Design of experiments investigation into the production of all cellulose composites using regenerated cellulosic textiles

• All cellulose composites were produced using Tencel regenerated cellulose textiles. • The use of interleaf cellulosic films was investigated. • Process conditions were explored using design of experiments. • The behaviour of the film was correlated to the structure of Tencel fibres. • Processing with the film allowed the process to be captured easier than without. All cellulose composites (ACCs) can be produced from native and man-made cellulosic fibres; use of the latter provides an additional application for waste-derived regenerated fibers. ACCs were prepared using an ionic liquid dissolution method, utilizing a regenerated cellulose (Tencel) textile, with and without an interleaf cellulosic film. A design of experiments methodology was applied to explore process-property relationships; concentration of the ionic liquid and the processing time and temperature were investigated. It was found that the film remained in-between the textile layers, rather than penetrating the fiber assembly, in contrast to our previous work on cotton-based ACCs. This is due to the structural differences between Tencel and cotton fabric. A multi-response optimization was conducted through a central composite face centered strategy, which captured the film system more strongly. Optimized processing conditions were identified, yielding a Young’s modulus and strain-to-failure of 5.3 GPa and 3.5% respectively,;alidated through in-lab samples.