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Potential of Natural Oil-Based Polyurethane As an Adhesive for Particleboard Production: a Review

Potential of Natural Oil-Based Polyurethane As an Adhesive for Particleboard Production: a Review

International Journal of Mechanical and (IJMET) Volume 9, Issue 7, July 2018, pp. 1485–1493, Article ID: IJMET_09_07_158 Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=7 ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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POTENTIAL OF NATURAL -BASED AS AN FOR PARTICLEBOARD PRODUCTION: A REVIEW

Norazwani Muhammad Zain and Farizah Adliza Ghazali Fabrication & Joining Section, Universiti Kuala Lumpur Malaysia France Institute, Jalan Teras Jernang, 43650 Bandar Baru Bangi, Selangor, MALAYSIA

Eida Nadirah Roslin Automotive Engineering Section, Universiti Kuala Lumpur Malaysia France Institute, Jalan Teras Jernang, 43650 Bandar Baru Bangi, Selangor, MALAYSIA

ABSTRACT Particleboard is one of the composite panels fabricated from particles blended and bonded together with a synthetic or natural under hot pressure. These panels are widely used in the production of and house such as cabinets, stair treads, table tops, sliding , and other applications. Many factors contribute to the quality and properties of the panels. The adhesive is one of the considerations that should be measured in the production process of panels which is directly interrelated to the conditions of product, costs, and use. The demands of formaldehyde-free particleboard are continuously rising nowadays due to its low environmental impact and it is not harmful to human health. The natural oil based polyurethane resin is one of the alternatives to formaldehyde-based . Keyword: Polyurethane, particleboard, natural oil, composite panel, and natural fiber Cite this Article: Norazwani Muhammad Zain, Farizah Adliza Ghazali and Eida Nadirah Roslin, Potential of Natural Oil-Based Polyurethane as an Adhesive for Particleboard Production: A Review, International Journal of Mechanical Engineering and Technology, 9(7), 2018, pp. 1485–1493. http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=7

1. PARTICLEBOARD AND ITS HISTORY The wood-based has become one of the major economic sectors within the last two decades. The particleboard has popularly grown over the years and widely used in furniture , , shelves, partition and rooftop development. Generally, particleboards is often used for interior applications because standard particleboard is not appropriate for areas that are susceptible to high humidity or and it is very prone to discoloration and expansion due to moisture. Consequently, it is infrequently utilized outdoors or in places where there are high levels of moisture. Particleboard originated in Germany was invented by a fighter pilot, German Luftwaffe, and an inventor named Max Himmelheber. The first commercial production of particleboard was at a factory in Bremen, Germany which is dated back to 1887, during the World War II. The first particleboard was made up of , wood scraps, and shavings; all glued together using a specific resin. In early 1903, the particle boards were manufactured traditionally by hot pressing a blend of sawdust and

http://iaeme.com/Home/journal/IJMET 1485 [email protected] Potential of Natural Oil-Based Polyurethane as an Adhesive for Particleboard Production: A Review blood albumen. The technology of particleboard production has evolved reasonably with the modernization of thermal press and adhesive technology. Later, the classification of particleboard is based on its density level which is low, medium and high. The significant improvement in particleboard production throughout the years indicates that the particleboard demand is considered rapidly growing. Nowadays particleboards are manufactured by using temperature and compression with various types of resin, particle, and .

2. RAW MATERIALS The main components in the particleboards can be divided into three categories i.e. adhesive (resin), fiber (particle) and additives or filler. The types of particleboards differ significantly in terms of the amount and types of resins used, the size and geometry of the particles, as well as the density of particleboard. Hence, the properties of the have a significant effect on both the manufacture and the physical properties of the final product. For instance, the quality of wood furnish in particleboard is controlled by the wood properties such as acidity, extractive content, density, and machinability. Besides, the impacts of particleboard on the environment are also the matter to be considered. The selection of resin is of important to make sure the particleboard produced has a low impact to the environment. In addition, the additives are used to -made the desired additional properties of particleboard.

2.1. Fibers/ Particles In the particleboard industry, a great range of wood and species are used as raw materials. The selected of the wood used is normally determined by the availability and price of the raw material. Particle size acts a significant role in affecting the properties of particleboard. There are wide range of particle sizes and shapes of used in particleboard production. However, the declining of reserves has attracted researchers to find other lignocellulosic fibers or particles as an alternative raw material for production of these particleboards [1, 2]. Agricultural residues, such as stems, stalks, leaves, and pods are the most suitable candidates as an alternative particle or fiber in particleboard. These crop residues are produced in large quantities throughout the world [3]. There are more than 30 agricultural residues were used as raw materials in particleboard production such as sisal, , , sunflower stalks, husk, fiber, shell, shell, , husk, coffee husk, sugar cane bagasse, pineapple leaf and peanut shell. All types of fiber used have their own characteristics and performances. The physical and mechanical properties of particleboard from various agricultural residue fibers as raw materials are shown in Table 1.

Table 1 Physical and mechanical properties of particleboard based on various wood and agricultural fibers. The resin used mostly from urea formaldehyde and melamine formaldehyde Thickness Water Modulus of Modulus of Density, Fibers Swelling 24 Absorption Rupture, Elasticity, Sources kgm-3 h (%) (%) MOR (MPa) MOE (MPa) Oil Palm 22 58 37 2700 1041 [4] Bamboo 14 – 16.5 45.2 – 47.9 15.7 – 19.2 1936.9 – 2636.6 801 – 873 [5] Stem 15 38.4 50.91 3939.25 780 [6] Coconut 35.28 131.89 17.05 2092.44 580 [2] 1253.22 – Kenaf 32 – 49 86 – 130 12.31 – 15.16 700 [7] 1558.96 Woody and 40 – 60 125 – 130 2.6 – 4.2 800 – 820 620 – 680 [8] Pineapple leaf straw 27.3 – 27.7 34.2 – 47.5 18.1 – 26.5 2281 – 3052 – [9] Sago 17 – 24 75 – 90 4 – 7.5 800 – 2500 600 [10] Peanut shell 27.54 - 10.98 1200 800 [3] Corn corb 11.5 121.06 0.8 80 413 [11] bagasse 14 – 18 150 – 240 3.8 – 12 – 300 – 500 [12] Rubberwood 35 94 15.56 2001.63 700 [7] 14.36 – 503.67 – Pinus – 4.03 – 13.87 – [13] 26.98 1827.49

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2.2. / Resin Adhesive or resin plays an important role in particleboard production as it works as a for the particles to bond together. In particleboard manufacture, factors pertaining to the application/pressing process parameter contribute as much as 50% to the final performance, the rest being due to how good the adhesive itself. A quantity of various categories of resins is used in the particleboard industry, and each has its advantages and disadvantages. Although the effect of resin on production costs is the main concern in the particleboard production the manufacturer also need to consider about the environmental impacts the resin probably cause especially when it encompasses to human health. In wood-based industry, adhesive is characterized as a thermoset resin that being utilized as the medium that attracts the wood particles together to assemble a wood-based panel. Many types of adhesives have been employed in the conventional production of particleboard. Generally, adhesives can be classified into two categories, i.e. synthetic and natural adhesives. Synthetic adhesives are the -based adhesive. Formaldehyde-based adhesive is the most common synthetic adhesive used in particleboard industry including urea formaldehyde, melamine formaldehyde, and phenol formaldehyde. These synthetic adhesives have rapidly grown commercially due to their excellent performance in improving mechanical properties of the composite panels. Although they could provide panels with superior properties but the consumption of formaldehyde-based adhesives generates an undesired problem as its emission is considered hazardous to human health. They can cause irritation of the eyes, risks of cancer, skin irritation and bronchial health impacts. Some of these adhesives are very sensitive to hydrolysis, and stress scission [14], consequently the formaldehyde-based particleboard are susceptible to have a low water resistance. These compounds also cause serious environmental damage and contribute to the global supply shortage of products [15]. Therefore, natural adhesives have been explored by the researchers to replace the formaldehyde resin. Natural adhesives are generally extracted from natural resources that commonly obtained from different sort of plants such as , , and . Starch and protein-based adhesive were the early natural adhesives for binding materials in particleboard production. The application of as a binder can be traced back to old time. Still, its early commercial utilization as a wood adhesive started after 1920s. The soy protein was altered with lime and metallic for enhancing moisture and microbial resistance of the composite panels. The significant commercial used of soy- based adhesives has been archived from 1930s to 1960s. Nevertheless, the particleboards from soy- based adhesives have a comparatively lower water resistance and strength compared to the synthetic adhesives.

2.3. Additives Along with a particle and resin, some additives may also be required in the course of particleboard production, principally to control and modify the reaction conditions, and also to finish or modify the final product. These include water repellent, crosslinkers, colorants, fillers, fire retardant, and others. For instance, wood is highly vulnerable to be attacked by insects and fungi. Poor water repellency may lead to this fungi and insect attack as well as dimensional instability which can eventually prompt to a reduction in strength properties and deteriorating of the material. Therefore, a treatment to get maximum durability in hostile condition is crucial. The application of water repellents agents to improve particleboard moisture resistance is one of the potential approach to solve this problem. For instance, the addition of water repellent agents in the form of emulsified paraffin is an effective way of improving water resistant properties.

3. POTENTIAL OF NATURAL OIL-BASED POLYURETHANE ADHESIVES IN PARTICLEBOARD (PU) are defined as which contain urethane groups (-NH-CO-O-). These groups are composed through a between a di- or polyisocyanate and . Isocyanates are essential components required for PU synthesis which act as hardener, while are the substances bearing plurality of hydroxyl groups. PU have found widespread use as adhesives in various industrial and household environments. They can be used to bond diverse substrates such as

http://iaeme.com/Home/journal/IJMET 1487 [email protected] Potential of Natural Oil-Based Polyurethane as an Adhesive for Particleboard Production: A Review metals, , rubbers, , and due to their high polarity and the bonding between PU and the substrates. The PU materials are being accepted as an adhesive in the manufacture of particleboard, replacing the traditional phenolic and urea-formaldehyde adhesives. The types of PU adhesives can be developed by varying structure and composition of polyols and isocyanate especially raw material basis in making polyols. Natural oil-based adhesives emerged as an environmentally friendly alternative for petrochemical-based adhesives. In recent years, PU adhesives developed from renewable resources, particularly natural have fascinated much attention due to their economic, and environmental advantages. Natural oils or vegetable oils, which are primarily comprised of molecules, are perfect substitution materials for the manufacture of bio-based polymers since they are renewable and can offer comparable performance and low cost in comparison to petroleum-based materials [16]. Therefore, the natural oil-based PU have environmental pluses over pure petroleum-based materials which are making them an attractive alternative. Natural oil-based adhesives derived from natural sources and , such as castor, palm, canola, and oils have been used to synthesize natural polyols [17].

3.1. Castor oil is a low-cost and renewable raw material which has captivated research effort because of its potential use in , adhesives, , and encapsulating compounds. Castor oil has long been a versatile and valuable feedstock for direct use in the PU industry due to its naturally occurring unsaturation and non-conjugated hydroxyl groups and wide availability. The wide range of industrial applications of castor oil has led to a steady increase in demand for this material in the world market. This oil is very flexible in its applications such as in wood adhesives [14, 18]. A wide range of variables that affect the performance of a wood adhesive which are related to the environment such as the level and rate of a change in both temperature and relative humidity [19]. The bonding mechanism of such adhesives is due to the complex chemistry of the cellulosic substrate, i.e. hydrogen bonding with some adhesive and attractive weak Vander Walls forces with others [20]. Thus, it will affect the physical and mechanical properties of the composite panel. The physical and mechanical properties castor oil based particleboards with various fibers are shown in Table 2.

3.2. Palm oil is now the world’s largest by volume. There are two major types of oil derived from oil palm , i.e. palm oil and oil. Palm oil derived from palm fruit, while is extracted from the palm seed. Although these oil comes from the same tree, but the properties of both oils are quite different especially in their fatty acids contents. Palm kernel oil has lower content of fatty acids compared to palm oil. The complexity of chemical structures in the palm oil making it difficult to be understandable. However, the versatility of palm oil-based polyurethane cannot be denied. Palm kernel oil-based polyols to prepare wood adhesives that showed good properties were studied and reported improvement of using hydrolysis polyol based on palm oil [21]. PU adhesives prepared from palm oil-based polyester polyol are advantageous of their convenient preparation with no volatile organic required while polyester polyol was synthesized from sustainable and renewable resources [22]. This palm oil-based PU adhesive has great potentials in particleboard industry and its characteristic is comparable to the petroleum-based adhesives.

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Table 2 Physical and mechanical properties of particleboard based on polyurethane adhesive derived from castor oil. Thickness Water Modulus of Modulus of Density, kgm- Fibers Swelling 24 h Absorption Rupture, Elasticity, 3 Sources (%) (%) MOR (MPa) MOE (MPa) Macademia 2.7 10.5 4.3 380 987 [23] Pine 12 43.4 8.7 930 691 [23] 641.38 – Bamboo 8.17 – 22.69 63.73 – 74.14 3.73 – 5.64 351.11 – 757.3 [24] 679.08 Coconut 15.3 36.59 17.94 1405 800 [1] 5280.16 – Sugarcane bagasse 10.8 – 12.81 29.73 – 37.27 23.8 – 37.05 820 – 870 [25] 6864.7 Rubber wood 17.09 38.8 13.21 1893.55 842.50 [26] Treated bamboo – – 38 – 150 5855 – 15805 890 – 912 [27] Schizolobium 1599.85 – – – 18.77 – 23.40 800 [28] amazonicum 2324.48

3.3. Canola protein exhibited adhesive potential for . The canola protein-based adhesive was found suitable for use in both indoor and outdoor conditions especially for making particleboard or veneer flooring due to high protein content and more hydrophobic. Contrary to canola protein, canola oil cannot be used directly as wood adhesives. However, like other vegetable oils, canola oil has chains with unsaturated double bonds, and the group enables them to be used in production of a wide variety of valuable products such as polyols. The physical properties of the canola oil based PU adhesives as wood adhesives have been compared to petroleum-derived commercially available PU adhesives. The canola oil based PU adhesives have comparable lap shear strength and chemical resistance properties to commercial PU adhesives whilst its resistance to hot water is also superior [29]. That implies the canola oil based PU adhesive has a great potential in particleboard production.

3.4. Soybean In recent years, increased demand for adhesives, limited resources of petroleum-based binders, and increasing interest in developing environmental friendly products have resulted in expanded application of soybean-based adhesives [30]. Due to its large quantities, renewability, and biodegradability, soybean protein has been considered as an alternative petroleum-based polymer in the production of numerous adhesives or binders. Soybean-based adhesives have been used predominantly in [31] and also in wood composites, which includes particleboard and medium-density fiberboard. The performance of soybean protein as wood adhesives is excellent in dry bond strength. However, its the poor water resistance has limited their application as high-performance wood adhesives compared with phenol formaldehyde adhesives. There is an essential to improve soy- protein-based adhesive to broaden its application. -based waterborne polyurethane (WPU) is used to improve wet strength in shear test of wood bonded with an adhesive of soy protein isolate (SPI) by dispersing WPU into SPI slurry [32].

3.5. Jatropha Oil Jatropha oil is a non-edible and renewable oil which consists of gum that can be into an adhesive and represents a , making it has significant potentials as a raw material for industrial applications. Furthermore, the jatropha oil has a competitive cost compared to soybean and oil [15, 33], thus it has attracted the industrialists and academics to explore these materials for wood adhesive applications. The gums content in jatropha oil can enhance the adhesion and mechanical properties of adhesive. Successively, the performance of jatropha oil-based adhesive is found higher than palm oil-based adhesive [15].

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4. PRODUCTION OF NATURAL OIL BASED POLYURETHANE PARTICLEBOARD There are three steps method in the production of natural oil based particleboard (Figure 1). The first step is selection and preparation of wood particles or fibers. Next, the preparation of natural oil-based polyurethane adhesive. The final step is blending and press.

Figure 1 Step by step of natural oil based particleboard production. In preparation of wood particles step, the selected woods or agricultural waste fibers are cut or chopped into small pieces by using a cutter prior to the crushing process using and sieved with desired size of mesh. The wood particles are then treated in alkaline medium or and dried in an at 35 – 40 ºC. Normally, the moisture content and particle size of wood particles are characterized and controlled to ensure the quality of the particleboard is maintained. For the preparation of PU adhesive, natural oil-based polyol is reacted with di- or poly-isocyanate. The isocyanate to polyol (NCO: OH) ratio is normally 1:1, but the ratio can be diversified appropriate with the functionality of the polyol. The formulation of adhesive can be tailored according to the desired applications. For instance, an insect or water repellent can be added in the formulation as a filler. The PU adhesive mixture is poured into the with wood particles and the materials are blended together by hand mixing or using mechanical mixer. The blending ratio of wood particles, PU adhesive and fillers also can be varied in order to get the optimum strength. Then, the blended materials are hot pressed by using hot press machine at a specific temperature, time and pressure. The particleboard panel is left at room temperature for complete curing (48 hours) before testing their performance properties. The particleboard s then trimmed according to the desired shapes. The physical and mechanical characteristics of particleboard are assessed for quality checking. The examples of particleboard production and particleboard from palm kernel oil based adhesive are shown in Figure 2.

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Figure 2 Process of particleboard making; (a) Sieve the wood particle, (b) Wood particles, (c) Blending or mixing the wood particle with natural oil polyurethane adhesive, (d) Hotpress the blended materials, (e) De- mould the particleboard, (f) Natural oil based particleboard with various particle sizes.

5. CONCLUSION Natural oil-based adhesives have been shown acceptable properties for use in the particleboards . Good moisture resistance makes them particularly attractive for use in humid environments, such as in kitchen applications. Their low environmental impact is also of considerable significance. Hence, the natural oil-based polyurethane adhesive can be considered to be a valuable substitute for existing petroleum-based adhesive materials in homogenous composite panel applications. However, the researchers more focused on the castor oil based polyurethane resin in particleboard production because of the advantages owns by this oil. Nevertheless there are more natural oils that can be deeply explored in particleboard production such as palm, palm kernel and jatropha oils.

ACKNOWLEDGEMENTS The authorS would like to acknowledge Universiti Kuala Lumpur for the financial support, SHORT TERM RESEARCH GRANT (STR18007).

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