Abstract
This study explored the development and characterization of laminated wallboard panels using renewable materials for building applications. The panels are based on cellulose nanofibrils (CNFs) as a binder and wood particles. Other additives included FiberLeanTM (microfibrillated cellulose/calcium carbonate composite), starch and fire retardant (boric acid/borax). These panels are also intended to address the environmental concerns of commercial gypsum boards. The manufacturing of the panels is via a wet-based process; hence no initial drying was required to remove the water from the CNF. It was found that the dosage of CNF (and/or FiberLeanTM) binder and the addition of starch had the largest impact upon the quality of the final product. The addition of starch was found more favorable in the presence of FiberLeanTM. The fire retardancy was induced by adding boric acid/borax (1:1). The burning test revealed that the panels treated with the fire retardant exhibited excellent burning properties comparable to that of gypsum board (inherently fire resistant). Interestingly, the addition of the boric acid/borax also appeared to increase the retention of starch in the system, leading to favorable mechanical properties.
Highlights
The manufacturing of wood-based panels is heavily relying on petroleum-based adhesives [1]
It was found that the dosage of cellulose nanofibrils (CNFs) binder and the addition of starch had the largest impact upon the quality of the final product
This paper addresses the problems linked to the gypsum board by developing and characterizing laminated wallboard panels based on CNF as a binder
Summary
The manufacturing of wood-based panels is heavily relying on petroleum-based adhesives [1]. These adhesives, despite their low cost, have severe impacts on the environment and human health. Using renewable and bio-based adhesives for wood-based panels does not often come without challenges, most of which are related to the commercialization of these bio-based adhesives [2]. The linear chains of cellulose molecules are bonded together through a network of intra- and intermolecular hydrogen bonds [8]. The network of hydrogen bonds gives the cellulose fibrils their high axial stiffness and renders this cellulose a relatively stable polymer [6]. CNF, first developed by Turbak et al (1983) and Herrick et al (1983) [9,10], are high aspect ratio nano-elements, mostly produced by high-pressure homogenization or an ultra-fine grinding of cellulosic materials [11]
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