Castor Oil-based Polyurethane Resin Research Articles

Polyethylene terephthalate (PET) as a recycled raw material for particleboards produced from pinus wood and biopolymer resin

Considering the significant demands for construction products and the increasing disposals of plastic and agroforestry residues, this research evaluated the influence of recycled particles of polyethylene terephthalate (PET) inserted in the manufacture of five particleboard prototypes based on Pinus elliottii wood and castor-oil-based polyurethane resin (CPUR). The following panel traits were obtained: 100% pine wood, 0% PET and 10% CPUR (M100P-0PET-10C); 70% pine, 30% PET, and 10% CPUR (M70P-30PET-10C); 50% pine, 50% PET, and 10% CPUR (M50P-50PET-10C); 70% pine, 30% PET, and 5% CPUR (M70P-30PET-5C); and, 50% pine, 50% PET, and 5% CPUR (M50P-50PET-5C). Panels were evaluated according to physical (density, moisture content, thickness swelling, and water absorption), mechanical (modulus of rupture, modulus of elasticity, perpendicular tensile), and morphological tests (scanning electron microscope). M50P-50PET-10C particleboards revealed the best performance in the physical and mechanical tests, as well as M70P-30PET-10C and M50P-50PET-5C panels showed equivalent results. The findings suggested a notable environmental contribution and a great economic feasibility. Thus, it is possible to obtain wood-based particleboards manufactured from recycled PET, reusing this highly discarded non-biodegradable plastic and using a smaller volume of adhesive, with physical-mechanical properties that meet the expected performance for this bioresource-based product.

Physical-mechanical properties of MDP panels with the addition of melamine paper in the internal layer

Particleboard panels find extensive application in the furniture sector, but their low stability in contact with water hinders their utilization. Simultaneously, the trimmings of melamine paper, exhibiting hydrophobic properties, used in panel finishing, represent unused industrial waste. This study aimed to evaluate the physical-mechanical properties of MDP (Medium Density Particleboard) panels produced with Pinus taeda and castor oil-based polyurethane resin with the addition of different proportions of melamine paper (0, 5, and 10%). The properties of density, moisture content, thickness swelling, water absorption, static bending, internal bonding, and screw withdrawal resistance, on face and top, were evaluated, following normative documents. At the end of the tests, statistical analysis was conducted at a 5% significance level to check any statistical differences among the means. The addition of melamine paper caused to an increase in panel density and moisture content, but all treatments remained within the ideal range. Thickness swelling and water absorption decreased, while all mechanical properties improved with an increase in the quantity of added melamine paper. Therefore, the use of melamine paper in MDP panels is viable and beneficial, notably the treatment with a 10% addition of melamine paper.

Evaluation and production of high-strength wood composite panels with polyethylene terephthalate (PET)

To reduce dependence on wood and deforestation, alternative materials have been considered. This research evaluated particleboards panels of Pinus elliotti mixed with residues of polyethylene terephthalate (PET) in flakes with 50% of each material, glued with 10% of castor oil-based polyurethane resin (PUR). The temperature during board production was varied to evaluate its influence on the physical and mechanical properties of the boards. The study concludes that the increase in temperature did not result in a significant improvement in the particleboard properties, but their results showed application potential according to the normative standards.

Investigating the Effects of Al2O3 Microparticles on Wood Waste OSBs: A Study on Physical, Mechanical, and Durability Performance.

The development of new materials for the construction sector is a global trend, and products that use by-products in their composition and have also incorporated technology are commercially competitive. Microparticles have large surface areas and can modify the microstructure of materials, positively affecting their physical and mechanical properties. In this context, this study aims to investigate the effect of incorporating aluminium oxide (Al2O3) microparticles on the physical and mechanical properties of oriented strand boards (OSBs) made from reforested residual balsa and castor oil polyurethane resin and to evaluate their durability performance under accelerated aging conditions. The OSBs were produced on a laboratory scale with a density of 650 kg/m3, strand-type particles measuring 90 × 25 × 1 mm3, using castor oil-based polyurethane resin (13%) and Al2O3 microparticle content ranging from 1% to 3% of the resin mass. The physical and mechanical properties of the OSBs were determined following the EN-300:2002 recommendations. The results obtained indicated that the OSBs with 2% Al2O3 presented thickness swelling significantly lower (at the 5% significance level) after being subjected to accelerated aging and internal bonding of the particles higher than the values obtained for the references, evidencing the positive effect of including Al2O3 microparticles in balsa OSBs.

Oriented Strand Board panels of residual reforestation wood with Al2O3 nanoparticles

The application of metal oxide nanoparticles (Al2O3) in Oriented Strand Board (OSB) panels has been studied as a way to provide greater efficiency in heat transfer rate during the thermopressing process, thus contributing to the polymerization process of the resin used in particle agglomeration. Studies on the subject, however, are still scarce and require further study in order to optimize the production process of OSB panels. Therefore, this study evaluated medium density OSB panels (650 kg/m3) of reforestation residual wood shaped with 13% castor oil-based polyurethane resin with 1% of commercially sourced Al2O3 nanoparticles and manufactured in the laboratory via the proteic sol-gel method. Microstructural analysis of the nanoparticles was performed to verify their dispersion within the resin; qualitative analysis of nanoparticles was performed with X-ray diffraction (XRD); and analysis by High Resolution Transmission Electron Microscopy (HRTEM) was performed to study commercially sourced and laboratory-produced nanoparticles. After analyzing the results, the panels were produced with commercial aluminum oxide nanoparticles and characterized by physical (thickness swelling) and mechanical (static bending and perpendicular traction) tests, according to current normative documents. The results indicated that commercial aluminum oxide nanoparticles provided better performance in microstructural and qualitative analysis, in addition to provide a better efficiency in the resin curing stage, causing an increase in the values of physical-mechanical properties in the transverse direction for the modulus of rupture (69.15%) and internal bond of the wood particles (53.57%).

Evaluation of the physical properties of composite panels with eucalyptus sawdust waste and castor oil-based polyurethane

Natural fibers have several advantages over synthetic fibers, and due to this, they are being increasingly used in various applications. Industrial waste generated during the production chain of different types of sectors is becoming a major environmental problem. The objective of this work was to produce and evaluate the physical properties of composite panels produced with waste from the wood industry, eucalyptus sawdust, and also with another waste, this time from the red ceramic industry, chamotte, and matrix polyurethane resin based on of castor oil. The composite panels were produced in volumetric fractions of 70, 75, 80, 85 and 90% of eucalyptus sawdust, and a variation of 0, 5 and 10% of chamotte. The tests to evaluate the physical properties were: Density, Moisture Content, Water Absorption and Thickness Swelling. The results showed that as the volumetric fraction of chamotte was incorporated into the composite, the higher the density value was obtained, and that this value decreased as the eucalyptus fiber fraction increased in the formulation. The SEM images revealed that chamotte provided a reduction in the amount of bubbles present in the resin. The moisture content, water absorption and swelling increased as the volumetric fraction of fiber increased, and decreased as the volumetric fraction of chamotte incorporation increased. It is concluded that there is technical feasibility for the use of eucalyptus residue, together with chamotte and castor oil-based polyurethane resin for the manufacture of composites. The perspective after this research is make a partner with a wood panels industry and create a new line of green composites panels made by recycled waste from industry.

Ecofriendly panels for building with eucalyptus sawdust and vegetal polyurethane resin: A mechanical evaluation

The use of natural fibers in composite materials has become an alternative to use synthetic ones. With the increase in consumption and the generation of waste, it becomes interesting to search for alternatives friendly to environment. The objective of this work was to evaluate the mechanical properties of composites manufactured using residues: from the wood industry (eucalyptus sawdust), from red ceramic (chamotte), and a vegetable based resin (castor oil-based polyurethane resin) as a matrix. The composites were manufactured in volumetric fractions of 70, 75, 80 and 85 of eucalyptus sawdust; and 0%, 5% and 10% of chamotte, totaling 12 formulations. Scanning electron microscopy (SEM) analyzes were performed on the eucalyptus sawdust used and on the composites produced with and without chamotte. The results indicates that both for the modulus of elasticity and modulus of rupture, the increase in the volumetric fraction of chamotte incorporated at composites causes an increase of properties in all compositions studied. In perpendicular tensile testing, it obtained values between 1.910 and 3.449 MPa. In the izod impact testing, values between 47.61 and 115.44 J/m were obtained. It was observed on SEM images that with the incorporation of chamotte on composites there was a great reduction in the amount of bubbles and voids presented at polymeric matrix and in some compositions have increased also the mechanical properties. Thus bringing a new option for use and adding value to this residue from the ceramic industry, producing an ecofriendly composite panel.

COMPARATIVE STUDY OF PARTICLEBOARDS WITH HEVEA BRASILIENSIS WASTE FROM DIFFERENT PRODUCTION AND MOISTURE CONFIGURATIONS

After the production cycle of latex, Hevea brasiliensistrees becomeresidual living plants for this activity, although their woody trunks are still potentially subject to industrial utilization. Bio-composites derived from rubberwood particles were manufactured using two different configurations as a strategy to examine the potential of this species with respect to mechanical behavior. Homogeneous panels were developed from particles at the saturation condition, and heterogeneous panels were obtained from dry particles conditioned at 12% moisture content. Both examples were heat-pressed and glued with castor oil-based polyurethane resin. Density, short-term water absorption and thickness swelling, modulus of rupture and modulus of elasticity in the static bending and perpendicular tensile were evaluated. Panels derived fromrubberwood particles proved to be viable according to the technical standards.

Particleboards manufactured from Tectona grandis wood waste with homogeneous and three-layer heterogeneous compositions for commercial purposes

Tectona grandis wood presents decent dimensional stability as well as highly suitable physical and mechanical properties. These characteristics have encouraged the intense usage of this species, which also includes the reuse of wood processing waste for panel production. Using teak wood waste, this study aims to manufacture and evaluate heat-pressed particleboards at 5 MPa and 100 °C, by being glued with castor oil-based polyurethane resin at proportions of 10% for the homogeneous boards and 12% for the heterogeneous solutions. Single-layer (homogeneous) boards were compared with three-layer particleboard specimens (heterogeneous) having the finer particles in the outer layers. The basic density, moisture content, modulus of rupture and modulus of elasticity in the static bending and perpendicular tensile, water absorption, and thickness swelling after 24 h were evaluated to support this comparative study. All the manufactured particleboards met the standardized requirements of performance, thus being very feasible for usage as non-structural boards. When the two different compositions were analyzed, a considerably better performance of the three-layered particleboards was identified when compared to the homogeneous panels.

PARTICLEBOARD PRODUCED WITH CHROMATED COPPER ARSENATE- AND BORATE-TREATED CAIXETA WOOD: A TECHNICAL FEASIBILITY STUDY

Brazilian flora has more than 12 thousand tropical wood species, which can be the raw material for the construction industry. Chromated copper borate (CCB) and chromated copper arsenate (CCA) are wood preservative chemicals, which can generate toxic waste. Particleboards are usually produced from Pinus sp. and Eucalyptus sp. wood particles and a polymeric matrix (often formaldehyde-based), and they are used as raw material mainly for the furniture industry. This study aimed to investigate the technical feasibility of particleboard production using caixeta wood (Simarouba amara Aubl.) particles and bicomponent castor oil-based polyurethane resin for tropical wood waste management, as well as study the impact of CCA/CCB treatments on the performance of these panels according to NBR 14810 standards. Analysis of variance (ANOVA) tests was performed to compare ten physical and mechanical properties of the panels produced with CCA, CCB, and non-treated caixeta wood particles. The performance of caixeta wood panels was similar to the usually produced boards (using Pinus sp. and Eucalyptus sp. wood). Furthermore, preservative treatments did not change significantly the mechanical performance of panels. However, water absorption increased and thickness swelling decreased in CCA/CCB treated samples.

Natural based polyurethane matrix composites reinforced with bamboo fiber waste for use as oriented strand board

Composites that use natural fibers as reinforcement have generated great interest in the industrial and scientific community due to the need for materials that present environmental responsibility and are economically viable. This work aimed to develop and establish a comparative analysis of the mechanical properties and physical characteristics between a castor oil based polyurethane resin composites reinforced with fibrous bamboo residue and a commercial Oriented Strand Board (OSB), in which where determined the technical issues of using these composites as OSB panels. Bamboo fibers used were obtained as a residue from a barbecue sticks industry. Composites were made with 20 and 40% volume fraction of continuous and aligned bamboo fiber. The density, moisture absorption, and mechanical strength of the composites were tested and compared with the commercial OSB. The composites not only presented mechanical performance superior to the commercial OSB, surpassing 1000 J/m, 85 MPa and 4.4 GPa for impact resistance, flexural strength, and flexural elastic modulus, respectively, but also fulfilled the standard requirements, while the commercial OSB, failed in most of the observed standards criteria. In addition, the developed materials contribute to a sustainable environment by using both bamboo waste and castor oil based polyurethane resin in a composite material.

Development and characterization of sustainable agglomerated composites formulated from castor polyurethane resin and reinforced with rice husk

The current accelerated development of industrial and agricultural production has intermittently generated a large amount of waste. One of these residues is the rice husk, which represents 20% of the total volume of the grain produced. It is a lignocellulosic material that can be used as a reinforcement for composite materials. In turn, castor oil-based polyurethane resin is a triglyceride extracted from the seed, widely used to replace synthetic resins that are more aggressive to the environment. Thus, the objective of this study was to obtain a sustainable agglomerated composite based on rice husk and castor oil polyurethane resin. The samples were obtained by cold molding according to a 2 k (DoE) factorial design, the matrix/reinforcement volume fraction and the molding volume being the factors studied. The composite obtained was tested according to NBR 14,810, used for medium-density composites. Density, swelling, water absorption and resistance to flexion were evaluated. The results obtained allow us to classify the composite as low density, with values below 640 kg/m3 according to the A 208.1 standard. Regarding the mechanical behavior, the composite does not meet the standard NBR 14,810 for medium density but meets the standard A 208.1 being classified as low-density LD-1 and LD-2.

USE OF RESIDUES FROM THE CELLULOSE INDUSTRY AND SUGARCANE BAGASSE IN PARTICLEBOARDS

The use of alternative materials such as lignocellulosic residues in the production of particleboards has increased considering that these residues are produced in large volumes and often do not have an appropriate destination. This research studied the use of residues from cellulose industries, sugarcane bagasse, and castor oil-based polyurethane resin in the production of wooden panels and evaluated the influence of using these residues on the physical and mechanical properties of the panels. The products were manufactured according to the Brazilian standard ABNT NBR 14810 and the requirements of the panels were evaluated based on national and international standards. All treatments partially met the regulatory requirements. The addition of bagasse led to an improvement in physical and mechanical properties, with treatment 2 (50% wood residue and 50% bagasse) presenting the best performance, which indicates the possibility of using panels with residues with non-structural purpose in environments to improve the thermoacoustic performance of rural buildings. The statistical analysis indicated that the percentage of bagasse was significant, improving the evaluated properties.

Trapezoidal core sandwich panel produced with sugarcane bagasse

The properties of traditional particleboards are limited by their flat shape. New shapes and configurations with alternative raw materials enable strength and stiffness gains without significantly increasing weight. In this context, the present work presents an investigation of the potential use of sugarcane bagasse particles agglomerated with castor oil-based polyurethane resin to produce trapezoidal core sandwich panels for building applications. Thickness swelling was analysed based on the Brazilian standard NBR 14810 and flexure tests were performed according to the standard ASTM C393. Maximum force at failure, bending stiffness (EI), maximum moment (FbS), maximum shear stiffness (U), and core shear modulus (G) were calculated. The obtained results were compared with specifications of the standard PS-2-10 – Performance Standard for Wood-Based Structural-Use, which provides values of bending stiffness and maximum moment requirements for OSB panels according to different classes of use. The evaluated sandwich panels presented bending properties (up to 2.1×106 N-mm2/mm for EI and 1199 N-mm/mm for FbS) similar to commercial OSB panels, showing potential for sealing, structural, and flooring applications. The castor oil polyurethane resin presented acceptable efficiency as the particle binder and as an adhesive for the face-core gluing of the low density sandwich panels (0.43 MPa), meeting the minimum requirements recommended by ABNT NBR 14810:2006.

Production of castor oil-based polyurethane resin composites reinforced with coconut husk fibres

In recent years, coconut tree cultivation has intensified worldwide. Therefore, it is necessary to analyse the agribusiness of coconut residues and the environmental impacts that its waste can cause to slow degradation of approximately eight years. Considering this and knowing that coconut is a highly reusable product, the aim of the present study was to investigate the physical, mechanical and microstructural properties of castor oil-based polyurethane resin composites, reinforced with different contents coconuts husk fibres. The coconut husk fibres were characterized according to chemical composition, basic density, pH and surface SEM images. The composites with dimensions of (200 × 200 × 3 mm) were produced by hand lay-up, in which the resin was mixed at magnetic shaking in a beaker at 150 rpm for 5 min under vacuum with the coconut husk fibres. Then, the mixture was placed in a mould and pressed at 1 MPa at room temperature. Four different compositions were tested: 30, 50, 65 and 75% coconut husk fibres. Specimens were obtained from the composites to perform tensile tests, determine the bulk density and water absorption, as well as visualize the matrix-reinforcement interface using SEM. The results showed no significant differences between the compositions for water absorption, bulk density and modulus of elasticity (MOE) obtained in the tensile tests. The tensile strength of the composites tended to increase as greater amounts of coconut husk fibres were added to the matrix. The averages were around 4.39 to 5.64 MPa for composites with 30 and 75% fibres, respectively. The photomicrographs obtained using SEM indicated detachment between the matrix and the reinforcement, which may be attributed to the high levels of extractives (19.78%) present in the fibres. The tests showed the viability of replacing polymer with fibres, in levels of up to 75%.

Development and characterization of novel castor oil-based polyurethane composites containing wood sawdust and rubber tire powder

New eco-friendly composites consisting of castor oil-based polyurethane (PU) resin, wood sawdust, and rubber tire powder were produced, and the morphological, physical, and flexural properties were investigated. The composites were composed of varying the concentration of the PU matrix (30, 40, and 50 m%) and the wood-to-rubber ratio of the disperse phase (100/0, 90/10, 80/20, 70/30, 60/40, and 50/50 m%/m% wood/rubber, respectively). The morphology of the composites was studied by optical microscopy and scanning electron microscopy, and the flexural properties, water absorption (WA), and thickness swelling (TS) were also investigated. The analysis of variance was used to study the effect of each factor (PU content and wood/rubber ratio) on the characteristics of the composites. PU/wood/rubber composites were successfully molded and their characteristics are promising for commercial use. According to the results, the composites presenting higher wood content (high wood/rubber ratio) showed higher modulus of rupture and modulus of elasticity values, although the addition and the increase of rubber content decreased these properties. Moreover, increasing PU or reducing the wood/rubber ratio significantly reduced the WA and TS, improving dimensional stability.

Application of Castor Oil Based Polyurethane Resin in the Dimension Stone Block Wrapping Process

The dimension stone wrapping process is a method used before the sawing of the block which aims to enhance the integrity of the rock, thus ensuring that fractured or altered blocks remain intact while they are handling and splitting into slabs. This method increases safety and allows the processing of many materials once not commercialized. Nevertheless, the epoxy resin used in the process comes from a non-renewable resource and contains toxic substances on its composition. Therefore, in order to increase the eco-efficiency in the sector of dimension stones, a comparison of the epoxy resin with an ecological and non-toxic resin based on the castor oil, was carried out aiming to know the resulting tensile strength in the contact of the polymer with the stone surface. Two types of rocks were tested, a silicate and a carbonate one. The results indicated that the castor oil resin performed a higher tensile strength regarding carbonate rocks, suggesting that the castor oil resin could replace the epoxy resin when applied to this rock group, providing an environmental advantage and a global marketing differential.

Use of sugarcane bagasse and industrial timber residue in particleboard production

Use of lignocellulosic materials in particleboard has turned into an alternative for the reuse of such materials, which are abundant and may have precarious disposal techniques. The present study fabricated particleboards using industrial sawmill waste from tropical hardwoods (a mix of species) and sugarcane bagasse with castor oil-based bicomponent polyurethane resin and evaluated the influence of the incorporation of sugarcane bagasse (0, 10, 20, 30, 40, and 50%) on the physical and mechanical properties of the composites. The particleboards were produced according to the Brazilian Standard ABNT NBR 14810 (2018), and performance requirements were assessed using Brazilian and international standards. Some of the particleboards met standardized requirements, with Treatment 5 (50% sawdust and 50% bagasse) showing better performance, indicating the possibility for use indoors in dry conditions. The addition of sugarcane bagasse increased dimensional stability of particleboards when compared with panels manufactured with timber residue. Statistical analysis indicated the percentage of bagasse was significant, increasing physical and mechanical properties when compared with the reference treatment.

Evaluation of CCB-preserved medium density particleboards under natural weathering

Wood engineered products are alternatives to the use of timber for civil construction, manufacturing, and the furniture industry. One of these products is the medium density particleboard (MDP) panel, which is made of wood particles and resin under high temperature and pressure. This research produced a prototype to evaluate the use of MDP panels waterproofed by castor oil-based polyurethane resin and Pinus sp. residues treated with CCB preservative for use as a wall coating. The influence of weathering, position of wood panel, and waterproof treatment were evaluated. Panels were made under the requisites of Brazilian Standard ABNT NBR 14810 (2013) and evaluated with international standards. MDP panels met standard requisites, with properties similar to that reported in the literature, indicating the possibility of use as wall coating. Statistical analysis indicated the only significant factor was weathering, which influenced physical and mechanical properties.

Eco-friendly piassava fiber reinforced composite for high performance coating application

High performance coatings (HPC) may be used as floors, made by mixing substrates with resin which are today applied in several types of floors by the Brazilian industries. The application of HPC floors is associated with some benefits such as speed of application, high mechanical performance and absence of expansion joints. The Brazilian standard requires that the manufacture of HPC uses epoxy resin and mineral aggregates. This work, however, aimed to study the mechanical performance of a similar material, made by using a castor oil based polyurethane resin, instead of epoxy, mixed with ground piassava natural fibers and determine if it is possible to use as a novel HCP. The piassava fibers were obtained as an industrial waste of a broom factory located in Campos dos Goytacazes, Brazil. A preliminarily characterization of the fibrous waste was carried out to determine its density and the fibers were subjected to a morphological analysis through scanning electron microscopy (SEM). The water absorption and compressive strength of the novel HPC were determined and the fracture surface was observed by SEM. The results proved the effectiveness of using 20% fiber, which made possible to apply this composition as HPC.