alkaline treatment removed large portions of hemicellulose and significantly degraded the crystalline cellulose and lignin, resulting in a small increase (2.4%) in overall crystallinity and with a negative impact on their thermal stability. SEM images showed defibrillation of the treated fiber and fibril separation, increasing roughness and surface contact area.Conclusions: In all, although the alkaline treatment substantially modified the fibers and no significant changes were observed in the mechanical properties of the composite, the total removal of hemicellulose was found to affect the integrity of cellulose fibers making harder their application as reinforcement. However, the higher cellulose content could be useful for other applications.

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Cited by 5 publications

References 106 publications

Three‐dimensional forming of plastic‐coated fibre‐based materials using a thermoforming process

Three‐dimensional forming of plastic‐coated fibre‐based materials using a thermoforming process

Fiber Evolution during Alkaline Treatment and Its Impact on Handsheet Properties

Hemicellulose Removal in Curaua (Ananas erectifolius) Fibers for Polyester Composites

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