Wood Sci. Technol.

25:73 82 (1991)
Wood Science
and Technology
9 Springer-Verlag 1991

Thickness swelling and density variation

in aspen flakeboards
J.Y. Liu and J.D. McNatt, M a d i s o n WI, U S A

Summary. This paper reports the relationship between thickness swelling and density in lab-
made aspen flakeboards. The boards were manufactured with several levels of initial mat
moisture content and urea resin content. Weight increase and thickness swelling at 12 locations
on each board were recorded under specified environmentalconditions over a period of 71 days.
Each board was then cut into 12 specimens, each containing one of the 12 locations at its center,
and density was calculated. No definite relationship was found between thickness swelling and
density among the 12 specimens of each board. Our results suggest that high initial moisture
content and high resin content can decrease thickness swelling. Variations in mat pressure and
core temperature during the press cycle and weight increase at 80 percent relative humidity are
discussed.

Introduction

For structural reconstituted wood products such as flakeboards, thickness swelling and
panel density vary from point to point in the plane of the board. Knowledge a b o u t
this intrinsic variation is essential to improving the m a n u f a c t u r i n g process as well as
the engineering application of such products.
A flake mat is formed by r a n d o m l y depositing adhesive-coated flakes on a flat
surface; the flakes are n o t uniformly distributed. The mat is densified by compression
in a hot press, a process that results in a considerable a m o u n t of plastic deformation.
Densification of the mat is strongly dependent on, a m o n g other things, the interaction
of heat and moisture transfer from the surfaces to the core and to the edges of the
mat during the press cycle. Therefore, a single localized density value or vertical
density profile does not characterize the density variation in the whole board.
W h e n pressure is released in the hot press, the thickness of the flakeboard increas-
es because of the elasticity of the flakes. Thickness swelling also subsequently occurs
as a consequence of moisture adsorption from the environment. The total increase in
thickness is believed to be related to the rheological properties of the flakes (deforma-
tion and flow) and resin, environmental conditions, and density variation. Therefore,
thickness increase is not uniform throughout the board.

The Forest Products Laboratory is maintained in cooperation with the University of

Wisconsin. This article was written and prepared by U.S. Government employees on official
time, and it is therefore in the public domain and not subject to copyright
74 J.Y. Liu and J.D. McNatt

The purpose of this study was to relate resin content and initial mat moisture
content to thickness swelling of the finished flakeboards, and in turn, to relate
thickness swelling to horizontal density distribution within a board. Aspen flakeboards
were manufactured with several values of initial moisture content and resin solids
content. The variations o f mat pressure and core temperature with time during the
press cycle were recorded. We then measured the thickness swelling at 12 evenly
distributed locations in each b o a r d at 80 percent relative humidity (RH) over a period
of 71 days. Each b o a r d was cut into twelve 51- by 64-mm specimens, each containing
one of the 12 locations at its center, and mean density values were calculated.

Literature Review

Studies on particleboards have focused on the relationships between pressing parame-

ters and physical properties. Suchsland (1959) showed that the pressure developed in
a particle mat during hot pressing is a function o f the stress-strain characteristics of
the w o o d particles in compression perpendicular to the grain. This led Kunesh (1961)
to p e r f o r m basic research on the inelastic behavior of wood. Kunesh tested solid
yellow-poplar 12.7- by 25.4- by 25.4-mm specimens in compression with the thickness
(12.7 mm) in either the radial or tangential direction. The specimens were maintained
at specified constant moisture content and temperature levels before, during, and after
testing. W h e n thickness was measured 1 h after compression, practically all the recov-
ery had already occurred. Therefore this thickness measurement should include the
immediate elastic swelling or recovery and the time-dependent elastic recovery or
retarded recovery as reported by Kass (1969). F o r a particleboard, total recovery can
take days or even weeks (Beech 1975).
K a v v o u r a s (1977) studied the effect o f resin content on the gas vapor pressure
within the mat by comparing gas vapor pressure as a fuction of time for mats with
0 and 12 percent resin solids content. He found that resin content had a negligible
effect on gas v a p o r pressure. H u m p h r e y (1982) c o m p a r e d the pressure variations with
pressing time for mats with and without resin. When the pressure leveled off as a
consequence of stress relaxation, the residual pressure for the mat without resin was
higher than that for the mat with resin. This difference in residual pressure was
believed to be related to the internal adhesive bonds.
In studying the behavior of a particle m a t during the press cycle, Suchsland (1967)
noted the nonuniformity of the arrangement of particles and discussed the horizontal
density variation. This is the first reference in the literature to horizontal density
variation, in a later article, Suchsland (1973) stated that efforts to reduce thickness
swelling should concentrate on reducing the horizontal density variation or on re-
straining higher density portions from d o m i n a t i n g the thickness swelling of the board.
Nevertheless, in a comprehensive review o f particleboard literature (Kelly 1977),
studies on vertical density profile and thickness swelling pertain to the whole b o a r d ;
that is, in these studies the whole b o a r d was characterized by one mean vertical
density profile for one mean density value and one thickness swelling. Thus, our study
on the relationship between thickness swelling and horizontal density distribution is
appropriate.
Thickness swelling and density variation in aspen flakeboards 75

Experimental procedures

The experimental design o f the study included four target levels o f resin solids content
(RSC) 0, 1, 6, and 12 percent - and three target levels o f initial moisture content
( I M C ) 6, 12, and 18 percent. The RSC was based on the ovendry weight o f wood,
and I M C was based on the ovendry weight o f w o o d plus resin. Actual values were
somewhat different from the design values, as described in the flakeboard manufac-
ture section.

Material preparation

Aspen disk-cut flakes, 0.38 by 12.7 by 38.1 mm, were used to m a k e the boards. The
blocks for the flakes were cut from logs without regard to annual ring orientation. The
flakes were dried in a r o t a r y - d r u m dryer to a b o u t 2 percent moisture content and were
then screened on a 6.35-mm screen. Flakes retained on the screen were stored in
plastic bags. Before mixing a urea-formaldehyde resin solution with the flakes in a
r o t a r y - d r u m blender, the measured moisture content o f the flakes in the bags varied
from 2.4 to 3.7 percent.

Flakeboard manufacture

Dimensions o f the mat-forming box were 30.48 by 35.56 cm. Design thickness of the
b o a r d was 12.7 ram. W i t h a specified target density o f 0.65, the total ovendry weight
o f the flakes and resin solids was 895 g. Thus, when water and resin solution were
mixed with the flakes in the blender to reach a specified I M C value for the mat, the
weight of flakes was adjusted to retain a total weight o f dry w o o d and resin solids of
895 g. Because the a m o u n t o f water a d d e d was based on the estimated moisture
content o f the flakes and the water loss in the blender, the exact design value of the

120
8

6
80
I3.

~4 E
E
40 ~.
G.

O ' ' ' ' ' ' ' J i , , | | i , i , i 1 1 1 , 1 0

40 80 120 160 200 240

Time (s)
Fig. I. Pressure and core temperature over time for mat with initial moisture content of
6.8 percent and resin solids content of 6 percent
76 J.Y. Liu and .I.D. McNatt

25./-.crn
~-5.1cm-~

1 9 T

Fig. 2. Trimmed board marked at 12 loca-

tions for measurement of thickness swelling
and density distribution

I M C was difficult to obtain. Actual average values and value ranges for the three I M C
levels were 7.0 (6.1 to 7.8) percent, 11.0 (9.6 to 11.6) percent, and 15.0 (14.0 to 15.2)
percent 9 The press temperature was 149 ~
M o v e m e n t o f the lower press platen t o w a r d the stationary upper platen in a press
cycle was b r o k e n into two segments, which were controlled by a computer. Sixteen
seconds were required to close the gap between the platens from 76.2 to 17.78 m m and
10 s from 17.78 to 12.7 ram, the design thickness o f the board. The lower platen
remained at that level for a specified period before opening up. The total press time
for the b o a r d s varied from 320 to 570 s. The longer time was used when the I M C was
relatively high to allow the steam to emit from the edges to reduce the risk o f blisters
(blows).
F o u r flakeboards were made for each combination of I M C and RSC values. F o r
each board, d a t a for pressure and core temperature over time were recorded in both
analog and digital forms starting when the gap between the platens was 50 mm. A
sample plot o f these relationships is shown in Fig. 1.
W h e n the flakeboards were removed from the press, they were m a r k e d with a
prefabricated template at 12 evenly distributed locations (Fig. 2). The boards with
resin adhesive were trimmed to 25.4 by 29.2 cm. Those without resin adhesive were
not trimmed to avoid possible disintegration 9

Thickness swelling, weight increase, and density distribution

Altogether, 40 boards with resin and 36 b o a r d s without resin were manufactured over
a period o f 2 weeks. After the boards were removed from the press, they were weighed
and the thickness measured at the 12 locations shown in Fig. 2. Boards were then
transferred to an environmental r o o m at 27 ~ and 80 percent R H , where they were
weighed and their 12 thickness values measured a b o u t once a week for 71 days. By
then, both thickness swelling and weight increase had largely stabilized.
Thickness swelling and density variation in aspen flakeboards 77

Boards that survived conditioning at 27 ~ and 80 percent R H were reconditioned

at 22~ a n d 65 percent R H for several weeks until equilibrium was established.
Boards with 7 a n d 11 percent I M C were then cut into twelve 5.1- by 6.4-cm specimens
so that the m a r k e d location was at the center o f the specimen (Fig. 2). F o r each
specimen, the density was determined by dividing the ovendry weight in grams by the
volume in cubic centimeters. Thus, the density could be taken as the m e a n density o f
the specimen.

Results and discussion

Since press closure was c o m p u t e r controlled, m a x i m u m pressure (and target thick-

ness) for all b o a r d s was reached at 19 s starting from the instant when the gap between
the platens was 5 cm.
Figure 3 presents the m a x i m u m pressure Pm,x at time t = 19 s against I M C for
several R S C values. Overall, Pm,x decreased with increasing I M C . Figure 3 does not
indicate a relationship between Pmax and RSC. A t t = 240 s, the residual pressure Pres
leveled off. Again, P,~s decreased slightly with increasing I M C and was independent
o f RSC. Whereas H u m p h r e y (1982) found that residual pressure for a m a t without
resin was greather than that for a m a t with resin, this is not evident in Fig. 3 for the
conditions in o u r study.
The curve for core temperature over time generally t o o k the shape shown in Fig. 1.
The sharp bend forming the so-called plateau temperature ( H u m p h r e y 1982) near to
the boiling p o i n t o f water was n o t so clearly defined as reported by Strickler (1959)
because o f the small b o a r d size relative to b o a r d edge area for venting.
As expected, relative moisture content o f b o a r d s immediately out o f the press
depended upon initial I M C . Average moisture content o f b o a r d s when removed from

7 RSC
9,'_. (%}
6 ",~ o 9 0 x 6
e+ 8~x o 1 + 12
9+ _,_, "I~ ~
5 §
o + 9 Pmox
~4
,, + T f O:.,gs
,oJ

++
2

"~'l'- [ (t =240s)
, , , , ,
)'6 8 10 12 14 16 18
Moisture content (%)
Fig. 3. M a x i m u m pressure Pm,x at t = 19 s and residual pressure P,e, at t = 2 4 0 s as a function of
initial moisture content for several resin solids content (RSC) values
78 J.Y. Liu and J.D. McNatt

Fig. 4. Cross section of a blister close to surface of flakeboard with 11 percent initial moisture
content and 12 percent resin solids content

the press was 2.0 percent for the 7-percent I M C boards, 3.5 percent for the l l - p e r c e n t
I M C boards, and 4.4 percent for the 15-percent I M C boards.
Stability of boards with no RSC depended very much on IMC. A t 27 ~ and 80
percent R H , those boards with 7 percent I M C became loose in 2 weeks and started
to fall a p a r t in a b o u t 1 month; the boards with 11 percent I M C also became loose in
2 weeks but remained intact during the rest of the test period. Boards with 15 percent
I M C remained intact with glossy surfaces during the entire 71-day conditioning
period. This could have been the results o f better contact between flakes as a result
o f plasticization (Kelley et al. 1987) and the adhesive effect of the lignin, which
became activated at higher moisture contents (Tomimura, M a t s u d a 1986).
Equilibrium moisture contents of all the boards at 80 percent R H were very
consistent, ranging from 11.6 to 13.4 percent and averaging 12.5 percent, based on
ovendry weight o f w o o d plus resin.
A l t h o u g h the vertical moisture movement in the boards could not be monitored
in the manufacturing process, it seemed to be restricted; blisters occasionally ap-
peared close to the surfaces of a number of boards in which 1MC was > 7 percent and
RSC > 6 percent. A cross section through a blister in a board with 11 percent I M C
and 12 percent RSC is shown in Fig. 4; a gap created by trapped steam is visible below
the upper surface o f the board. The blisters could not be totally eliminated by
increasing the pressing time from 320 to 530 s. This observation agrees with that
reported by M a k u et al. (1959), who stated that vertical movement of moisture was
restricted within flake-type particles. Blisters in boards with 0 or 1 percent RSC were
not evident, possibly because moisture movement was not greatly or only slightly
h a m p e r e d by resin adhesive.
Figure 5 presents the thickness changes with time o f a b o a r d with 7 percent I M C
and 6 percent RSC at the 12 locations shown in Fig. 2. After the b o a r d had been
reconditioned at 22 ~ and 65 percent R H until equilibrium, it was cut into twelve 6.4-
by 5.1-cm specimens (Fig. 2). The thickness and density of each piece were measured
Thickness swelling and density variation in aspen flakeboards 79

- - end 8 0 percent RH
Thickness, 27~
------ Thickness,22~ and 6 5 percent RH
qP-.---o Density (basedon ovendry weight)
.•. t 0.86
j\I".
24 / \ /10.82
20
2

~12
,I ! .t " ~
8

2 ,J
i.--
4

0 f
~
1 2
'
3
~
4
L
5
,
6
~

Location number
7
~
8
,
9
, ,
10
,
11
~n0.70
12

Fig. 5. Thickness swelling with time for flakeboard with 7 percent initial moisture content and
6 percent resin solids content at 27 ~ and 80 percent relative humidity (RH) and after condition-
ing at 22 ~ and 65 percent RH. Density values based on initial thickness and ovendry weight
of small specimens (Fig. 2)

and the percentage of residual thickness swelling (springback) recorded (Fig. 5). The
residual thickness swelling curve thus obtained follows essentially the same pattern as
the curves obtained during conditioning o f the b o a r d at 80 percent R H , indicating the
reconditioning and cutting of the b o a r d did not significantly affect the relative thick-
ness changes at the 12 locations. As used here, the term residual thickness swelling
does not refer entirely to springback because initial thickness measurements were
made at a b o u t 2 to 4 percent moisture content and final thickness measurements were
made at a b o u t 8 to 10 percent moisture content. (Moisture contents o f the specimens
after conditioning at 65 percent R H were a b o u t 8 to 10 percent.)
The corresponding density curve shows that density did not bear a definite rela-
tionship to thickness (Fig. 5). The r a n d o m variation of thickness swelling with density
serves to verify the inconsistent findings in the literature that thickness swelling might
or might not increase with increasing density (e.g., Gatchell et al. 1966; Halligan,
Schniewind 1972; Lehmann, Hefty 1973; Stewart, L e h m a n n 1973). It also implies that
the relationship between thickness swelling and density in a b o a r d is much more
complex than that described by Suchsland (1967).
Total thickness swelling at 80 percent R H and residual thickness swelling follow-
ing conditioning at 65 percent R H are presented in Fig. 6 for flakeboards made at 6
and 12 percent R S C and 7, 11, and 15 percent I M C . Boards m a d e with 0 and 1 percent
RSC were excluded because their spongy nature precluded accurate thickness mea-
80 J.Y. Liu and J.D. McNatt

24 Location number

20

~_4
Fig. 6. Thickness swelling over time for
0 i i ! I I I I I several locations (from Fig. 5)
0 10 20 30 40 50 60 70 80
Time (day)

16 Location 5 7

s
10 11

~8

Fig. 7. Thickness swelling over density

at 22 ~ and 65 percent relative humidity
i I I I (from Fig. 5)
0.70 0.74 0.78 0.82 0.86
Density

surements. Each d a t a point is the mean of the average of 12 measurements on each

o f the 4 boards.
Actual average density o f the boards m a d e with 6 or 12 percent RSC ranged from
0.7 to 0.83, which was 8 to 28 percent higher than the target density o f 0.65. Except
for six o f the eight boards m a d e with 7 percent I M C , the range o f density was 0.7 to
0.78. Those six b o a r d s had density values o f 0.81 to 0.83 (Fig. 7). At first glance, Fig. 7
suggests that thickness swelling increased with density. However, a wider range o f
density is needed, especially at the 11 and 15 percent I M C levels, before definite
conclusions can be drawn.
A l t h o u g h we recognize that the boards had small differences in moisture content
prior to conditioning at 80 percent R H , our results nevertheless indicate the follow-
ing:
1. A t 7 percent m a t I M C , thickness swelling was reduced considerably by increasing
resin content from 6 to 12 percent.
Thickness swelling and density variation in aspen flakeboards 81

2. At both 6 and 12 percent RSC, thickness swelling was reduced considerably by

increasing mat I M C from 7 to 11 percent.
3. At 11 and 15 percent mat IMC, thickness swelling varied little for both RSC levels.
These observations reflect the positive influence of increasing resin content and
initial moisture content on flake bonding. Our results also indicate that this beneficial
effect is limited beyond certain RSC or I M C levels. This agrees with L e h m a n n ' s
findings (1973).
As would be expected, residual thickness swelling, as we have defined, followed a
similar pattern.

Conclusions

U n d e r the environmental conditions prescribed for this study, initial m a t moisture

content and resin solids content affect the thickness swelling and density of lab-made
aspen flakeboards as follows:
1. M a x i m u m pressure on the m a t and residual pressure near the end of the press cycle
both decrease with increasing mat moisture content.
2. Density and thickness swelling at 80 percent relative humidity vary from point to
point in the plane of the board, but they do not bear a definite relationship to each
other.
3. Because flake plasticization increases at high initial moisture content and internal
b o n d increases at high resin content, more thickness swelling occurs in boards with
a low percentage of initial moisture content and resin content.

References

Beech, J. C. 1975: The thickness swelling and wood particleboard. Holzforschung 29:11-18
Gatchell, C. J.; Heebink, B. G. ; Hefty, F. V. 1966: Influence of component variables on proper-
ties of particleboard for exterior use. Forest Prod. J. 16(4): 46-59
Halligan, A. E; Schniewind, A. P. 1972: Effect of moisture on physical and creep properties of
particleboard. Forest Prod. J. 22(4): 41-48
Humphrey, P. E. 1982: Physical aspects of wood particleboard manufacture. Ph.D. thesis,
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82 J.Y. Liu and J.D. McNatt

Maku, T.; Hamada, R. ; Sasaki, H. 1959: Studies on the particleboard (chipboard). IV. Temper-
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hardwood flakes. Forest Prod. J. 23(8): 52-60
Strickler, M. D. 1959: Effect of press cycles and moisture content on properties of Douglas-fir
flakeboard. Forest Prod. J. 9 : 2 0 3 - 2 1 5
Suchsland, O. 1959: An analysis of the particleboard process. Quarterly Bull. of the Michigan
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(Received June 7, 1989)

Jen Y. Liu
J. D. McNatt
USDA Forest Service
Forest Products Laboratory
One Gifford Pinchot Drive
Madison WI 53705-2398
USA