Synergistic Strength-Toughness Gradient Design in Co-Extruded WPC/CFMP Composites
Wood-plastic composites (WPCs) have gained recognition in the architectural and construction industries due to their sustainability, ease of processing, and aesthetic flexibility. However, their limited load-bearing capacity and inherent brittleness restrict their use in demanding structural applications. The integration of carbon fabric mesh prepregs (CFMPs) through co-extrusion offers a new pathway to overcome these challenges. By combining material science and architectural engineering principles, this study explores the development of a high-performance composite system (BPC-CFMP) with superior mechanical adaptability for architectural components.
Problem Identification and Research Gap
Conventional WPCs exhibit inferior toughness and low fracture resistance, leading to early failure under high-stress conditions. Although fiber fabric prepregs provide bidirectional reinforcement, their post-curing rigidity often limits flexibility, resulting in brittle fractures under load. This reveals a significant research gap: how to achieve a balanced strength-toughness synergy in composite materials suitable for flexible yet durable architectural systems.
Development of Carbon Fabric Mesh Prepregs (CFMP)
To address these limitations, carbon fabric mesh prepregs (CFMP) were designed using resin modification to induce a gradient in mechanical properties. The novel formulation enabled a controlled distribution of strength and toughness, achieving optimal reinforcement behavior. This advancement provides the foundation for constructing multi-layered composite structures that can adapt to varying load conditions encountered in architectural applications.
Co-Extrusion Fabrication Strategy
The co-extrusion molding technique was employed to integrate CFMP layers with WPC matrices into a unified composite system—termed BPC-CFMP. This single-step manufacturing process ensures precise alignment and bonding between layers, enhancing production efficiency while maintaining material uniformity. The resulting architecture allows for fine-tuned mechanical gradient control, bridging the gap between flexibility and rigidity—critical for long-span roofs and prefabricated structural systems.
Mechanical Performance and Structural Evaluation
The optimized BPC-CFMP composite exhibited remarkable mechanical improvements compared to traditional WPCs. Tensile strength (53.9 MPa), flexural strength (63.6 MPa), and impact strength (23.7 kJ m−2) improved by 87.7 %, 43.7 %, and 98.4 %, respectively. Furthermore, flexural deflection increased by 72.9 %, while under a 10 J drop hammer test, peak impact force rose by 59.7 % and surface damage area decreased by 48.9 %. These results confirm a robust enhancement in energy absorption and damage resistance, making the material suitable for high-performance architectural use.
Architectural Applications and Future Prospects
The proposed co-extrusion design not only enhances mechanical properties but also promotes scalability for architectural implementation. Its potential extends to prefabricated building systems, long-span roofs, and modular structural panels requiring lightweight yet durable materials. This research contributes to the future of sustainable construction materials, integrating composite engineering innovations with architectural performance needs.
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