Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin

An ultra low formaldehyde emission melamine-fortified urea formaldehyde (UF) resin with formaldehyde to urea molar ratio (F/U) as low as 0.88 was developed. Melamine- fortified resin yields a lower pH drop after addition of the hardener than UF resin and also causes a decrease of the hardening rate...

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Main Author:	Lee, Seng Hua
Format:	Thesis
Language:	English
Published:	2013
Subjects:	Formaldehyde Melamine Urea-formaldehyde resins
Online Access:	http://psasir.upm.edu.my/id/eprint/39133/1/FH%202013%202%20IR.pdf
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id	my-upm-ir.39133
record_format	uketd_dc
spelling	my-upm-ir.391332016-04-11T07:54:17Z Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin 2013-06 Lee, Seng Hua An ultra low formaldehyde emission melamine-fortified urea formaldehyde (UF) resin with formaldehyde to urea molar ratio (F/U) as low as 0.88 was developed. Melamine- fortified resin yields a lower pH drop after addition of the hardener than UF resin and also causes a decrease of the hardening rate of the resin and, therefore, a lengthening of the hot press time is necessary. This study aimed to establish the optimum processing parameters to work with this resin in order to produce particleboard with formaldehyde emission and properties that comply with Japanese Industrial Standard (JIS). The processing parameters consist of shelling ratio of particles, pressing time and temperature. The tests for physical and mechanical properties were conducted in accordance with JIS A 5908:2003. Rubberwood served as the main raw material in this study. Oil palm trunk was used in the first stage of the experiment to examine its feasibility as an alternative raw material to replace conventional rubberwood. However, utilization of oil palm trunk failed to show convincing results. The ratio of 60% surface particles and 40% core particles showed the best result in MOR and TS for the particleboard produced. The newly-developed resin worked well under pressing temperature of 180°C for 270 seconds. Despite the satisfied mechanical properties, particleboard made with this resin showed poor dimensional stability and failed to meet the JIS requirement. Optimization with different wax content and resin usage level was carried out to impart better dimensional stability upon the particleboard. The predicted values were obtained by running optimizer with the desirability function chosen to minimize the TS value. Based on the prediction results, the required TS value can be achieved by the application 1.47% of wax and 10:13% of resin which seem not practical from economic point of view. In addition, further addition of wax exceed 1% did not bring any worthwhile improvement on the dimensional stability of the particleboard. Regarding to the matter, heat treatment was carried out with intention to improve the dimensional stability of particleboard. Two treatment methods with treatment temperature ranged from 100°C to 200°C were conducted. Significant reduction in TS value occurred starting from the treatment temperature of 160°C with the methods involved re-press process. Finally, particleboard complied with all criterions stated in JIS A 5908:2003 was successfully produced by the combination of wax and resin optimization along with the heat treatment. Formaldehyde Melamine Urea-formaldehyde resins 2013-06 Thesis http://psasir.upm.edu.my/id/eprint/39133/ http://psasir.upm.edu.my/id/eprint/39133/1/FH%202013%202%20IR.pdf application/pdf en public phd doctoral Universiti Putra Malaysia Formaldehyde Melamine Urea-formaldehyde resins
institution	Universiti Putra Malaysia
collection	PSAS Institutional Repository
language	English
topic	Formaldehyde Melamine Urea-formaldehyde resins
spellingShingle	Formaldehyde Melamine Urea-formaldehyde resins Lee, Seng Hua Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
description	An ultra low formaldehyde emission melamine-fortified urea formaldehyde (UF) resin with formaldehyde to urea molar ratio (F/U) as low as 0.88 was developed. Melamine- fortified resin yields a lower pH drop after addition of the hardener than UF resin and also causes a decrease of the hardening rate of the resin and, therefore, a lengthening of the hot press time is necessary. This study aimed to establish the optimum processing parameters to work with this resin in order to produce particleboard with formaldehyde emission and properties that comply with Japanese Industrial Standard (JIS). The processing parameters consist of shelling ratio of particles, pressing time and temperature. The tests for physical and mechanical properties were conducted in accordance with JIS A 5908:2003. Rubberwood served as the main raw material in this study. Oil palm trunk was used in the first stage of the experiment to examine its feasibility as an alternative raw material to replace conventional rubberwood. However, utilization of oil palm trunk failed to show convincing results. The ratio of 60% surface particles and 40% core particles showed the best result in MOR and TS for the particleboard produced. The newly-developed resin worked well under pressing temperature of 180°C for 270 seconds. Despite the satisfied mechanical properties, particleboard made with this resin showed poor dimensional stability and failed to meet the JIS requirement. Optimization with different wax content and resin usage level was carried out to impart better dimensional stability upon the particleboard. The predicted values were obtained by running optimizer with the desirability function chosen to minimize the TS value. Based on the prediction results, the required TS value can be achieved by the application 1.47% of wax and 10:13% of resin which seem not practical from economic point of view. In addition, further addition of wax exceed 1% did not bring any worthwhile improvement on the dimensional stability of the particleboard. Regarding to the matter, heat treatment was carried out with intention to improve the dimensional stability of particleboard. Two treatment methods with treatment temperature ranged from 100°C to 200°C were conducted. Significant reduction in TS value occurred starting from the treatment temperature of 160°C with the methods involved re-press process. Finally, particleboard complied with all criterions stated in JIS A 5908:2003 was successfully produced by the combination of wax and resin optimization along with the heat treatment.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Lee, Seng Hua
author_facet	Lee, Seng Hua
author_sort	Lee, Seng Hua
title	Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
title_short	Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
title_full	Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
title_fullStr	Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
title_full_unstemmed	Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
title_sort	development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin
granting_institution	Universiti Putra Malaysia
publishDate	2013
url	http://psasir.upm.edu.my/id/eprint/39133/1/FH%202013%202%20IR.pdf
_version_	1747811771078410240

Development of ultra low formaldehdye emission particleboard using a new melamine-fortified urea formaldehyde resin

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