![Particleboard](https://upload.wikimedia.org/wikipedia/commons/d/d1/Particleboard.jpg)
Particle board, also known as chipboard or low-density fiberboard, is an
engineered wood
Engineered wood, also called mass timber, composite wood, man-made wood, or manufactured board, includes a range of derivative wood products which are manufactured by binding or fixing the strands, particles, fibres, or veneers or boards of woo ...
product manufactured from
wood chips
Woodchips are small- to medium-sized pieces of wood formed by cutting or chipping larger pieces of wood such as trees, branches, logging residues, stumps, roots, and wood waste.
Woodchips may be used as a biomass solid fuel and are raw materia ...
and a synthetic
resin
In polymer chemistry and materials science, resin is a solid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers. Resins are usually mixtures of organic compounds. This article focuses on n ...
or other suitable binder, which is pressed and
extruded
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex c ...
. Particle board is often confused with
oriented strand board
Oriented strand board (OSB) is a type of engineered wood similar to particle board, formed by adding adhesives and then compressing layers of wood strands (flakes) in specific orientations. It was invented by Armin Elmendorf in California in 1963 ...
(OSB) (also known as flakeboard, or waferboard), a different type of
fiberboard
Fiberboard (American English) or fibreboard (British English) is a type of engineered wood product that is made out of wood fibers. Types of fiberboard (in order of increasing density) include particle board or low-density fiberboard (LDF), med ...
that uses machined wood flakes and offers more strength.
Characteristics
![Particle_board-cross_section_scan](https://upload.wikimedia.org/wikipedia/commons/a/ab/Particle_board-cross_section_scan.jpg)
Particle board is cheaper,
denser and more uniform than conventional wood and
plywood and is substituted for them when cost is more important than strength and appearance. Particleboard can be made more appealing by painting or the use of wood
veneers on visible surfaces. Though it is denser than conventional wood, it is the lightest and weakest type of fiberboard, except for insulation board.
Medium-density fibreboard
Medium-density fibreboard (MDF) is an engineered wood product made by breaking down hardwood or softwood residuals into wood fibres, often in a defibrator, combining it with wax and a resin binder, and forming it into panels by applying high t ...
and
hardboard
Hardboard, also called high-density fiberboard (HDF), is a type of fiberboard, which is an engineered wood product. It is used in furniture and in the construction industry.
Description
Hardboard is similar to particle board and medium-densi ...
, also called high-density fiberboard, are stronger and denser than particleboard. Different grades of particleboard have different densities, with higher density connoting greater strength and greater resistance to failure of screw fasteners.
A significant disadvantage of particleboard is its susceptibility to expansion and discoloration from moisture absorption, particularly when it is not covered with
paint or another sealer. Therefore, it is rarely used outdoors or in places where there are high levels of moisture, except in bathrooms, kitchens and laundries, where it is commonly used as an underlayment shielded beneath a moisture resistant continuous sheet of
vinyl
Vinyl may refer to:
Chemistry
* Polyvinyl chloride (PVC), a particular vinyl polymer
* Vinyl cation, a type of carbocation
* Vinyl group, a broad class of organic molecules in chemistry
* Vinyl polymer, a group of polymers derived from vinyl ...
flooring.
In dry environments, veneered particleboard is preferred over veneered plywood because of its stability, lower cost, and convenience.
History and development
Particleboard originated in Germany. It was first produced in 1887, when Hubbard made so-called "artificial wood" from
wood flour
Sawdust (or wood dust) is a by-product or waste product of woodworking operations such as sawing, sanding, milling, planing, and routing. It is composed of small chippings of wood. These operations can be performed by woodworking machinery ...
and an adhesive based on
albumin
Albumin is a family of globular proteins, the most common of which are the serum albumins. All the proteins of the albumin family are water-soluble, moderately soluble in concentrated salt solutions, and experience heat denaturation. Albumins ...
, which was consolidated under high temperature and pressure.
During the
Second World War
World War II or the Second World War, often abbreviated as WWII or WW2, was a world war that lasted from 1939 to 1945. It involved the vast majority of the world's countries—including all of the great powers—forming two opposi ...
,
phenolic resin
Phenol formaldehyde resins (PF) or phenolic resins (also infrequently called phenoplasts) are synthetic polymers obtained by the reaction of phenol or substituted phenol with formaldehyde. Used as the basis for Bakelite, PFs were the first commerc ...
was more readily accessible than top-grade wood veneer in Germany, and
Luftwaffe
The ''Luftwaffe'' () was the aerial-warfare branch of the German ''Wehrmacht'' before and during World War II. Germany's military air arms during World War I, the ''Luftstreitkräfte'' of the Imperial Army and the '' Marine-Fliegerabtei ...
pilot and inventor
Max Himmelheber
Max Himmelheber (24 April 1904 in Karlsruhe, Baden – 17 December 2000, Baiersbronn, Baden) was a German inventor and ''Luftwaffe'' fighter pilot.
Biography
In 1932, Himmelheber invented particle board.
During the Second World War Himmelheber ...
played a role in making the first sheets of particleboard, which were little more than pourings of floor sweepings, wood chips, and ground-up off-cuts and
glue. The first commercial piece was produced during the Second World War at a factory in
Bremen, Germany. For its production, waste material was used, such as planer shavings, off-cuts or sawdust,
hammer-milled into chips and bound together with a phenolic resin. Hammer-milling involves smashing material into smaller and smaller pieces until they can pass through a screen. Most other early particleboard manufacturers used similar processes, though often with slightly different resins.
It was found that better strength, appearance and resin economy could be achieved by using more uniform, manufactured chips. Producers began processing solid
birch
A birch is a thin-leaved deciduous hardwood tree of the genus ''Betula'' (), in the family Betulaceae, which also includes alders, hazels, and hornbeams. It is closely related to the beech- oak family Fagaceae. The genus ''Betula'' contains ...
,
beech,
alder
Alders are trees comprising the genus ''Alnus'' in the birch family Betulaceae. The genus comprises about 35 species of monoecious trees and shrubs, a few reaching a large size, distributed throughout the north temperate zone with a few sp ...
,
pine
A pine is any conifer tree or shrub in the genus ''Pinus'' () of the family Pinaceae. ''Pinus'' is the sole genus in the subfamily Pinoideae. The World Flora Online created by the Royal Botanic Gardens, Kew and Missouri Botanical Garden accepts ...
and
spruce into consistent chips and flakes; these finer layers were then placed on the outside of the board, with its core composed of coarser, cheaper chips. This type of board is known as three-layer particleboard.
![Particle_board_manufacturing_process](https://upload.wikimedia.org/wikipedia/commons/9/99/Particle_board_manufacturing_process.jpg)
More recently, graded-density particleboard has also evolved. It contains particles that gradually become smaller as they get closer to the surface.
Manufacturing
Particleboard or chipboard is manufactured by mixing particles or flakes of wood or
jute-stick together with a
resin
In polymer chemistry and materials science, resin is a solid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers. Resins are usually mixtures of organic compounds. This article focuses on n ...
and forming the mixture into a sheet. The raw material is fed into a
disc chipper with between four and sixteen radially arranged blades. The chips from disk chippers are more uniform in shape and size than from other types of wood chippers. The particles are then dried, and any oversize or undersized particles are screened out.
Resin
In polymer chemistry and materials science, resin is a solid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers. Resins are usually mixtures of organic compounds. This article focuses on n ...
is then sprayed as a fine mist onto the particles. Several types of resins are used in the procces. Amino-formaldehyde based resins are the best performing based on cost and ease of use. Urea
melamine resins offer water resistance with more melamine offering higher resistance. It is typically used in external applications, with the coloured resin darkening the panel. To further enhance the panel properties,
resorcinol
Resorcinol (or resorcin) is an organic compound with the formula C6H4(OH)2. It is one of three isomeric benzenediols, the 1,3-isomer (or '' meta''-isomer). Resorcinol crystallizes from benzene as colorless needles that are readily soluble i ...
resins can be mixed with
phenolic resins
Phenol formaldehyde resins (PF) or phenolic resins (also infrequently called phenoplasts) are synthetic polymers obtained by the reaction of phenol or substituted phenol with formaldehyde. Used as the basis for Bakelite, PFs were the first commerc ...
, but that is more often used with
marine plywood
Plywood is a material manufactured from thin layers or "plies" of wood veneer that are glued together with adjacent layers having their wood grain rotated up to 90 degrees to one another. It is an engineered wood from the family of manufactured ...
applications.
Panel production involves other chemicals including
wax
Waxes are a diverse class of organic compounds that are lipophilic, malleable solids near ambient temperatures. They include higher alkanes and lipids, typically with melting points above about 40 °C (104 °F), melting to giv ...
, dyes, wetting agents and release agents, to aid processing or make the final product resistant to water, fire or insects.
After the particles pass through a mist of resin sufficient to coat all surfaces, they are layered into a continuous carpet. This 'carpet' is then separated into discrete, rectangular 'blankets' which will be compacted in a cold press. A
scale weighs the flakes, and they are distributed by rotating rakes. In graded-density particleboard, the flakes are spread by an air jet that throws finer particles further than coarse ones. Two such jets, reversed, allow the particles to build up from fine to coarse and back to fine.
The formed sheets are cold-compressed to reduce thickness and make them easier to transport. Later, they are compressed again, under pressures between and temperatures between to set and harden the glue. The entire process is controlled to ensure the correct size, density and consistency of the board.
The boards are then cooled, trimmed and sanded. They can then be sold as raw board or surface improved through the addition of a wood veneer or laminate surface.
Furniture design
Particle board has had a huge influence on furniture design. In the early 1950s, particle board kitchens started to come into use in furniture construction but, in many cases, it remained more expensive than solid wood. A particle board kitchen was only available to the very wealthy. Once the technology was more developed, particle board became cheaper.
Some large companies base their strategies around providing furniture at a low price. To do this, they use the least expensive materials possible. In almost all cases, this means particle board,
medium-density fibreboard
Medium-density fibreboard (MDF) is an engineered wood product made by breaking down hardwood or softwood residuals into wood fibres, often in a defibrator, combining it with wax and a resin binder, and forming it into panels by applying high t ...
(MDF), or the like. However, in order to maintain a reputation for quality at low cost, manufacturers may use higher grades of particle board, e.g., higher density particle board, thicker particle board, or particle board using higher-quality resins. One may note the amount of sag in a shelf of a given width in order to draw the distinction.
In general, the much lower cost of sheet goods (particle board, medium density fiberboard, and other engineered wood products) has helped to displace solid wood from many cabinetry applications.
Safety
Safety concerns exist for both manufacturing and use. Fine dust and chemicals are released when particleboard is machined (e.g., sawing or
routing). Occupational exposure limits exist in many countries recognizing the hazard of wood dusts.
Cutting particle board can release
formaldehyde
Formaldehyde ( , ) (systematic name methanal) is a naturally occurring organic compound with the formula and structure . The pure compound is a pungent, colourless gas that polymerises spontaneously into paraformaldehyde (refer to section ...
,
carbon monoxide
Carbon monoxide (chemical formula CO) is a colorless, poisonous, odorless, tasteless, flammable gas that is slightly less dense than air. Carbon monoxide consists of one carbon atom and one oxygen atom connected by a triple bond. It is the simple ...
,
hydrogen cyanide in the case of
amino resins, and
phenol
Phenol (also called carbolic acid) is an aromatic organic compound with the molecular formula . It is a white crystalline solid that is volatile. The molecule consists of a phenyl group () bonded to a hydroxy group (). Mildly acidic, it ...
in the case of
phenol formaldehyde resin
Phenol formaldehyde resins (PF) or phenolic resins (also infrequently called phenoplasts) are synthetic polymers obtained by the reaction of phenol or substituted phenol with formaldehyde. Used as the basis for Bakelite, PFs were the first commerc ...
s.
The other safety concern is the slow release of formaldehyde over time. In 1984 concerns about the high indoor levels of formaldehyde in new
manufactured home
Manufactured housing (commonly known as mobile homes in the United States) is a type of prefabricated housing that is largely assembled in factories and then transported to sites of use. The definition of the term in the United States is regu ...
s led the
United States Department of Housing and Urban Development
The United States Department of Housing and Urban Development (HUD) is one of the executive departments of the U.S. federal government. It administers federal housing and urban development laws. It is headed by the Secretary of Housing and Ur ...
to set construction standards. Particleboard (PB), medium-density fibreboard (MDF), oriented strand board (OSB), and laminated flooring have been major sources of formaldehyde emissions. In response to consumer and woodworker pressure on the industry, PB and MDF became available in "no added formaldehyde" (NAF) versions, but were not in common use . Many other building materials such as furniture finish, carpeting and caulking give off formaldehyde, as well as
urea-formaldehyde foam insulation, which is banned in Canada for installation in a residential closed cavity wall.
Formaldehyde is classified by the
WHO
Who or WHO may refer to:
* Who (pronoun), an interrogative or relative pronoun
* Who?, one of the Five Ws in journalism
* World Health Organization
Arts and entertainment Fictional characters
* Who, a creature in the Dr. Seuss book '' Horton He ...
as a known human
carcinogen
A carcinogen is any substance, radionuclide, or radiation that promotes carcinogenesis (the formation of cancer). This may be due to the ability to damage the genome or to the disruption of cellular metabolic processes. Several radioactive subs ...
.
See also
*
Fiberboard
Fiberboard (American English) or fibreboard (British English) is a type of engineered wood product that is made out of wood fibers. Types of fiberboard (in order of increasing density) include particle board or low-density fiberboard (LDF), med ...
*
Glued laminated timber
Glued laminated timber, commonly referred to as glulam, is a type of structural engineered wood product constituted by layers of dimensioned lumber, dimensional lumber bonded together with durable, moisture-resistant structural adhesives so that ...
*
Masonite
Masonite is a type of hardboard, a kind of engineered wood, which is made of steam-cooked and pressure-molded wood fibers in a process patented by William H. Mason. It is also called Quartrboard, Isorel, hernit, karlit, torex, treetex, and ...
*
Pressed wood
Pressed wood, also known as presswood, is any engineered wood building and furniture construction material made from wood veneers, wood shavings and particles, sawdust or wood fibers bonded together with an adhesive under heat and pressure.
See ...
*
Waferboard
Waferboard belongs to the subset of reconstituted wood panel products called flakeboards. It is a structural material made from rectangular wood flakes of controlled length and thickness bonded together with waterproof phenolic resin under extreme ...
*
Haskelite
Haskelite is the brand name of a plywood, once made by the Michigan-based Haskelite Manufacturing Corporation. It was made from waterproof glue developed by Henry L. Haskell. The moldable plywood was originally called Ser-O-Ply. It was used i ...
References
External links
Composite Panel Association: ParticleboardEuropean Panel Federation: Particleboard
{{DEFAULTSORT:Particle Board
Composite materials
Woodworking materials
Engineered wood
German inventions of the Nazi period
es:Madera#Aglomerados o conglomerados