Effect of fibre aspect ratio onto the modulus of palm-based medium-density fibreboard

Polyurethane prepolymer (pPU) was used as a binder in the production of palm-based medium-density fibreboard (MDF). Untreated empty fruit bunch fibre (EFB) with three different fibre sizes was used and their effects on the mechanical and thermal properties of the MDF were studied. Palm kernel oil-based monoester polyol (PKO-p), 4,4-diphenylmethane diisocyanate (MDI) and polyethylene glycol 200 (PEG 200) were used to prepare the resin. Acetone was added into the resin as a solvent. Three different fibre sizes were used; 250 µm to 500 µm (MDF S1), 500 µm to 1000 µm (MDF S2) and 1000 µm to 2000 µm (MDF S3). Three points bending test showed that the flexural strength and modulus increased as the EFB fibres size decreased with optimum flexural strength at 46.7 MPa and optimum flexural modulus of 1923 MPa. The results were supported by the morphological study that showed better matrix encapsulation occurred in MDF S1, followed by MDF S2. The scenario was rather different in MDF S3 whereby uneven matrix distribution can be seen obviously with some matrix rich spots were found clearly. Bomb calorimetry analysis had also supported the results showing a decreasing trend in heat of combustion, led by MDF S1, followed by MDF S2 and finally MDF S3.