Progress 09/15/05 to 09/14/07
Outputs
Energy costs has been identified as one of the major issues impacting the wood products manufacturing competiveness of the forest product industry. During the last two years (2005-2007), our focus has been on the evaluation of technology capable of improving energy efficiency and the production of high value products at minimum cost. Vacuum drying technology was identified as a sustainable and economical technology to dry hardwood boards and timbers with minimum degrade defects for the production of high value products such as base ball bats, flooring, case good, chairs and table legs. This project was conducted in collaboration with private local industry. Ash, maples and oaks species were used . Oven capable of promoting the boiling of water within the wood cell wall at temperature lower than 100 degree Celsius under vacuum was used to dry eastern hardwood. Red oak, walnut, ash, cherry and sugar maple with thickness ranging from 16/4 to 6/4 were dried from green (40%
moisture) to about 10 percent moisture content within 48 hours versus 10-20 days conventional dry kiln method at temperature of about 70 C under vacuum. Dimensional stability and color integrity were maintained, defects such as checking darkening were absent. SEM (scanning electron microscopy) analysis comparing green samples to vacuum dried samples from the same parent board revealed that cell structure was not modified during the drying. Research is ongoing to confirm the low VOC emission, 50% energy reduction and negligible lumber degrade during vacuum drying. Continuous vacuum drying methods also improved the hardness in tangential and end surfaces better than other drying methods. Three low density wood species namely silver maple, yellow poplar and aspen were used to produce laminated veneer lumber (LVL)-an engineered wood products using different pressure levels and durations with thermoset and thermoplastic adhesives. LVL made with silver maple processed at lower temperature
and shorter pressure duration exhibited better properties as compared to yellow poplar and aspen. Currently silver maple is a "non commercial and lesser used species" considered weed in Michigan. In few instances, silver maple is utilized in making inexpensive boxes, crates, furniture, firewood, etc., our research findings suggest that silver maple can be used more suitably in producing high value-added products such as laminated veneer flooring, kitchen cabinets, molding, etc. Since most of WPC (wood plastic composites) degradation is surface phenomenon, we believed that it is not cost-effective and efficient to incorporate additives into the bulk of the composites. Consequently, the long-term goals of the proposed research project is to develop a co-extrusion process where two or more materials are extruded through a single die with two orifices arranged so that the extrudates merge and weld together into skin/core structure before chilling. The advantage of co-extrusion is that
each layer imparts a desired characteristic property, such as strength, stiffness, UV, fungi, mold, flame stability or resistance to some environment, all of which would be impossible to attain with any single material.
Impacts
The impact of vacuum drying of wood and wood products includes the economic benefit of supporting just in time (JIT) inventory and lumber production , an improved supply chain due to the reduced period of drying when compared to conventional drying from 20 days to 2 days (relatively short time), the benefit to the environment with the reduced VOC emission due to the low temperature drying and therefore less release of organic compound with high molecular weight in the environment and an almost 50% reduction in energy needs.The reduction of drying costs and time, coupled with the increased quality of dried products will give a considerable competitive edge to Michigan's forest products industry. The simultaneous processing of different species and thickness can occur without significant modification of wood quality (color changes, scalable and grade defects). An additional advantage that will be gained through commercial development of vacuum drying technology is the
control of insects in wood, such as the emerald ash borer and Asian long horned beetle, without the use of toxic chemicals . Wood-based composites such as particleboard and medium density fiberboard are currently made with formaldehyde-containing adhesives. Since the government is continuously developing and implementing very stringent regulations to eliminate formaldehyde emissions into the environment, alternative approaches must be developed to replace these adhesives. In response to the need for new adhesives for wood composite products, a new and non-toxic approach of manufacturing wood composites (a formaldehyde-free binding system) that could incorporate low value wood species was developed in our laboratory through a reactive extrusion process. The developed composites contain no formaldehyde-based adhesive, but still perform very well in mechanical tests, in some cases exceeding the standard requirements for particleboard of medium density made with formaldehyde-based
adhesive. As a result, formaldehyde emissions from wood composite products are eliminated, which will benefit public health and the environment.develop science and technology knowledge through research that can be applied to provide domestic wood products manufacturing industries with improved competitiveness in the global market place.
Publications
- L.M. Matuana and O. Faruk, Rigid PVC-based Nanocomposites Produced through a Novel Melt-Blending Approach, SPE ANTEC, Tech. Papers, 65: 1243-1247 (2007).
- L.M. Matuana and O. Faruk, Hybrid Nanoclay-Rigid PVC-Wood-Flour Composites," SPE ANTEC, Tech. Papers, 65: 1248-1252 (2007). Han, K.-H., Ko, J.-H., and Yang, S.H.. 2007. Functional genomics approach to optimizing lignocellulosic feedstock for improved biofuel productivity and processing. BioFPR 1: 135-146 Ko, J.-H., Yang, S., Park, A.H., Lerouxel, O., and Han, K.-H. 2007. ANAC012, a member of the plant-specific NAC transcription factor family, negatively regulates xylary fiber development in Arabidopsis thaliana. Plant J 50: 1035-1048
- Jiang H and DP Kamdem. 2007. Thermal and Dynamic Mechanical Behavior of Poly (vinyl chloride)/Wood Flour Composites" J Appl Polym Sci. 107(2):951-957. Jiang H and DP Kamdem.2007. Differential scanning calorimetry characterization of the cure of phenol-formaldehyde adhesive in the presence of copper-based preservative. Wood Sci.Technol 41:637-644.
- Shukla S.R. and D. Pascal Kamdem (2007). Properties of laminated veneer lumber (LVL) made with low density hardwood species I: effect of the pressure duration. Holz als Roh- und Werkstoff (publish on line)
- L.M. Matuana, S. Cam, K.B. Yuhasz, and Q.J. Armstrong, Composites of Acrylonitrile-Butadiene-Styrene Filled with Wood Flour, Polymers & Polymer Composites, 15 (5): 343-348 (2007).
- L.M. Matuana and J.W. Kim, "Fusion Characteristics of Wood-Flour Filled Rigid PVC by Torque Rheometry," Journal of Vinyl & Additive Technology, 13 (1): 7-13 (2007).
- B. Dawson-Andoh and L.M. Matuana, High Density Polyethylene-Wood Flour Composite Lumber: Efficacy of Two Proprietary Biocides in the Control of Fungal Colonization and Discoloration, Holz als Roh-und Werskstoff, 65: 331-335 (2007).
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Progress 09/15/05 to 09/15/06
Outputs
Energy costs and energy supply are identified as the issues impacting the manufacturing competiveness of the forest product industry. Vacuum drying technology was identified as a sustainable and economical technology to dry hardwood boards and timbers with minimum degrade defects. Oven capable of promoting the boiling of water within the wood cell wall at temperature lower than 100 degree Celsius under vacuum was used to dry eastern hardwood. Boards of red oak and sugar maple measuring 5/4 thickness by 6 inch by 8 inch were dried from green (40% moisture) to 10 percent within 2hours (versus 15 days conventional method) at temperature of about 70 C under vacuum). In both species, dimensional stability was maintained, defects such as checking were absent. Research is ongoing to confirm the low VOC emission, 50% energy reduction and negligible lumber degrade during vacuum drying. Parallel and cross laminated veneer technology for sandwich type wood composite was used to
laboratory manufacture engineered wood flooring (EWF) using locally available low-density and low grade hardwood species and hot/cold setting resins. This technique allows the increase in physical and mechanical properties of the resulting products. An innovative co-extrusion process is being developed as a means of manufacturing hardwood-based wood-plastic composite lumber with enhanced overall mechanical performance and improved resistance to biological agents, ultraviolet light, flame and freeze-thaw actions. A co-extrusion system has been set up using a capping die that will completely encapsulate the wood-plastic composites using various strategies. Currently, we are exploring the use nanotechnology to produce hybrid composites by combing both the inorganic nano-particles such as nano clay and nano calcium carbonate. Simultaneously, a new and non-toxic approach of manufacturing wood composites (a formaldehyde-free binding system) that incorporate low value wood species has been
developed through a reactive extrusion process. The developed composites contain no formaldehyde-based adhesive, but still perform very well in mechanical tests, in some cases exceeding the standard requirements for particleboard of medium density made with formaldehyde-based adhesive. To meet the increasing demands for environmentally-friendly, cost-effective wood-based products and services, it is required to increase and apply fundamental knowledge on the formation, structure, and properties of woods produced in the US. In this research, we have identified 52 candidate genes as regulators of wood formation. Especially, we found that NAC transcription factor genes control wood fiber differentiation. We are currently characterizing their specific functional roles in the differentiation of wood tissues and its biochemistry. Once verified for their involvement, these genes will serve as a means to biotechnologically modify the structure and biochemistry of wood for value-added wood
products and bio-energy feedstock. In addition, we started to assess dormancy depth of poplar trees for potential control of active growth-dormancy cycle to maximize tree growth potentials
Impacts
The impact of vacuum drying research includes the economic benefit of supporting just in time (JIT) inventory and lumber production, benefit to the environment with the low VOC emission and also the 50 percent reduction in energy. Vacuum drying can positively impact the industry's market share of hardwood market showing significant loss to substitute and import competition. Several novel co-extruded wood-plastic composite products will be developed as new alternative to preservative-treated solid wood lumber. Because of low value wood species are utilized in these products, co-extrusion of composites will provide an opportunity to increase the value-added utilization of wood. Eliminating formaldehyde emissions from wood composite products will benefit public health and the environment. In addition, because no solvent is involved during processing, reactive extrusion is an environmentally friendly, which will bring a new and green technology to the forest products
industry.We will develop science and technology knowledge through research that can be applied to provide domestic wood products manufacturing industries with improved competitiveness in the global market place.
Publications
- Pilarski, J.M. and Matuana, L.M. 2006. Durability of Wood-Flour Plastic Composites Exposed to Accelerated Freeze-Thaw Cycling Part II: High Density Polyethylene Matrix, Journal of Applied Polymer Science, 100 (1): 35-39.
- Kim, J.W., Matuana, L.M., and McCullough, D.G. 2005. Emerald Ash Borer Infested Ash Trees as Raw Materials for Wood-Based Composites, Forest Products Journal, 55 (11): 89-92.
- Shah, B.L. and Matuana, L.M. 2005. Novel Coupling Agents for PVC/Wood-Flour Composites, Journal of Vinyl & Additive Technology, 11 (4): 160-165.
- Carlborn, K. and L.M. Matuana, L.M. 2005. Composite Materials Manufactured From Wood Particles Modified Through a Reactive Extrusion Process, Polymer Composites, 26 (4): 534-541.
- Pilarski, J.M. and Matuana, L.M. 2005. Durability of Wood-Flour Plastic Composites Exposed to Accelerated Freeze-Thaw Cycling Part I: Rigid PVC Matrix, Journal of Vinyl & Additive Technology, 11 (1): 1-8.
- Dawson-Andoh, B., Matuana, L.M., and Harrison, J. 2005. Susceptibility of High Density Polyethylene/Wood-Flour Composite to Mold Discoloration, Journal of the Institute of Wood Science, 17 (2): 114-119.
- Carlborn, K. and Matuana, L.M. 2006 Response Surface Modeling of Formaldehyde Free Wood Composites, SPE ANTEC, Tech. Papers, 64: 214-218.
- Matuana, L.M. 2005. Effect of Impact Modification on the Foamability of Woodfiber-Plastic Composites, in the Proceedings of the 8th International Conference on Woodfiber-Plastic Composites (and Other Natural Fibers), Forest Products Society (May 23-25, 2005 Madison-WI), pp. 37-42.
- Matuana, L.M., Pilarski, J.M. and Armstrong, Q.J. 2005 Resistance of HDPE/Wood-Flour Composites to Cyclic Freezing and Thawing Exposures, in the Proceedings of the 8th International Conference on Woodfiber-Plastic Composites (and Other Natural Fibers), Forest Products Society(May 23-25, 2005 Madison-WI), pp. 257-263.
- Carlborn, K. and Matuana, L.M. 2005. A Novel Approach to Manufacture Formaldehyde-Free Wood Based Biocomposites, SPE ANTEC, Tech. Papers, 63: 1326-1330.
- Shah, B.L, Matuana, L.M. and Heiden, P.A. 2005. Novel Coupling Agents for PVC-Wood Flour Composite SPE ANTEC, Tech. Papers, 63: 3862-3866.
- Ko, J.-H., Beers, E.P., and Han, K.-H. 2006. Global comparative transcriptome analysis identifies gene network regulating secondary growth in Arabidopsis thaliana. Molecular Genetics and Genomics, In Press (Online First 10.1007/s00438-006-0157-1)
- Ko, J.-H., Kim, J.H., Jayanty, S.S., Howe, G.A., and Han, K.-H. 2006. Loss of function of COBRA, a determinant of oriented cell expansion, invokes cellular defense responses in Arabidopsis thaliana. Journal of Experimental Botany 57: 2923-2936
- Ko, J.-H., Yang, S., and Han, K.-H. 2006. Upregulation of an Arabidopsis RING-H2 Gene, XERICO, Confers Drought Tolerance through Increased ABA Biosynthesis. Plant J 47: 343-355.
- Ko, J.-H., Prassinos, C., and Han, K.-H. 2006. Developmental and seasonal expression of PtaHB1, a Populus gene encoding a class III HD-Zip protein, is tightly associated with secondary growth and inversely correlated with the level of microRNA (miR166). New Phytologist 169: 469-478.
- Prassinos, C., Ko, J.-H., Yang, J., and Han, K.-H. 2005. Transcriptome profiling of vertical stem segments provides insights into the genetic regulation of secondary growth in hybrid aspen trees. Plant Cell Physiology 46(8): 1213-1225.
- L.M. Matuana, Patricia A. Heiden and B.L. Shah, Wood Particle Filled Polyvinyl Chloride Composites and their Foams, US Patent, (Pending since April 2006)
- L.M. Matuana and K. Carlborn, Process for the Preparation of Maleated Polyolefin Modified Wood Particles in Composites and Products, US Patent, (Pending since July 30, 2005).
- L.M. Matuana, Patricia A. Heiden and B.L. Shah, Wood Flour Filled Polyvinyl Chloride Composites and their Foams, MSU invention disclosure 05-086 (April 2005).
- Nzokou, P., K. Wehner, and D. P. Kamdem 2005. Natural Durability of Eight Tropical Hardwoods Species from Africa. Journal of Tropical Forest Science 17(3): 325-336
- Nzokou, P., J. Zyskowski, and S. Boury, D. P. Kamdem 2005. Evaluation Of Natural Durability of Laminated Veneer Lumber Made of Veneers From Decay Resistant And/Or Non-Durable Hardwoods. Holz als Und Wesktoff 63: 173-178.
- Jusoh I. B., P. Nzokou and D. P. Kamdem 2005. The Effect Of Silicone On Some Properties Of Flakeboard. Holz als Und Wesktoff 63:266-271
- Nzokou P., and D. P. Kamdem 2005. X-Rays Photoelectron Spectroscopy Study of Red Oak (Quercus rubra), Black Cherry (Prunus serotina) and Red Pine (Pinus resinosa) Extracted Wood Surfaces. Surface and Interface Analysis 37:689-694
- Jinzhen Cao and D. Pascal Kamdem. 2005. Microdistribution of Copper in Copper-Ethanolamine (Cu-EA) Treated Southern Yellow Pine (Pinus spp.) related to density distribution. Holzforschung. 59(1):82-89.
- Nzokou, P., J. Freed, and D. P. Kamdem 2006. Relationship between Non Destructive and Static Modulus of Elasticity of Commercial Wood Plastic Composites. Holz als Und Wesktoff 90-93
- Weining C., P Girods, A. Jaxqueson and D P Kamdem. 2005. Effect of the addition of ammonia in the retention and leaching of copper amine treated southern pine. Forest prod. J. 55(10)92-94.
- Kamdem D. P. 2006. Recycling of wood treated with Chromated copper arsenate into composite construction materials. In Environmental Impacts of treated wood edited by Townsend T and H Solo-gabriele. Taylor and Francis ed. CRC press New York NY.
- Nzokou P., S. M. Pankras, D. Pascal Kamdem. 2006. Preservatives treatment of ash wood from emerald ash borer (Agrilus planipennis) infested trees. Forest prod. J. 56(10):69-72
- Mehta G., A. K. Mohanty, L. T. Drzal, D. P. Kamdem and M. Misra.2006. Effect of accelerated weathering on biocomposites processed by SMC and compression molding. J Polym environ (Online First August 31, 2006).
- Nzokou P., T.R. Petrice, R. A. Haack, D.P. Kamdem. 2006. Borate and imida~loprid treatment of ash logs infested with the emerald ash borer. Forest Prod. J. 56 (5):78
- Carlborn, K. and Matuana, L.M. 2006. Modeling and Optimization of Formaldehyde-Free Wood-Based Composites Using a Box-Behnken Design, Polymer Composites, 27 (5): 497-503.
- Kim, J.W., Carlborn, K., Matuana, L.M. and Heiden, P.A. 2006. Thermoplastic Modification of Urea-Formaldehyde Wood Adhesives for Increased Moisture Resistance, Journal of Applied Polymer Science, 101 (6): 4222-4229.
- Carlborn, K. and Matuana, L.M. 2006. Functionalization of Wood Particles Through a Reactive Extrusion Process, Journal of Applied Polymer Science, 101 (5): 3131-3142.
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