Effect of processing parameters on physical and structural properties of lightweight foam core sandwich panels

Shalbafan, Ali; Welling, Johannes; Luedtke, Jan

doi:10.1080/17480272.2012.684704

Cited by 16 publications

(14 citation statements)

References 10 publications

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“…In addition, the polystyrene may contribute to binding because during the panels manufacturing, polystyrene expands between the wood particles, so that the particles are positively connected. On the other hand, wooden coarse particles are surrounded by expanded hydrophobic materials what reduces the accessibility of water molecules to the OH groups (Shalbafan et al 2013b). Increasing amount of expandable fillers (from 5 to 15 %) leads to a more reduced TS for both panel densities and thicknesses.…”

Section: Physical Propertiesmentioning

confidence: 99%

“…Due to the higher amount of voids in lightweight panels the water can penetrate faster into the samples, especially into the core layer of the samples. This can lead to more water absorption by the samples as well as more thickness swelling after the first 2 h of soaking (Shalbafan et al 2013b). It is worth mentioning that all tests were carried out on unsanded boards, which means that press skin has not been removed.…”

Section: Physical Propertiesmentioning

confidence: 99%

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Using of expandable fillers to produce low density particleboard

2015

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In this study three types of layered lightweight particleboard were produced by using different amounts of expandable polystyrene in the core layer as the filler material. The objective of this study was to compare the effect of varying amounts of expandable filler (5, 10 and 15 %) for two panel densities (450 and 500 kg/m 3 ) and two panel thicknesses (16 and 19 mm) on the panel properties. The results showed that using expandable fillers has a significant effect on the bending properties, internal bond, edge screw withdrawal resistance, thickness swelling and water absorption. The surface soundness and face screw withdrawal resistance were not affected by the usage of expandable filler, as it depends mainly on the quality and density of the surface layer. Panel density and panel thickness also have significant influence on the physical and mechanical properties of the panels produced. Physical and mechanical properties of the boards did not dramatically change when the amount of expandable filler was increased from 5 to 15 %.

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Section: Physical Propertiesmentioning

confidence: 99%

Section: Physical Propertiesmentioning

confidence: 99%

Using of expandable fillers to produce low density particleboard

2015

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“…The TS in foam core panels is influenced by the surface layer thickness (Luedtke 2011). It seems that the wooden particles were saturated after a short time (48 h) of soaking, and this condition does not vary with the prolongation of soaking until 786 h (Shalbafan et al 2013a). It has to be also considered that the foam core layer has no influence on thickness swelling because of its hydrophobic nature.…”

Section: Effect Of Layer Thicknessmentioning

confidence: 99%

Development of a One-Step Process for Production of Foam Core Particleboards using Rigid Polyurethane Foam

Shalbafan

Chaydarreh

Welling³

2016

BioResources

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A simulated one-step process has been developed for the production of foam core particleboards using rigid polyurethane as the core layer. The results showed that the different techniques used for surface layer separation (unresinated particles and sprayed water) and foam injections (open system and closed system) had no influences on panels' characteristics. Mechanical properties (e.g., bending strength and internal bond strength) were mostly influenced by the surface layer thickness, while the water absorption and edge screw withdrawal were influenced by the foam cell structure. The use of sprayed water for surface layer separation doubled the formaldehyde emission (FE) of the panels. The addition of urea (based on 10% of the dry resin) to the sprayed water had a positive effect of reducing the final FE. Furthermore, increasing the surface layer thickness had a positive, linear relationship with FE.

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“…The least improvement was obtained with FRV adhered with FUA and processing temperature of 160°C (Figure ). Our microscopic observation of the surface layer densification revealed a relatively low compacted surface layer (in panels produced with a processing temperature of 160°C) in which some of the adhesive can penetrate into the surface layers, resulting in a relatively weak bond as well as in higher porosity for the volatiles to flow . Additionally, the FUA is described in the EnviroGraf literature as to not give adhesive strength at high temperatures during cone test.…”

Section: Resultsmentioning

confidence: 85%

“…For each surface layer thickness, 4 panel replicates were produced. Shalbafan et al described in detail the pressing schedules and foaming conditions.…”

Section: Methodsmentioning

confidence: 99%

Cone calorimeter testing of foam core sandwich panels treated with intumescent paper underneath the veneer (FRV)

Dietenberger

Shalbafan

Welling³

2017

Fire and Materials

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Summary Surfaces of novel foam core sandwich panels were adhered with intumescent fire‐retardant paper underneath the veneers (FRV) to improve their flammability properties. The panels were evaluated by means of cone calorimeter test (ASTM E 1354). Variables tested were different surface layer treatments, adhesives used for veneering, surface layer thicknesses, and processing conditions, having the objective of obtaining similar or better flammability as that of solid particle boards. Previous research showed that sandwich panels without FRV compared to panels with FRV generally had much higher heat release rates, somewhat higher heat of combustion and much higher smoke production due to the polymeric foam component of tested panels. The present study shows that using FRV adhered to the surface layer of sandwich panels dramatically improved flammability properties; the best FRV performance resulted from panels produced with thicker face layer (5 mm) and lower press temperature (130°C) and adhered with an acrylic thixotropic adhesive. Such protected foam core particleboard has heat release rate profiles as low as that is typical of commercially available fire‐retardant–treated plywood, thus implying a low flammability rating when tested in accordance with both single burn item (Euro Class B anticipated) and steiner tunnel (North America Class A anticipated) tests.

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Effect of processing parameters on physical and structural properties of lightweight foam core sandwich panels

Cited by 16 publications

References 10 publications

Using of expandable fillers to produce low density particleboard

Using of expandable fillers to produce low density particleboard

Development of a One-Step Process for Production of Foam Core Particleboards using Rigid Polyurethane Foam

Cone calorimeter testing of foam core sandwich panels treated with intumescent paper underneath the veneer (FRV)

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