Design and processing of a thermoplastic composite reinforced wood structure

Abstract Reinforced wood structures retain the advantages of natural wood while they allow increased life and better performance. Wood reinforced with thermoset composites has been studied earlier. We for the first time develop a process and design methodology for a thermoplastic‐reinforced wood structure. A wood floor structure was reinforced by the means of adhering a thin layer of consolidated thermoplastic composite. The process for consolidating commingled E‐glass/polypropylene yarns and adhering the composite to wood was designed and tested. The time for preheating and consolidating the commingled thermoplastic yarns on top of wood was predicted analytically and compared with experimental results. An optimal design methodology for the wood/composite floor structure is also developed. Polym. Compos. 25:119–133, 2004. © 2004 Society of Plastics Engineers.