Browse > Article
http://dx.doi.org/10.7469/JKSQM.2022.50.1.169

A Case Study of Applying Mixture Experimental Design to Enhance Flame Retardancy of Wood-Plastic Composites  

Seo, Ho-Jin (Department of Industrial and Systems Engineering, Gyeongsang National University)
Kwon, Minseo (Sejong Deck)
Lee, Gun-Myung (Department of Mechanical Engineering, Gyeongsang National University)
Ju, Hyejin (Department of Industrial and Systems Engineering, Gyeongsang National University)
Byun, Jai-Hyun (Department of Industrial and Systems Engineering, Gyeongsang National University)
Publication Information
Journal of Korean Society for Quality Management / v.50, no.1, 2022 , pp. 169-181 More about this Journal
Abstract
Purpose: This paper addresses a case study of developing a flame retardant wood-plastic composites (WPC) by adding tannic acid to the existing synthetic wood. The optimal mixing ratios of six components are explored to minimize the burning time using two mixture designs. Methods: In the preliminary experiment, six components are considered to find important components and their ranges. Seven D-optimal mixture design points are generated. Two points are removed for the balance of plastic components to be maintained, and the remaining five points are augmented with two basic compositions. Four components are selected to be considered in the main experiment. In the main experiment, pellets are extruded at the eight mixture design points. In-house testing of burning time is executed three times. Specimens made of pellets from two promising flame retardant compositions are sent to the accredited laboratories and tested. Results: The test results are as follows: 1) The best composition (Wood flour, Tannic acid, PE, Lubricant) = (25, 41, 10, 2) (wt%) shows the burning time of 1 second, which is 9-fold improvement compared to the the burning time of 9 seconds from the existing composition (58, 0, 10, 2) (wt%). 2) The second best composition (41, 25, 10, 2) (wt%) results in the burning time of 2 seconds. This composition is inferior to the best composition in terms of the flame retardancy, but more economical since it needs less tannic acid which is 100-fold expensive than the wood flour. Conclusion: Flame retardant compositions are found by adding tannic acid to the existing WPC employing optimal mixture designs. This case study will be helpful to practitioners who try to develop new products with additional physical properties with as small number of experimental trials as possible. Future research direction includes exploring conditions which satisfy both performance level and cost limitation simultaneously.
Keywords
Wood-Plastic Composites; Flame Retardancy; Burning Time; Design of Experiments; Mixture Design;
Citations & Related Records
Times Cited By KSCI : 3  (Citation Analysis)
연도 인용수 순위
1 Byun, J. -H. and Kim, C. -H. 2014. Simplex Evolutionary Operation for Mixture Production Processes. Quality Engineering 26(4):383-391.   DOI
2 Byun, J. -H., Jung, C. S., Kim, D., and Park, K. -H. 2019. A Case Study of Enhancing Flame Retardancy of Mixture Material. Journal of Korean Society for Quality Management 47(3):631-639.   DOI
3 Byun, J. -H., Seo, P. S., Shin, J. E., Lee, L. G., and Yeom, J. H. 2014. A Case Study of Developing Rapid-Hardening Ultra-Low Temperature Adhesives by Mixture Design and Multiple Response Optimization. Journal of Korean Society for Quality Management 42(4):757-768.   DOI
4 Box, G. E. P. 1957. Evolutionary Operation: A Method for Increasing Industrial Productivity. Applied Statistics 6:81-101.   DOI
5 Kim, J. -S., Byun, J. -H.. and Choi. K. 2007. An Economic Screening Method for Mixture Experiments Using Correlation Coefficients. Journal of the Korean Institute of Industrial Engineers 33(3):349-354.
6 Chung, J. H. and Lim, Y. B. 2020. Efficient Designs to Develop a Design Space in Mixture Response Surface Analysis. Journal of Korean Society for Quality Management 48(2):269-282.   DOI
7 Cornell, J. A. 2002. Experiments with Mixtures, Designs, Models, and the Analysis of Mixture Data, 3rd Edition. Wiley, New York.
8 Johnson, M. E. and Nachtsheim, C. J. 1983. Some Guidelines for Constructing Exact D-Optimal Design on Convex Design Space. Technometrics 25(3):271-277.   DOI
9 Shin, B. W., Song, Y, H., Rie, D. H.. and Chung, K. S. 2010. A Study on Combustion Characteristics of Wood-Plastic Composites. Journal of Korean Institute of Fire Science and Engineering 24(6):120-125.
10 Kim, C. -H. and Byun, J. -H. 2003. An Evolutionary Operation with Mixture Variables for Mixture Production Process. Journal of the Korean Institute of Industrial Engineers 29(4):334-344.
11 Smith, W. F. 2005. Experimental Design for Formulation, SIAM, VA.
12 Clemons, C. 2002. Wood-Plastic Composites in the United States: The Interfacing of Two Industries. Forest Products Journal 52(6):10-18.
13 Mitchell, T. J. 1974. An Algorithm for the Construction of D-optimal Experimental Designs. Technometrics 16(2):203-210.   DOI
14 Nam, S. H., Condon, B. D., Xiz, Z. Nagarajan, R. Hinchliffe, D. J.. and Madison, C. A. 2017. Intumescent Flame-Retardant Cotton Produced by Tannic Acid and Sodium Hydroxide. Journal of Analytical and Applied Pyrolysis 126:239-246.   DOI
15 Kim, J. -S. and Byun, J. -H. 2006. A Study on Implementation Guideline of Screening Mixture Design and Analysis for the Development of New Mixture Products. IE Interfaces 19(2):117-123.