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Paper composite panels are a phenolic resin/cellulose composite material made from partially recycled paper and phenolic resin. Multiple layers of paper are soaked in phenolic resin, then molded and baked into net shape in a heated form or press. Originally distributed as a commercial kitchen surface in the 1950s, it has recently been adapted for use in skateboard parks as well as various other applications, such as residential counters, cabinetry, fiberglass cores, guitar fingerboards, signage, exterior wall cladding, and a variety of architectural applications.
There are several manufacturers in North America who use a different composition of materials to form the final product. One composition is cellulose fiber and phenolic resin (a type of polymer) which is combined and baked for a smooth hard surface. The natural fibers are made from plant, animal and mineral sources. However most natural fibers are predominantly cellulosic. [1]
Because of the resin's thermoset properties the resulting cooled material is hard.
It was used for the Boeing 747 for their air tables, hydroforming dyes, vacuum chuck faces, work holders, and proofing materials.[ citation needed ] Architecturally, it is used for countertops. [2] It has also been used for whaleboard in fiberglass boat building. Other commercial uses include cutting boards, prep tables, pizza peels,[ citation needed ] and the dashboard of a pickup truck prototype vehicle. [2]
Since the last quarter of the 20th century, phenolic resin and cellulose based compound materials have been used as an alternative to ebony and rosewood to make stringed instrument fingerboards. [3] From 2012 to 2018 guitarmaker Gibson used Richlite, a paper composite material, for the fingerboard on several top-of-the-line production guitars.
Even if it is formed by laminating many layers of paper together, the finished material appears as a solid, and is not considered to be a sandwich panel. Resistance to high temperatures has been claimed to be up to 350 °F.
Wood is a porous and fibrous structural tissue found in the stems and roots of trees and other woody plants. It is an organic material – a natural composite of cellulose fibers that are strong in tension and embedded in a matrix of lignin that resists compression. Wood is sometimes defined as only the secondary xylem in the stems of trees, or it is defined more broadly to include the same type of tissue elsewhere such as in the roots of trees or shrubs. In a living tree it performs a support function, enabling woody plants to grow large or to stand up by themselves. It also conveys water and nutrients between the leaves, other growing tissues, and the roots. Wood may also refer to other plant materials with comparable properties, and to material engineered from wood, or woodchips or fiber.
Fiber or fibre is a natural or artificial substance that is significantly longer than it is wide. Fibers are often used in the manufacture of other materials. The strongest engineering materials often incorporate fibers, for example carbon fiber and ultra-high-molecular-weight polyethylene.
Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
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 wood, together with adhesives, or other methods of fixation to form composite material. The panels vary in size but can range upwards of 64 by 8 feet and in the case of cross-laminated timber (CLT) can be of any thickness from a few inches to 16 inches (410 mm) or more. These products are engineered to precise design specifications, which are tested to meet national or international standards and provide uniformity and predictability in their structural performance. Engineered wood products are used in a variety of applications, from home construction to commercial buildings to industrial products. The products can be used for joists and beams that replace steel in many building projects. The term mass timber describes a group of building materials that can replace concrete assemblies. Broad-base adoption of mass timber and their substitution for steel and concrete in new mid-rise construction projects over the coming decades could help mitigate climate change.
Phenol formaldehyde resins (PF) or phenolic resins are synthetic polymers obtained by the reaction of phenol or substituted phenol with formaldehyde. Used as the basis for Bakelite, PFs were the first commercial synthetic resins (plastics). They have been widely used for the production of molded products including billiard balls, laboratory countertops, and as coatings and adhesives. They were at one time the primary material used for the production of circuit boards but have been largely replaced with epoxy resins and fiberglass cloth, as with fire-resistant FR-4 circuit board materials.
Lamination is the technique/process of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance, or other properties from the use of the differing materials, such as plastic. A laminate is a permanently assembled object created using heat, pressure, welding, or adhesives. Various coating machines, machine presses and calendering equipment are used.
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.
Zon Guitars is a US manufacturer of bass guitars founded in 1981 by Joseph Zon. The company is known for its use of non-traditional designs and materials. Zon Guitars is associated with endorser and player Michael Manring, who collaborated with the company in the mid-1990s to design the innovative Zon Hyperbass instrument, a bass guitar that enables the player to retune the instrument during play.
A binder or binding agent is any material or substance that holds or draws other materials together to form a cohesive whole mechanically, chemically, by adhesion or cohesion.
Micarta is a brand name for composites of linen, canvas, paper, fiberglass, carbon fiber, or other fabric in a thermosetting plastic. It was originally used in electrical and decorative applications. Micarta was developed by George Westinghouse at least as early as 1910 using phenolic resins invented by Leo Baekeland. These resins were used to impregnate paper and cotton fabric which were cured under pressure and high temperature to produce laminates. In later years this manufacturing method included the use of fiberglass fabric, and other resin types were also used. Today Micarta high-pressure industrial laminates are produced with a wide variety of resins and fibers. The term has been used generically for most resin impregnated fiber compounds. Common uses of modern high-pressure laminates include electrical insulators, printed circuit board substrates, and knife handles.
Fiberboard or fibreboard is a type of engineered wood product that is made out of wood fibers. Types of fiberboard include particle board or low-density fiberboard (LDF), medium-density fiberboard (MDF), and hardboard.
Ebonol is a synthetic material whose name derives from its similarity in appearance, hardness, and stability to ebony wood. Ebonol is used as a substitute for ebony in the construction of stringed and woodwind instruments. The material is particularly well suited for the fingerboards of fretless bass.
A biocomposite is a composite material formed by a matrix (resin) and a reinforcement of natural fibers. Environmental concern and cost of synthetic fibres have led the foundation of using natural fibre as reinforcement in polymeric composites. The matrix phase is formed by polymers derived from renewable and nonrenewable resources. The matrix is important to protect the fibers from environmental degradation and mechanical damage, to hold the fibers together and to transfer the loads on it. In addition, biofibers are the principal components of biocomposites, which are derived from biological origins, for example fibers from crops, recycled wood, waste paper, crop processing byproducts or regenerated cellulose fiber (viscose/rayon). The interest in biocomposites is rapidly growing in terms of industrial applications and fundamental research, due to its great benefits. Biocomposites can be used alone, or as a complement to standard materials, such as carbon fiber. Advocates of biocomposites state that use of these materials improve health and safety in their production, are lighter in weight, have a visual appeal similar to that of wood, and are environmentally superior.
Building insulation materials are the building materials which form the thermal envelope of a building or otherwise reduce heat transfer.
Polymer engineering is generally an engineering field that designs, analyses, and modifies polymer materials. Polymer engineering covers aspects of the petrochemical industry, polymerization, structure and characterization of polymers, properties of polymers, compounding and processing of polymers and description of major polymers, structure property relations and applications.
Parchment paper, or vegetable parchment, is a cellulose-based composite that has been processed to give it additional properties like non-stickiness, grease resistance, and resistance to humidity. It is commonly used in baking as a disposable non-stick, grease resistant surface. It should not be confused with waxed paper, which is paper that has been coated in wax.
Carbon fiber-reinforced polymers, carbon-fibre-reinforced polymers, carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic, also known as carbon fiber, carbon composite, or just carbon, are extremely strong and light fiber-reinforced plastics that contain carbon fibers. CFRPs can be expensive to produce, but are commonly used wherever high strength-to-weight ratio and stiffness (rigidity) are required, such as aerospace, superstructures of ships, automotive, civil engineering, sports equipment, and an increasing number of consumer and technical applications.
Fiberglass reinforced plastic grating is a composite material manufactured by combining a matrix of resin and fiberglass. Fiberglass grating does not corrode like steel grating and is therefore used in corrosive environments to reduce maintenance costs. It is used in a variety of applications including walkways and overhead platforms. FRP grating is a structural product that can be weight-bearing between spans.
Alkenyl succinic anhydrides (ASA) are modified five-membered succinic anhydrides bearing a branched iso-alkenyl chain (C14 to C22). They are colorless, and usually viscous liquids. They are widely used, especially in surface sizing of paper, paperboard, and cardboard, as well as in the hydrophobicization of cellulose fibers. Products treated with it show reduced penetration of aqueous media, such as inks or drinks (like milk or fruit juices).
In materials science, a polymer matrix composite (PMC) is a composite material composed of a variety of short or continuous fibers bound together by a matrix of organic polymers. PMCs are designed to transfer loads between fibers of a matrix. Some of the advantages with PMCs include their light weight, high resistance to abrasion and corrosion, and high stiffness and strength along the direction of their reinforcements.