International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 5, May 2017, pp. 59–64, Article ID: IJMET_08_05_007

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=5
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

PREPARATION AND PROPERTIES OF

PHENOL-FORMALDEHYDE RESIN
REINFORCED WITH RECYCLED CELLULOSE
FIBER
N. Pugazhenthi, J. Thamilarasan and A. Sathesh Kumar
Assistant Professor, Department of Mechanical Engineering
Vel Tech Dr. RR & Dr. SR University, Chennai, India

ABSTRACT
This study will help in the development of polymer materials in industries for
withstanding mechanical and thermal properties of phenol-formaldehyde. In this,
reinforcing materials was used to improve the mechanical and thermal properties of
phenol-formaldehyde. The reinforcing material was recycled cellulose fiber. Here the
composite preparation of polymer was discussed and SEM image of the composite was
taken and analyzed. By using TGA test, thermal stability of the composite was
discussed respectively. The mechanical properties like tensile strength and impact
strength were taken and compared with original material. The mat was prepared by
using compression molding machine and specimens were prepared with ASTM STD
for testing the mechanical properties. The composite materials have increased
mechanical properties when compared with the original material.
Key words: phenol, formaldehyde, cellulose fiber, hexamine
Cite this Article: N. Pugazhenthi, J. Thamilarasana and A. Sathesh Kumar,
Preparation and Properties of Phenol-Formaldehyde Resin Reinforced with Recycled
Cellulose Fiber. International Journal of Mechanical Engineering and Technology,
8(5), 2017, pp. 59–64.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=5

1. INTRODUCTION
The polymers which on heating change irreversibly into hard rigid and infusible materials are
called thermosetting polymers. These polymers are usually prepared by heating relatively low
molecular mass, semi fluid polymers, which becomes infusible and form an insoluble hard
mass on heating. The hardening on heating is due to the formation of extensive cross-linking
between different polymeric chains. This leads to the formation of a 3-Dimnesional network
of bonds connecting the polymer chains. Since the 3D network structure is rigid and does not
soften on heating, the thermosetting polymers cannot be reprocessed. Some important
examples of thermosetting polymers are Urea-Formaldehyde resin and Melamine-
Formaldehyde resins.

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 Preparation and Properties of Phenol-Formaldehyde Resin Reinforced with Recycled Cellulose
Fiber

Phenol-formaldehyde was one type of thermosetting material and this was highly cross
linked. This resin was produced in the presence of acidic catalyst with poly-condensation of
phenol and formaldehyde. This resin has various applications when compared to other types.
This was used as bonding agent, household articles and electrical fittings. Generally, this was
the first commercially available resin but still this has wide range of applications from home
to high technology aerospace. Even now, this was irreplaceable in many fields like molding
compounds, foundry, composite materials and wood industry. Phenol formaldehyde was
reinforced with many materials to enhance the properties like mechanical, thermal and
electrical. When phenol formaldehyde with nano hydroxyapatite had showed, the
improvement on mechanical and thermal properties. Similarly, when phenol-formaldehyde
resin with silica hybrid composite material has produced good transparency and this
composite, shows excellent improvement in mechanical and thermal properties. In this, the
temperature has increased from 281 to 350º C at 5% weight loss and flexural strength shows
up to 30% more increment. When zeolite was reinforced with this resin, the heat resistance
and electrical insulation has increased which was compared to GF-filled composite. When the
clay was imported into this resin, the water absorption was reduced and low coefficient of
thermal expansion was achieved.
In this, recycled cellulose fiber was used as reinforcing material, which was obtained from
cardboard, printed paper, recycled newspaper and other types of waste papers. This material
was used in many applications in household purpose and in industries. These composites
could also be used in doors, windows, furniture and automotive industry [7,9,10]. There is a
significant amount of literature on the effects of additional cellulose fibers on physical and
thermal properties of the polymer systems. Generally, this fiber has good properties on crack
resistance, high impact compressive strength and thermal conductivity.

2. EXPERIMENTAL PROCEDURE
Materials Required
Glacial acetic acid, 40% formaldehyde solution, phenol, conc. Sulphuric acid, hexamine,
recycled cellulose fiber

Matrix Preparation
Place 5ml of glacial acetic acid and 2.5ml of 40% formaldehyde solution in a 500ml beaker
and add 2 grams of phenol. Add few ml of conc. Sulphuric acid into the mixture carefully.
Within 5 min. a large mass of plastic is formed. The residue obtained is washed several times
with distilled water, and filtered product is dried and yield is calculated.

RCF reinforced Composites

Here, the phenol-formaldehyde was used as the matrix material. RCF sheets were reinforced
on the matrix. First, RCF dried for 60 min at 70 ºC. After that, RCFs sheets were fully-soaked
into a mixture of phenol-formaldehyde resin and hexamine. Here examine acts as a hardener
for phenol-formaldehyde. Then the fiber was becoming entirely wetted by the mixture, before
they were laid down in a closed silicone mold under 8.2 kPa compressive pressures and left
24 h for curing at room temperature. Then, the mat was prepared and this was cut into ASTM
std size for testing the mechanical properties. The amount of RCF in the final products was
about 40 wt.%. RCF was bought for Sakshi Chem Sciences Private Limited, Nagpur, India.

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 N. Pugazhenthi, J. Thamilarasana and A. Sathesh Kumar

3. RESULT AND DISCUSSION

Composite Characterization
Scanning Electron Microscopy (SEM)
Scanning electron microscope (Zeiss Evo 40XVP) was used to investigate the microstructures
and the surfaces of composites. Samples were coated with a thin layer of gold to prevent
charging before the observation by SEM. In Fig.1 the composite structure was magnified 100
micrometer through which the carbon fiber arrangement was a visible layer by layer. The
reinforcement was arranged in a linear manner with phenol-formaldehyde resin. Generally the
reinforced fibre should be arranged for getting a better result, in which the composites
successfully shown the image.

Figure 1
In fig 1, the SEM image of RCF reinforced composite, a) shows the 100 micrometer and
b) shows 20 micrometers of composite and the matrix of phenol-formaldehyde and carbon
fiber were visible clearly.

Thermal Properties of the Composite

Thermo Gravimetric Analysis (TGA)

The thermal stability of samples was studied by thermo gravimetry analysis (TGA). A Perkin
Elmer, Diamond star system analyzer was used for all these measurements. Samples with 10
mg were placed in a platinum can and tests were carried out in a nitrogen atmosphere with a
heating rate of 20.0 ºC/min from 50.0 ºC to 900.0 ºC. From the graph 1, the phenol-
formaldehyde and RCF composite exhibits two different stages of decomposition. The stage
one may be, the moisture was vaporized in the composite and stage two was degradation of
phenol formaldehyde of all samples in the range of 400 to 500º C.

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 Preparation and Properties of Phenol-Formaldehyde Resin Reinforced with Recycled Cellulose
Fiber

Figure 1 TGA curve of composite Figure 2 DTGA curve of RCF reinforced composite
For thermal stability, the graph 2 indicates, the addition of RCF to the phenol -
formaldehyde matrix was found to accelerate the composites degradation and decreased the
temperature of maximum degradation. But, at higher temperature higher than 400ºC, the
presence of RCF led to an enhancement in thermal stability by increasing the char yield.

4. MECHANICAL PROPERTIES OF THE COMPOSITE

For testing the mechanical properties, the mat was cut into ASTM D2344 for flexural
strength, through which the property of RCF reinforced composite has increased 40% more
when compared to the original material. Similarly, the impact strength of this composite also
increased 76% more and finally the presence of RCF significantly enhanced the impact
toughness of the matrix. The impact toughness for phenol-formaldehyde and RCF reinforced
phenol-formaldehyde are 0.8 and 1.4 kJ/m2 respectively. This remarkable enhancement is due
to the unique properties of cellulose fiber in withstanding bending forces and resisting fracture
force.
This result indicates that recycled cellulose fibers improved the impact toughness of the
composite material.

5. CONCLUSION
Here the composite preparation of phenol-formaldehyde with reinforced cellulose fiber was
described and material characterization of this composite was identified. Then, mechanical
properties of this composite were found, through which the composite shows increased
properties when compared to pure phenol formaldehyde. Similarly, the thermal properties
were found through TGA shows decreased temperature with maximum degradation. So, RCF
can be completely suitable for increasing mechanical and thermal properties.

ACKNOWLEDGMENT
My sincere thanks to
 IIT-Madras
 Department of Chemistry, AERI
 Department of Mechanical Engineering, Vel Tech Dr. RR & Dr.SR University.

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 N. Pugazhenthi, J. Thamilarasana and A. Sathesh Kumar

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