Composition Boards Containing Bark - ACS Publications

age in late 1973, large quantities of wood and bark residues have found increased markets ... Unused. Pacific Coast. 7. 2 .... Lumber Company. A descr...
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15 Composition Boards Containing Bark

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RAYMOND A. CURRIER Forest Research Laboratory, Oregon State University, Corvallis, Ore. 97331

Competition among various segments of the forest products industry for wood residues is becoming more intense each year. For example, some pulp mills now can use sawdust and shavings, which until recently were the major residue utilized for furnish in manufacturing wood particleboard. In addition, since the energy shortage in late 1973, large quantities of wood and bark residues have found increased markets as fuel. Efforts to use bark in composition boards predate the energy shortage, but they appear to be slated for renewed interest as the competition for clean woody residues accelerates. A review of past efforts in North America to utilize bark in composition boards is desirable to assess potential needs and the possibilities of producing salable composition boards wholly or partially from bark. The term composition boards is meant to include both fibrous and particle products. It includes what are commonly termed insulation board, hardboard, medium density fiberboard, and particleboard. This review of composition boards containing bark will not include references on the use of bark or bark extracts in the role of bonding agents for composition boards. That subject has been covered in the paper by Dr. A. B. Anderson. Amounts of Bark Available An appropriate beginning is an attempt to answer the question, "How much bark might be available for composition board furnish?" Estimates of total bark available in the United States have been difficult to obtain, and the published estimates have shown considerable variation. A recent estimate made by E l l i s (1) is based upon four regional compilations i n 1973. E l l i s estimated 17 million tons (ovendry) of bark are produced annually, of which 7 million tons presently are unused (Table I ) . At least 1 million tons presently are unused i n each region. The entire amount, of course, would not be available for composition boards as other potential uses, such as fuel and mulch, would siphon off part of the unused bark. 243

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

WOOD TECHNOLOGY:

244 Table I .

CHEMICAL

ASPECTS

Estimated 1973 U.S. P r o d u c t i o n of Bark Residues and Amounts P r e s e n t l y Unused, i n M i l l i o n s of Tons, Ovendry Basis. Total production

Unused

P a c i f i c Coast

7

2

Rocky Mountains

2

1

South

6

2-3

North

2

1-2

17

7

Region

Total

A more s p e c i f i c t a b u l a t i o n of bark p r o d u c t i o n and present uses f o r one s t a t e , Oregon, d u r i n g 1972 was compiled by Schuldt and Howard ( 2 ) . T h e i r f i n d i n g s , shown i n Table I I , i n d i c a t e the unused p o r t i o n of bark i s 22.5%, which i s under the estimated unused amounts shown f o r any r e g i o n l i s t e d i n Table I . Use of bark f o r f u e l i n Oregon came to 61.5% of the t o t a l produced, and the amount no doubt has increased g r e a t l y s i n c e 1972.

Table I I .

P r o d u c t i o n and D i s p o s i t i o n of Bark Residues i n Oregon, 1972, i n Tons, Dry-weight B a s i s . Unused

Total bark produced

Pulp & board

Fuel

Miscellaneous

3,556,103

40,470

2,188,155

529,131

798,347

1.1

61.5

14.9

22.5

% of t o t a l

Used

From the above, we can conclude that s u f f i c i e n t bark s t i l l i s a v a i l a b l e f o r use as composition board f u r n i s h . The amounts a v a i l a b l e , however, vary g r e a t l y from one g e o g r a p h i c a l r e g i o n to another. P o t e n t i a l volumes are l a r g e enough to be a source of f u r n i s h f o r p r o d u c t i o n of composition boards.

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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Bark

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Previous Bark Board B i b l i o g r a p h i e s and S t a t e - o f - t h e - A r t Review An e x c e l l e n t comprehensive c o m p i l a t i o n of the l i t e r a t u r e on a l l phases o f t r e e bark was prepared by Marian and W i s s i n g and pub­ l i s h e d over a span of 2 years (1956-1957) i n 11 d i f f e r e n t i s s u e s of Svensk P a p p e r s t i d n i n g ( 3 ) . T h e i r b i b l i o g r a p h y l i s t s the sub­ j e c t under 12 d i f f e r e n t major subheadings; bark composition boards may be found under the subheading "The U t i l i z a t i o n of Bark F i b e r s . " Another e x c e l l e n t b i b l i o g r a p h y by Roth and coworkers (4) l i s t s 1,339 references w i t h a c o n c i s e a b s t r a c t f o r each. Since the o r i g i n a l c o m p i l a t i o n was p u b l i s h e d i n 1960, two supplements have appeared, I i n 1968 (5) and I I i n 1973 ( 6 ) . References to bark composition boards a r e l i s t e d under the subheading " U t i l i z a t i o n . " The Chemical U t i l i z a t i o n D i v i s i o n of the F o r e s t Products Research Society p u b l i s h e d a "Review of Chemical U t i l i z a t i o n " i n 1960 (7) · The a u t h o r s , P e a r l and Rowe, i n c l u d e d a s e c t i o n t i t l e d "Bark," and i t s use i n composition boards was reviewed. This review was f o l l o w e d up by another p u b l i s h e d 3 years l a t e r by Rowe (8). Gregory and Root i n 1961 (9) prepared what they termed a " s t a t i s t i c a l a n a l y s i s " of the l i t e r a t u r e c o v e r i n g bark u t i l i z a t i o n and, i n a d d i t i o n , reviewed examples of commercial and p i l o t p l a n t o p e r a t i o n s . They found 52 r e f e r e n c e s on use of bark i n composi­ t i o n boards. The r e p o r t concludes w i t h s e c t i o n s c o v e r i n g " L i m i t a ­ t i o n s and Hurdles i n Bark U t i l i z a t i o n " and a d i s c u s s i o n of "Future Opportunities." (10) 1· 1966 compiled r e f e r e n c e s that have been pub­ l i s h e d s i n c e Roth e t a l . (4) reported on the bark l i t e r a t u r e i n 1960. Ross c a t e g o r i z e d the l a t e s t r e f e r e n c e s under one of 12 headings; bark composition boards were i n c l u d e d under the t i t l e , "Bark F i b e r , Cork, and Dust P r o d u c t s , Boards, P a n e l s , Adhesives, and T i l e s . " A g e n e r a l s t a t e - o f - t h e - a r t p l u s b i b l i o g r a p h y was p u b l i s h e d by H a r k i n and Rowe i n 1969 (11). Included was a s e c t i o n l a b e l e d "Wood-base M a t e r i a l s , " which covered i n s u l a t i o n board, hardboard, f i b e r b o a r d , and p a r t i c l e b o a r d c o n t a i n i n g bark. The same year (1969) , Walters (12) prepared a r e p o r t s p e c i ­ f i c a l l y r e v i e w i n g the c u r r e n t s t a t u s o f bark used f o r board p r o ­ ducts . I n f o r m a t i o n was g i v e n r e g a r d i n g p o t e n t i a l maximum amounts of bark u t i l i z a b l e i n v a r i o u s types of composition boards, based on research up to t h a t time. A s h o r t review by C u r r i e r and Lehmann (13) on use of bark i n composition boards was contained i n the proceedings from a c o n f e r ­ ence i n 1971 on "Converting Bark i n t o O p p o r t u n i t i e s . " H a l l a l s o came out the same year (1971) w i t h a comprehensive t e c h n i c a l review and b i b l i o g r a p h y o f the uses f o r D o u g l a s - f i r bark (14). Included i s a s t a t e - o f - t h e - a r t r e p o r t under the s u b t i t l e "Board and T i l e Manufacture." R o s s

η

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

246

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CHEMICAL

ASPECTS

Another review of u t i l i z i n g a s i n g l e bark s p e c i e s i n composit i o n boards was presented by Scroggins and C u r r i e r f o r western redcedar bark ( 1 5 ) . One of the few textbooks c o v e r i n g p a r t i c l e b o a r d was p u b l i s h e d i n 1974 w i t h Moslemi as the author (16). An e n t i r e chapter covers the s u b j e c t "Bark i n P a r t i c l e b o a r d , " and a v a i l a b l e l i t e r a t u r e i s reviewed e x t e n s i v e l y . The most recent s t a t e - o f - t h e - a r t r e p o r t was p u b l i s h e d l a s t year under the sponsorship of the Bark and Residues Committee of the F o r e s t Products Research S o c i e t y . The author, Bhagwat ( 1 7 ) , i n c l u d e d a s e c t i o n on p a r t i c l e b o a r d , hardboard, and molded p r o ducts where bark was a c o n s t i t u e n t i n the f u r n i s h . Review of E f f o r t s to Use Bark i n Composition Boards The f i r s t p u b l i s h e d r e s u l t s of e f f o r t s to u t i l i z e bark as f u r n i s h f o r composition boards i n North America appeared a f t e r the end of World War I I . In 1947, Schwartz, Pew, and Schafer o f the Forest Products L a b o r a t o r y , Madison, Wisconsin, r e p o r t e d on e x p e r i ments to produce i n s u l a t i o n board and hardboard from 8 types o f western s a w m i l l and l o g g i n g residues (18). I n c l u s i o n of l o g g i n g residues as p o t e n t i a l f u r n i s h i s of i n t e r e s t , because t h i s aspect of f o r e s t u t i l i z a t i o n has r e c e i v e d g r e a t l y renewed a t t e n t i o n only r e c e n t l y . Most gains to date i n r e s i d u e u t i l i z a t i o n have been made u s i n g m a t e r i a l generated a t sawmills and plywood and other wood p r o c e s s i n g p l a n t s , not from m a t e r i a l l e f t i n the woods a f t e r logging. Although Schwartz et: a l . do not s p e c i f i c a l l y mention t h a t bark was present i n the r e s i d u e s they used, we can assume t h a t i t was i n c l u d e d on the s l a b s and edgings s e r v i n g as a source of raw m a t e r i a l , and a l s o i n the l o g g i n g r e s i d u e s . T h e i r r e s u l t s showed t h a t s a t i s f a c t o r i l y s t r o n g i n s u l a t i o n board could be made from western hemlock slabwood, white f i r l o g g i n g r e s i d u e s , or a 50-50 mixture of white f i r l o g g i n g r e s i d u e s and D o u g l a s - f i r s l a b s . Dimensional s t a b i l i t y , however, was poor i n a l l combinations. None of the r e s i d u e s produced a hardboard that was a c c e p t a b l e , w i t h the e x c e p t i o n of western hemlock slabwood. In 1948 and 1949, i n v e s t i g a t o r s a t the F o r e s t Products Laboratory, Ottawa, Canada, r e p o r t e d r e s u l t s of the f i r s t p r e l i m i n a r y s t u d i e s where bark alone was the raw m a t e r i a l f o r wet p r o cess s o f t b o a r d and hardboard. Three a r t i c l e s were p u b l i s h e d , each c o n t a i n i n g e s s e n t i a l l y the same i n f o r m a t i o n . One was by Clermont and Schwartz ( 1 9 ) , and the other two by Schwartz (20, 21). Bark from e a s t e r n white cedar and western redcedar was used as the e n t i r e f u r n i s h , or w i t h a mixture of 10% pulp s c r e e n i n g s . These s p e c i e s were chosen because of the n a t u r a l f i b r o u s nature of t h e i r b a r k s . Although t e s t s showed the experimental hardboards could not meet standards then i n f o r c e , e a s t e r n white cedar bark showed some promise. For s o f t b o a r d s , the e a s t e r n white cedar produced acceptable boards.

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

15.

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Boards Containing

Bark

247

The next s e r i e s o f r e p o r t s based on use o f bark f o r wet p r o cess hardboard were p u b l i s h e d over a 7-year span from 1950-1956 by Anderson and Runckel. I n the f i r s t r e p o r t (22) , the r e s u l t s i n cluded l a b o r a t o r y boards made from D o u g l a s - f i r slabwood c o n t a i n i n g bark, which v a r i e d between 15 and 45% of the t o t a l f u r n i s h . Bending t e s t s i n d i c a t e d adequate s t r e n g t h s were o b t a i n e d , and a d d i t i o n of bark enhanced moisture r e s i s t a n c e o f the boards. Acceptable boards a l s o were made when white f i r and western hemlock barks made up a p o r t i o n of the f u r n i s h . No b i n d e r was added to the Asplund-type f i b e r . A 1952 r e p o r t (23) by Anderson and Runckel i n d i c a t e d f u r t h e r experiments had been performed u s i n g 100% D o u g l a s - f i r , white f i r , or western hemlock bark as wet-process hardboard f u r n i s h without any chemical a d d i t i v e s . Boards made from D o u g l a s - f i r bark had by f a r the b e s t s t r e n g t h and dimensional s t a b i l i t y . The r e p o r t a l s o d i s c l o s e d that a commercial p l a n t to manufacture a hardboard cont a i n i n g bark was under c o n s t r u c t i o n a t Dee, Oregon, by the Oregon Lumber Company. A d e s c r i p t i o n of the p l a n t a f t e r 1 year of operat i o n was given by Runckel (24). I n a c t u a l p r o d u c t i o n , adding 3/4% p h e n o l i c r e s i n to the f u r n i s h was necessary, but no s i z i n g was required. Another i n t e r e s t i n g r e p o r t by Anderson and Runckel d i s c u s s e d use o f D o u g l a s - f i r branchwood i n wet-process hardboard (25). This i s one of the e a r l i e s t r e f e r e n c e s to u t i l i z i n g t h i s type o f mater i a l as composition board f u r n i s h ; s a t i s f a c t o r y boards were made from 100% branchwood. No b i n d e r was added. A c t u a l percentage o f bark i n the f u r n i s h was not d i s c l o s e d . Anderson c o n t r i b u t e d a paper to the 1956 I n t e r n a t i o n a l Consult a t i o n on I n s u l a t i o n Board, Hardboard and P a r t i c l e Board (26). I n a d d i t i o n t o a good review o f the l i t e r a t u r e , the paper contained r e s u l t s o f f u r t h e r experimentation u s i n g the barks o f s e v e r a l more species as f u r n i s h f o r wet-process hardboard. New s p e c i e s i n c l u d e d ponderosa p i n e , sugar p i n e , southern p i n e , pinyon p i n e , lodgepole p i n e , noble f i r , and r e d oak. Ponderosa pine bark produced hardboard comparable to D o u g l a s - f i r bark i n both s t r e n g t h and moisture r e s i s t a n c e . The other s p e c i e s v a r i e d w i d e l y i n these p r o p e r t i e s . A condensed v e r s i o n o f t h i s work appears i n r e f e r e n c e (27). K i n g and Bender of the Canadian F o r e s t Products Laboratory a t Ottawa c o n t r i b u t e d two s t u d i e s to the l i t e r a t u r e on bark composit i o n boards. The f i r s t , i n 1951, was concerned w i t h producing wetprocess i n s u l a t i n g f i b e r b o a r d from western redcedar s h i n g l e m i l l waste (28) . Laboratory boards c o n t a i n i n g up t o 100% bark were made from a t t r i t i o n m i l l prepared f u r n i s h . Other raw m a t e r i a l s i n c l u d e d wood, s h i n g l e hay, and sawdust. Some combinations of f u r n i s h made boards that were a c c e p t a b l e . The next year (1952), r e s u l t s of u s i n g the same type f u r n i s h t o make l a b o r a t o r y - s i z e d wet-process hardboard were p u b l i s h e d (29) . Boards were made w i t h and without added b i n d e r . Those of 100% bark and no b i n d e r would not meet s p e c i f i c a t i o n s . Higher d e n s i t y and a d d i t i o n a l b i n d e r were found t o improve p r o p e r t i e s of the boards.

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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Up u n t i l 1952, a l l r e f e r e n c e s found on bark i n composition board were based upon wet-process s o f t b o a r d or hardboard. The f i r s t mention of a dry process came i n a one-page a r t i c l e p u b l i s h e d by the B r i t i s h Columbia Research C o u n c i l (30). The b r i e f r e p o r t i n d i c a t e d a dry process had been developed f o r making an i n t e r i o r w a l l b o a r d p o s s e s s i n g good s t r e n g t h and moisture r e s i s t a n c e . No b i n d e r was necessary f o r the cedar m i l l r e s i d u e s , which i n c l u d e d bark. A p p a r e n t l y , the process never was t r i e d commercially. A r e p o r t p u b l i s h e d i n 1954 by Cooke (31) was the f i r s t r e f e r ence found g i v i n g p e r t i n e n t d e t a i l s of a dry process f o r making a p a r t i c l e b o a r d - t y p e composition board c o n t a i n i n g bark. Ponderosa pine s l a b s c o n t a i n i n g 30% bark were chipped and hammermilied. P h e n o l i c r e s i n was added a t 4% s o l i d s , as was s i z i n g agent. Boards c o n t a i n i n g bark had lower bending s t r e n g t h s than all-wood boards; a d d i t i o n of a k r a f t paper o v e r l a y helped i n c r e a s e s t r e n g t h of boards that contained bark. Density of the boards ranged from 40.6 to 46.8 pounds per c u b i c f o o t . A s a t i s f a c t o r y sheathing-type board could be made from ponderosa pine s l a b s , w i t h or w i t h o u t i n c l u d e d bark. Three years a f t e r the r e p o r t by Cooke, an a r t i c l e appeared d e s c r i b i n g a commercial p a r t i c l e b o a r d p l a n t o p e r a t i n g on unbarked white pine and e a s t e r n hemlock s l a b s and edgings (32). The p l a n t , G r a n i t e Board, I n c . a t Goffstown, New Hampshire, s t a r t e d i n 1955 and operated s u c c e s s f u l l y f o r s e v e r a l y e a r s . Another r e p o r t came from Canada i n 1959 when Bender p u b l i s h e d research r e s u l t s of u t i l i z i n g e a s t e r n Canadian barks as f u r n i s h f o r wet-process i n s u l a t i o n board and hardboard (33). Bark s p e c i e s i n c l u d e d i n the study were b l a c k spruce and balsam f i r ; each cont a i n e d 25-35% wood. A Sprout-Waldron d i s k r e f i n e r was used to prepare the bark f i b e r , and boards were made w i t h lh% wax emulsion but contained no added b i n d e r . P h y s i c a l t e s t s i n d i c a t e d the boards met some commercial s p e c i f i c a t i o n s ; the author b e l i e v e d that a d d i t i o n o f more woody f i b e r would improve the p r o p e r t i e s . I n a d d i t i o n , a few experimental dry-process p a r t i c l e b o a r d s were made w i t h a d d i t i o n of some unnamed b i n d e r that was a byproduct m a t e r i a l . Burrows i n 1959 c o n t r i b u t e d a study based on making a f l o o r t i l e from the cork f r a c t i o n of D o u g l a s - f i r bark (34). Added b i n d e r i n the dry-process t i l e s was e i t h e r 5% butadiene styrene or d i e t h y l e n e g l y c o l . Comparison t e s t s were made a g a i n s t t i l e s from Mediterranean oak cork. Dimensional s t a b i l i t y was b e t t e r i n D o u g l a s - f i r cork t i l e s , and most other p r o p e r t i e s compared f a v o r a b l y . No known commercial a p p l i c a t i o n r e s u l t e d . One year l a t e r , Burrows p u b l i s h e d r e s u l t s from a comprehens i v e s e r i e s of experiments u s i n g 100% D o u g l a s - f i r bark as f u r n i s h f o r p a r t i c l e b o a r d (35). No b i n d e r was used; he r e l i e d upon the " s e l f - b o n d i n g " p r o p e r t i e s of D o u g l a s - f i r bark. V a r i a b l e s i n c l u d e d bark p a r t i c l e s i z e , mat moisture c o n t e n t , p r e s s i n g p r e s s u r e , and use of v a r i o u s o v e r l a y s . A d d i t i o n a l boards were made from ponderosa p i n e , western hemlock, and white f i r b a r k s . A p i l o t p l a n t - s i z e run was made u s i n g r e s u l t s gathered from the study.

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

15.

CURRIER

Composition

Boards Containing

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I n c r e a s i n g p r e s s i n g pressure and use of an o v e r l a y on the bark core improved p r o p e r t i e s the most. Burrows concluded t h a t a commercial board product could be made from a l l - b a r k f u r n i s h w i t h out added b i n d e r i f the bark were o v e r l a i d w i t h k r a f t paper or veneer. Further work i n Canada to produce r i g i d * , wet-process i n s u l a t i o n boards from a bark-wood mixture was r e p o r t e d by Branion i n 1961 (36). He made boards c o n t a i n i n g 85% p o p l a r wood and 15% white spruce bark; a few boards were made w i t h added p o p l a r or j a c k p i n e bark. White spruce bark worked b e s t ; i t appeared to cause a s i g n i f i c a n t i n c r e a s e i n t e n s i l e s t r e n g t h compared to boards made from 100% p o p l a r wood f i b e r . T h i s e f f e c t a l s o was demonstrated i n a hardboard. Other boards were made w i t h up to 80% bark. Water a b s o r p t i o n decreased as bark content i n c r e a s e d . An e f f o r t was made to d i s c o v e r the bark i n g r e d i e n t r e s p o n s i b l e f o r the s t r e n g t h i n c r e a s e . A f t e r a s e r i e s of e x t r a c t i o n s , the a c t i v e component was concluded to be present i n the h o l o c e l l u l o s e . Lewis i n 1961 d i s c u s s e d why composition boards c o n t a i n i n g bark seldom had found commercial a p p l i c a t i o n (37). He b e l i e v e s the reasons are that bark u s u a l l y contains d i r t and g r i t , which causes r a p i d d u l l i n g o f chipper and f l a k e r k n i v e s ; i n p u l p i n g processes, bark may r e q u i r e d i f f e r e n t c o n d i t i o n s than wood; increased foam and s l i m e problems occur w i t h bark i n wet processes ; m a i n t a i n i n g constant bark-to-wood r a t i o s i s d i f f i c u l t ; and bark causes darkening of the board s u r f a c e . Whatever the reason, a dearth of r e s e a r c h i n North America on composition boards c o n t a i n i n g bark i s apparent a f t e r 1961. The next p u b l i c a t i o n appeared i n 1968 when Stewart and B u t l e r r e p o r t e d on making wet-process hardboard from 100% western redcedar bark or mixtures o f bark and up to 36% wood by weight (38). F i b e r was prepared by Asplund or Sprout-Waldron r e f i n e r s , and p h e n o l i c r e s i n was added as b i n d e r . C o n t r o l boards were made from D o u g l a s - f i r woody f i b e r , e i t h e r commercially produced or l a b o r a t o r y made. ALl-bark boards showed a marked r e d u c t i o n i n l i n e a r expansion and i n t e r n a l bond when compared to boards made p a r t i a l l y from wood f i b e r . Modulus o f r u p t u r e , water a b s o r p t i o n , and thickness s w e l l showed no change. When compared to all-wood boards, the a l l - b a r k board l o s t 25-30% of bending s t r e n g t h and some degree of i n t e r n a l bond. Renewed i n t e r e s t i n bark p a r t i c l e b o a r d was evidenced by a short a r t i c l e w r i t t e n by Murphey and R i s h e l (39). They r e p o r t e d r e s u l t s of p r e l i m i n a r y s t u d i e s on r e l a t i v e s t r e n g t h s of v a r i o u s bark s p e c i e s compared to aspen f l a k e b o a r d . Bark s p e c i e s i n c l u d e d aspen, b l a c k l o c u s t , green oak, white p i n e , oak and l o c u s t , p o p l a r , red oak, and mixed oak. O v e r l a y i n g was suggested as a means of i n c r e a s i n g bending s t r e n g t h s .

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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Results o f a comprehensive r e s e a r c h p r o j e c t i n which three types o f p a r t i c l e b o a r d f u r n i s h c o n t a i n i n g bark were i n c l u d e d (pole p e e l i n g s , l o g g i n g r e s i d u e s , and bark) were r e p o r t e d by C u r r i e r and Lehmann i n 1970 and 1972 (40, 41). Three-layer boards were made w i t h v a r i o u s percentages (25, 50, and 100) of D o u g l a s - f i r , ponderosa p i n e , western hemlock, o r a mixture o f a l l three barks i n the core l a y e r . Urea formaldehyde r e s i n a t 6% s o l i d s was added t o core f u r n i s h and 8% s o l i d s t o face f u r n i s h . From s t r e n g t h and dimensional s t a b i l i t y t e s t s , they concluded that both types o f p r o p e r t i e s were lowered d r a s t i c a l l y when bark content o f the core exceeded 25%. Boards made w i t h l o g g i n g r e s i d u e as core f u r n i s h were a c c e p t a b l e , because amount of bark o c c u r r i n g i n the l o g g i n g r e s i d u e n a t u r a l l y d i d not exceed 25%. An announcement was made i n 1970 that a l a r g e producer o f p a r t i c l e b o a r d , Boise Cascade C o r p o r a t i o n , La Grande, Oregon, planned t o i n i t i a t e f u l l - s c a l e p r o d u c t i o n t e s t s o f an underlayment grade board c o n t a i n i n g 25% p i n e bark (42). D o u g l a s - f i r , white f i r , and redwood barks a l s o were t r i e d i n p r e l i m i n a r y boards made i n the l a b o r a t o r y . Scheduling o f the p l a n t run was p r e d i c a t e d on s u c c e s s f u l r e s u l t s from the laboratory-made boards. A p p a r e n t l y , the p r o d u c t i o n run d i d not prove t o be s u c c e s s f u l , even though the l a b o r a t o r y boards met a l l s p e c i f i c a t i o n s . One o f today's f a s t e s t growing segments o f the wood composit i o n board i n d u s t r y i s p r o d u c t i o n o f medium d e n s i t y f i b e r b o a r d (MDF) u s i n g a dry process s i m i l a r t o that used f o r p a r t i c l e b o a r d . F i r s t mention o f the p o s s i b i l i t y o f u t i l i z i n g bark f o r MDF came i n a p r e s e n t a t i o n by Brooks i n 1971 (43). He d e s c r i b e d a process i n which a homogenous board w i t h s u p e r i o r p r o p e r t i e s could be made from such raw m a t e r i a l s as mixed, unbarked hardwood pulp c h i p s ; unbarked pine c h i p s , i f bark content was l e s s than 30%; f o r e s t t h i n n i n g s , branches, and so on; and hardwood bark. F u r n i s h was prepared by double-disk p r e s s u r i z e d r e f i n e r s . Brooks concluded a p l a n t could be b u i l t t o operate on 100% hardwood bark. Dost i n 1971 r e p o r t e d on a study where redwood bark f i b e r was used i n t h r e e - l a y e r p a r t i c l e b o a r d (44). Amount o f bark i n the f u r n i s h , by weight, was 0, 10, 20, and 30%; hammermilied d i s k f l a k e s o r Pallmann f l a k e s o f redwood wood made up the remainder o f the f u r n i s h . Urea formaldehyde r e s i n was a p p l i e d a t three p e r c e n t ages. Test r e s u l t s showed s u r f a c e smoothness and s t r e n g t h p r o p e r t i e s (MOR, MOE, and IB) decreased w i t h i n c r e a s i n g bark content i n the boards. Water a b s o r p t i o n decreased, but t h i c k n e s s s w e l l i n g and l i n e a r expansion increased as the amount o f bark i n c r e a s e d . I n 1971, Marra and Maloney of Washington S t a t e U n i v e r s i t y were i n t e r v i e w e d r e g a r d i n g t h e i r p i l o t - p l a n t r e s e a r c h on bark board ( 4 5 ) . They p r e d i c t e d t h a t a shortage o f easy-to-use s a w m i l l and plywood p l a n t wood-type r e s i d u e s would l e a d composition board manufacturers t o seek bark, l o g g i n g s l a s h , and r e c l a i m e d waste paper as a source o f f u r n i s h . Some p o t e n t i a l problems w i t h bark were d i s c u s s e d , e s p e c i a l l y that bark n a t u r a l l y possesses lower s t r e n g t h p r o p e r t i e s than wood o f the same s p e c i e s .

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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Two years l a t e r , Maloney p u b l i s h e d r e s u l t s of h i s comprehens i v e bark board study (46). Included were barks from western l a r c h , D o u g l a s - f i r , ponderosa p i n e , and western redcedar. Homogeneous boards contained e i t h e r 7.5 o r 10% urea formaldehyde as b i n d e r , or 6% phenol formaldehyde. Boards were made a t four s p e c i f i c g r a v i t i e s , 0.40, 0.55, 0.70, and 0.85. Strength t e s t s showed homogeneous boards o f ponderosa p i n e o r D o u g l a s - f i r approached o r e q u a l l e d the i n t e r n a l bond s p e c i f i c a t i o n s f o r low-to-medium dens i t y p a r t i c l e b o a r d ; l a r c h met only the low d e n s i t y c r i t e r i o n . None could meet modulus o f rupture s p e c i f i c a t i o n s . Western redcedar boards met MOR s p e c i f i c a t i o n s , but had low i n t e r n a l bond. L i n e a r expansion was h i g h , e s p e c i a l l y f o r ponderosa p i n e . A d d i t i o n a l work was r e p o r t e d on u s i n g impregnating r e s i n s t o "beef up" bark s t r e n g t h , w i t h some success. At about the same time as Maloney s r e s e a r c h , Chow was attempting t o e l u c i d a t e the s o - c a l l e d s e l f - b o n d i n g c a p a b i l i t i e s o f some types o f bark when s u b j e c t e d to c e r t a i n combinations o f time, temperature, and pressure (47). Mois ture content was not a v a r i able and was kept a t 2.5% o r l e s s . Boards were made from Douglasf i r bark a t temperatures of 180 and 200°C and p r e s s i n g times from 5 t o 120 minutes. C o n t r o l boards were pressed w i t h bark f u r n i s h c o n t a i n i n g 4.5% phenol formaldehyde r e s i n . Tests i n d i c a t e d that boards made without b i n d e r a t optimum time-temperature p r e s s i n g c o n d i t i o n s possessed i n t e r n a l bond and bending s t r e n g t h s equal to boards made w i t h 4.5% r e s i n b i n d e r . I n a d d i t i o n , the best no-binder boards had much b e t t e r d i m e n s i o n a l . s t a b i l i t y p r o p e r t i e s than those made w i t h b i n d e r . Optimum c o n d i t i o n s were a p r e s s i n g temperature of 200°C and from 40 to 120 minutes press time. About t h i s time (1973) , widespread i n t e r e s t appeared i n a f u r t h e r m o d i f i c a t i o n o f the o l d b a s i c p a r t i c l e b o a r d products. One example was p r o d u c t i o n o f a s o - c a l l e d s t r u c t u r a l board, u s u a l l y from f u r n i s h c o n s i s t i n g o f wood f l a k e s o r wafers. A s u c c e s s f u l commercial product had been produced from aspen wood wafers f o r s e v e r a l y e a r s , and G e r t j e j a n s e n and Haygreen (48) e x p l o r e d the e f f e c t o f u s i n g as f u r n i s h aspen that contained bark. Because aspen bark changes d r a s t i c a l l y i n p h y s i c a l c h a r a c t e r i s t i c s from b u t t t o top l o g s , i t s source on the l o g was a v a r i a b l e . Both wafer and f l a k e - t y p e boards were made, w i t h phenol formaldehyde as b i n d e r . Test r e s u l t s showed wafer-type boards w i t h b u t t - l o g bark l o s t 30% i n moduli of rupture and e l a s t i c i t y , l i n e a r s w e l l i n g increased 75%, and t h i c k n e s s s w e l l i n g decreased 28%. I n t e r n a l bond i n c r e a s e d 28%. Upper-log bark reduced MOR and MOE 15% and had l i t t l e o r no e f f e c t upon IB or s t a b i l i t y p r o p e r t i e s . Regardl e s s o f bark source, f l a k e - t y p e boards l o s t MOR and MOE; IB d i d not change. L i n e a r s w e l l i n g was g r e a t e r and t h i c k n e s s s w e l l i n g lower w i t h b u t t - l o g bark. Both types o f s w e l l i n g i n c r e a s e d w i t h upper-log bark. Another proposed composite product, t h i s one s t r i c t l y nons t r u c t u r a l , was a d e c o r a t i v e i n t e r i o r p a n e l c o n s i s t i n g o f a pressed bark o v e r l a y on a base m a t e r i a l such as plywood, hardboard, 1

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or gypsum board (49). P r e f e r r e d bark s p e c i e s were those chunky i n n a t u r e , such as f i r or p i n e . During 1974, Anderson and co-workers Wong and Wu produced a s e r i e s of three p u b l i c a t i o n s d e a l i n g w i t h the i n c l u s i o n of white f i r or ponderosa pine bark i n p a r t i c l e b o a r d (50, 51, 52). The l a s t two r e p o r t s a l s o i n c l u d e d bark e x t r a c t as b i n d e r s . The f i r s t study on white f i r (50) i n c l u d e d a d d i t i o n of 2% paraformaldehyde to r e a c t w i t h the p o l y p h e n o l i c e x t r a c t i v e components of the 100% bark f u r n i s h . Although some improvement was noted, bending s t r e n g t h was too low and l i n e a r expansion too h i g h . A b e t t e r board was made by u s i n g bark i n the core and wood p a r t i c l e s on the f a c e s . Homogeneous boards from a wood-bark mix were s a t i s f a c t o r y i f the amount of bark was 25% o r l e s s . R e s u l t s of the l a t e r s t u d i e s showed bark-paraformaldehyde f u r n i s h as core of t h r e e - l a y e r p a r t i c l e b o a r d r e s u l t e d i n white f i r boards meeting medium-density p a r t i c l e b o a r d s p e c i f i c a t i o n s f o r bending and i n t e r n a l bond s t r e n g t h s , as w e l l as l i n e a r expansion (51). The use o f ponderosa p i n e bark p l u s 2% paraformaldehyde as f u r n i s h f o r a l l - b a r k boards, or as core of t h r e e - l a y e r boards w i t h wood faces was r e p o r t e d i n the t h i r d p u b l i c a t i o n (52). Tests i n d i cated the a l l - b a r k boards had very low bending s t r e n g t h and very h i g h l i n e a r expansion. I n t e r n a l bond, however, was adequate, as was thickness s w e l l i n g . By going to the t h r e e - l a y e r c o n f i g u r a t i o n , both bending s t r e n g t h and l i n e a r expansion were markedly improved. B i b l o s and Coleman i n v e s t i g a t e d another type of p o t e n t i a l s t r u c t u r a l composite product (53). They made and t e s t e d panels c o n s i s t i n g o f a p a r t i c l e b o a r d core from sawdust and bark and faces of veneer. A l l m a t e r i a l was southern p i n e , and 9% urea formaldehyde served as b i n d e r . Strength t e s t s i n d i c a t e d the composite panels were s u p e r i o r to c o n v e n t i o n a l two-layer f l o o r systems of 1/2-inch plywood p l u s 5/8-inch p a r t i c l e b o a r d underlayment. In the same y e a r , 1974, Lehmann, Geimer, McNatt and Heebink of the F o r e s t Products Laboratory a t Madison, W i s c o n s i n , p u b l i s h e d three r e p o r t s , each r e l a t i n g to s t r u c t u r a l - t y p e p a r t i c l e b o a r d from f o r e s t r e s i d u e f u r n i s h (54, 55, 56). Amount of n a t u r a l l y o c c u r r i n g bark i n the raw m a t e r i a l s t u d i e d ( D o u g l a s - f i r , true f i r , western hemlock, and lodgepole pine) was low a t 7-8%. Various types of mechanically prepared p a r t i c l e s were s t u d i e d ; board c o n f i g u r a t i o n s i n c l u d e d s t r u c t u r a l f l a k e b o a r d , t h r e e - l a y e r boards, homogeneous boards, and o v e r l a i d panel s i d i n g . S y n t h e t i c r e s i n b i n d e r and wax s i z e were added to a l l board f u r n i s h . R e s u l t s of s t r e n g t h and s t a b i l i t y t e s t s i n d i c a t e d i n c l u s i o n of bark or branchwood or both i n l a r g e amounts r e s u l t s i n severe l o s s of s t r e n g t h and dimensional s t a b i l i t y , e s p e c i a l l y i n f l a k e b o a r d s . The recommendation was that bark/branchwood content not exceed 15% of the t o t a l f u r n i s h . In a d d i t i o n to l o s s of s t r e n g t h and s t a b i l i t y , bark contained about 10 times as much s i l i c a as woody r e s i d u e s . Thus, machining problems may occur i n boards w i t h h i g h bark contents.

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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A r e p o r t from West V i r g i n i a U n i v e r s i t y by Koch and H a l l (57) discussed the use of hardwood bark as p a r t i c l e b o a r d f u r n i s h , w i t h and without added b i n d e r s . Species i n c l u d e d red oak, s o f t maple, and b l a c k b i r c h . I n i t i a l s t u d i e s i n d i c a t e d no-binder boards had to be compressed to 70 pounds per c u b i c f o o t to m a i n t a i n t h e i r i n t e g r i t y . Both s t r e n g t h and dimensional s t a b i l i t y were enhanced by p r e s s i n g boards a t 400°F i n s t e a d of 300°F. Longer press times (15, r a t h e r than 10 minutes) a l s o helped. L a t e r , boards were made w i t h 5% added s t a r c h powder. One p o t e n t i a l use of t h i s product was f o r expandable h o r t i c u l t u r a l p l a n t i n g c o n t a i n e r s . Both raw and composted barks were t r i e d , w i t h promising r e s u l t s . The thermal p r o p e r t i e s of composite boards were the s u b j e c t of a recent r e p o r t by P l a c e and Maloney (58). Thermal c o n d u c t i v i t y t e s t s were made on t h r e e - l a y e r boards w i t h s u r f a c e s of white pine wood f l a k e s and cores of e i t h e r D o u g l a s - f i r or grand f i r bark. Density was v a r i e d a t 34, 42, and 52 pounds per c u b i c f o o t . The composite boards c o n t a i n i n g bark proved to be b e t t e r i n s u l a t o r s than wood p a r t i c l e b o a r d of comparable d e n s i t y . D o u g l a s - f i r bark cores had lower thermal c o n d u c t i v i t y than d i d grand f i r . Two a r t i c l e s p u b l i s h e d l a s t year (59, 60) d i s c u s s e d work a t the Vancouver, B r i t i s h Columbia, Western F o r e s t Products Laboratory t h a t a m p l i f i e d the 1972 f i n d i n g s by Chow on the s e l f - b o n d i n g of bark and the mechanism r e s p o n s i b l e f o r i t . High p r e s s i n g temperatures (200 to 300°C) were found to be the key to a c t i v a t i n g the chemicals n a t i v e to bark t h a t w i l l polymerize i n the hot p r e s s . P r e s s i n g times ran from 2 to 60 minutes. Species of bark i n v e s t i gated i n c l u d e d D o u g l a s - f i r , western hemlock, lodgepole p i n e , and western redcedar. Board s p e c i f i c g r a v i t y was 0.9 to 1.0 grams per cc. Tests showed MOR and IB values were r e l a t e d d i r e c t l y to timetemperature parameters. Higher temperatures, e s p e c i a l l y above 250°C, and longer p r e s s i n g times gave the best r e s u l t s . A f t e r 2 hours o f b o i l i n g , the b e t t e r bark boards r e t a i n e d most of t h e i r bending s t r e n g t h , u n l i k e c o n v e n t i o n a l wood p a r t i c l e b o a r d . Dimens i o n a l s t a b i l i t y a l s o was enhanced by h i g h e r temperatures and longer press times. Chow f i g u r e d the e x t r a c t i v e - l i g n i n polymer bond formed was equal to that obtained by a d d i t i o n of 4.5 to 7% s y n t h e t i c r e s i n b i n d e r . R e s u l t s comparable to D o u g l a s - f i r were found f o r western hemlock and lodgepole pine b a r k s ; western r e d cedar proved to be u n p r e d i c t a b l e . So f a r t h i s y e a r , two r e p o r t s have been p u b l i s h e d on the e f f e c t of bark i n medium-density f i b e r b o a r d . The f i r s t by Woodson (61) covered the bark of three southern hardwoods, sweetgum, southern red oak, and mockernut h i c k o r y ; percentage of bark i n the whole-tree f u r n i s h was 13.4, 2Ô.0, and 18.6%, r e s p e c t i v e l y . Ureamelamine formaldehyde b i n d e r was added a t 8-10%, and wax at 1%. Test r e s u l t s showed i n c l u s i o n of bark decreased t e n s i l e and bending s t r e n g t h s by 16-18%, MOE by 10-14%, and IB by 8%. L i n e a r expans i o n was not a f f e c t e d s i g n i f i c a n t l y by bark. Thickness s w e l l i n g was improved i n two of the three s p e c i e s . Woodson concluded good q u a l i t y , medium-density f i b e r b o a r d could be made from barky c h i p s .

Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.

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ASPECTS

The second r e p o r t on MDF i n 1976 came from Chow a t the U n i v e r ­ s i t y o f I l l i n o i s (62). He, t o o , worked w i t h hardwood barks i n c l u d ­ i n g cottonwood, red oak, white oak, and walnut. F u r n i s h was p r e ­ pared i n p r e s s u r i z e d r e f i n e r s and by hammermi11ing. Urea formalde­ hyde r e s i n percentages were 5.0, 7.5, and 10.0%, p l u s 1% wax. He concluded that the f i b e r from the p r e s s u r i z e d r e f i n e r s was s u p e r i o r t o hammermilled p a r t i c l e s . Cottonwood and white oak f u r n i s h gave b e t t e r boards, exceeding o r approaching requirements of present standards f o r type 1-B-l commercial p a r t i c l e b o a r d . The most recent p u b l i c a t i o n reviewed was by Einspahr and Harder ( 6 3 ) , who d i s c u s s the b a s i c p r o p e r t i e s o f hardwood barks that c o u l d be important i n the manufacture of any f i b r o u s product. This was a progress r e p o r t showing r e s u l t s f o r 16 pulpwood species ; work i s i n progress on 16 a d d i t i o n a l s p e c i e s . Measured were such bark f a c t o r s as s p e c i f i c g r a v i t y , e x t r a c t i v e s content, s t r e n g t h , toughness, r e a c t i o n to hammermi11ing, and ash content.

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Goldstein; Wood Technology: Chemical Aspects ACS Symposium Series; American Chemical Society: Washington, DC, 1977.