MECHANICAL PROPERTIES OF GRIDCORETM a one-step forming process.

Additionally, the process could

PANELS (FPL SPACEBOARD) MADE FROM accommodate underutilized fiber sources such as mixed hard-
COMPOSITIONS OF RECYCLED CORRUGATED, woods and wastepaper. These two goals set the stage for
NEWSPRINT AND KENAF several breakthroughs in molded pulp processing technology at
FPL. Subsequent process improvements were developed by
C. Tim Scott Tim Newburn Hunt, Gunderson, Gleisner, and Scott (2-4). One of these
John F. Hunt Julee Herdt improvements was the development of a resilient mold con-
USDA Forest Service Colin Jessop taining an array of hexagonal (hex) pads. Spaceboard panels
Forest Products Laboratory1 Gridcore Systems International made from these hex molds results in the honeycomb rib
Madison, WI 53705-2398 Long Beach, CA 90813 structure shown in Figure 2.

In 1992, the Spaceboard patents (5-9) were licensed for

ABSTRACT specific fields of use in construction and furniture by Gridcore
Systems International (GSI). A Cooperative Research and
Development Agreement (CRADA) was initiated between FPL
and GSI to support the transfer of Spaceboard technology to
GRIDCORETM (FPL Spaceboard) is a three-dimensional, pulp- GSI. The hex mold concept was initially adopted because of
molded sandwich panel made by depositing and densifying a the many desirable features of the honeycomb panels. A
pulp slurry on a specifically designed resilient mold. Unlike significant research effort was undertaken by GSI to produce a
low density pulp-molded products, GRIDCORETM panels can new hex mold that would accommodate their production and
be highly densified to impart significant mechanical properties. marketing needs. Spaceboard panels made from these molds
This paper describes our initial efforts at producing became known as GRIDCORETM panels. In 1993, GSI was
GRIDCORETM panels from blends of old corrugated contain- awarded a grant from the USDA Alternative Agricultural
ers (OCC), old newsprint (ONP), and kenaf. The panels were Resource and Commercialization Center (AARC) to explore the
tested for edge crush strength, flat crush strength, bending commercial potential of producing Spaceboard panels produced
strength, and dimensional stability. The results indicate that from kenaf fiber.
desirable mechanical properties can be achieved from all panel
compositions. This report is a preliminary evaluation of the physical and me-
chanical properties of GRIDCORETM panels produced from
OCC, ONP, and kenaf as part of the AARC-funded study. All
panels were produced and tested at FPL as part of CRADA
BACKGROUND activities.

The development of new process technology to produce struc- TESTS ON GRIDCORETM PANELS
tural products from cellulose pulps has been an active area of
research at the USDA Forest Service, Forest Products Labora- Stock Preparation and Panel Production
tory (FPL). A decade ago, Setterholm (1) introduced the unique
method of forming a three-dimensional, waffle-like structure For this study, hammermilled kenaf stalks were obtained from
from molded wood pulp. He called the board “Spaceboard” KENAF International and shipped to Sprout-Bauer for
because of the open cells or “space” between the ribs of the thermomechanical refining. The hammermilled stalks were
“board” (Figure 1). At the time, Setterholm envisioned produc- soaked in water prior to refining, then fed into a pressurized
ing a Spaceboard panel that would have strength characteristics double-disk refiner at 2.07 bar steam pressure and a 1.5-min
similar to that of corrugated boxboard but could be produced in retention. A 2% sodium hydroxide charge was added to the kenaf
in the eye of the refiner. This first refiner pass resulted in a
shive content of 39% at 653 Canadian standard freeness (CSF).
1 A second refiner run was made in an atmospheric refiner to
The Forest Products Laboratory is maintained in cooperation
lower the shive content to 24% and freeness to 410 CSF. Both
with the University of Wisconsin. This article was written and OCC and ONP pulps were produced by hydropulping each at
prepared by U.S. Government employees on official time, and
3% consistency and 60°C. Neither pulp was refined before use.
it is therefore in the public domain and not subject to copy-
right. All GRIDCORETM panels were formed by the flow-through
The use of trade or firm names is for reader information and method of producing Spaceboard (2,5). This method incorpo-
does not imply endorsement by the U.S. Department of rates an integrated mold in which the hexagonal pads are con-
Agriculture of any product or service. nected to a wire screen (Fig. 3). First, a pulp slurry at 1% con-

1995 Recycling Symposium / 345

 sistency is added to the deckle box, as shown in Figure 3a. With note, however, that bearing strength is directly affected by rib
the aid of an applied vacuum, the water is drawn through the alignment. Strength values can be severely compromised if the
screen. The wet mat is removed from the deckle box while still ribs are even slightly misaligned. To determine the bearing
on the mold. A screen is then placed on the top surface (facing) strength of fully aligned panels, unbonded half-panels or sub-
and the mat is placed in a hot press. As heat and pressure are panels were tested. These values are also listed in Table I.
applied, the hexagonal pads compress and deform laterally, den-
sifying the fiber web or “ribs” (Fig. 3b). Press conditions of Finally, each panel was tested for dimensional changes subject
175°C and 690 kPa were used on all panels. to a 60% variation in relative humidity (30% to 90% RH).
Because of the susceptibility of fiber-based panels to moisture,
Finished panels were nominally 1.2 m by 2.4 m and 9.5 mm particularly when no provision has been made to supplement
thick. Four pulp compositions were chosen for this study: 100% hydroxyl bonding, it is important to characterize dimensional
OCC, 100% kenaf, 50%-OCC/50%-kenaf, and 50%-kenaf/ stability if structural applications are being considered. Linear
25%-GCC/25%-GNP. Both heavy (7.5 kg) and light (5.5 kg) expansion and z-direction expansion were measured for all
panels were made from each composition. Each panel was cut panels (Table I).
into six segments. The segments were then paired and bonded
rib-to-rib to produce a test panel, using polyvinyl acetate CONCLUSIONS
adhesive.
Traditional pulp-molded products, such as egg cartons, are typi-
Tests on Mechanical Properties cally of low density and function primarily as cushioning for
packaging. At the Forest Products Laboratory, the development
Each test panel was cut into three 70-mm-wide strips for bend- of Spaceboard process technology has been an attempt to pro-
ing tests. The remaining 75-mm-wide strip was cut into 75-mm- duce highly densified, three-dimensional structures from paper
square blocks for edge crush and flat crush tests and one pulp. One of these structures is a GRIDCORETM panel. The
75-mm by 250-mm block for linear expansion measurements. hex mold configuration and process conditions used result in
All tests were implemented according to the appropriate ASTM panel facings with specific gravities near 1. At these densities,
standard protocol for sandwich panel construction. significant internal bond strength is developed and mechanical
properties suitable for structural applications can be achieved.
Two bending tests were implemented to determine modulus of For example, from bending tests at 50% RH, calculate MOE
elasticity (MOE), modulus of rupture (MOR), and type of fail- values ranged from 5 GPa for 100% OCC panels to 6 GPa for
ure. A 457-mm span was used for a center-point load bending 100% kenaf panels. The MOR values range from 20 to 35 MPa
test, and a 686-mm span was used for the third-point load bend- for the same respective panels. These values are very near re-
ing test. The width was chosen such that four ribs were aligned ported values for high density hardboard and above the geo-
parallel to the long axis of the beam. The tests revealed that the metric mean for high strength papers. Sheathing grade plywood,
MOE values range from 5 to 6 GPa (Table I) for panels tested at however, has about twice this strength. However, Spaceboard
50% relative humidity (RH) and from 2.5 to 4 GPa at 90% RH. has less than one-half the basis weight of an equivalent
Although most panel types failed in compression, the heavier, thickness of plywood.
blend panels were susceptible to shear stresses and resulted in
shear failures in the ribs, limiting the corresponding MOR One of the most desirable features of the Spaceboard forming
values. process, in terms of recycling, is the ability to tolerate “con-
taminated” fiber sources. The kenaf pulp used in this study had
Edge crush tests were implemented to determine the edge com- a rather high shive content (24%). This shive content is unac-
pression strength of panel blocks. Both gross compression ceptable for making paper but works well in Spaceboard.
strength and facing stresses were calculated and are listed in Therefore, pulps made from agricultural fiber sources such as
Table I. We anticipated an orientation effect as a result of the kenaf need not be reduced to single fibers, reducing both the
hexagonal geometry of the ribs, but this was not apparent in the energy required to produce pulp and damage to fiber integrity.
results. However, the rib structure did influence the type of fail- The ONP used in this study was not deinked. Drainage rates are
ures observed, especially in the light panels. This effect was an important aspect of the Spaceboard process and are affected
due to the lower density regions in the facing over the ribs. by contaminate level and mold design. Provisions can be made
to circumvent these problems.
Flat crush tests were implemented to determine the load bear-
ing potential of the ribs. Table I lists the gross fail stress mea- Although our results show that the mechanical properties of
sured for each panel composition produced. These results show Spaceboard may be suitable for structural applications, there
that panels made from 100% kenaf could sustain bearing stresses are other significant issues that must be addressed before it can
nearly 50% higher than 100% OCC panels. It is important to be used in these applications. Of utmost concern is the issue of

346 / TAPPI Proceedings

durability. To meet code requirements, sheathing panels must
pass a wet/redry cycle. Therefore, wet strength and stiffness
must be imparted to the panels. Other concerns are fire resis-
tance, pest and fungal resistance, and fastening requirements.
These areas are the focus of continued research under CRADA
activities with GSI.

REFERENCES

ACKNOWLEDGMENTS

This material is based upon work supported by the AARC Cen-

ter, U.S. Department of Agriculture, under Venture Capital
Agreement No. 93-AARC-1-0019.

Theodore Laufenberg (FPL), Robert Noble (GSI), and Joseph

Roetheli (AARC) were instrumental in developing the CRADA
and AARC agreements. Technical assistance was provided by
Rollie Gleisner (FPL), Chris Hunt (FPL), Rose Smyrski (FPL),
and Kermit Hovey (GSI).

1995 Recycling Symposium / 347

 Table I - Physical and Mechanical Properties of GRIDCORE
100% OCC 100% KENAF 50% KENAF 50% KENAF
+ 50% OCC + 25% OCC
+ 25% ONP

Basis Weight (kg/m2) 4.3 4.4 4.2 4.0

Thickness (mm)
full panel 17.6 17.9 17.4 18.2
facing 1.85 1.96 1.83 1.78
rib 0.43 0.43 0.30 0.38
Density (g/cc)
full panel 0.24 0.25 0.24 0.22
facing 1.16 1.12 1.15 1.12

3rd point Bending @ 50%RH

MOE (GPa) 5.7 6.2 6.1 5.8
MOR (MPa) 27.2 34.7 25.3 24.1
failure mode comp comp shear shear

Centerpoint Bending @ 50%RH

MOE (GPa) 5.4 5.8 5.7 5.6
MOR (MPa) 24.3 35.7 27.1 29.3
failure mode comp comp shear comp

Centerpoint Bending @ 90%RH

MOE (GPa) 3.2 4.3 3.3 4
MOR (MPa) 12.9 24 16.1 19.3
failure mode comp comp shear comp

Edge Crush Test @ 50%RH

gross fail stress (kPa) 3.1 4.8 4.3 3.6
facing stress (MPa) 14.8 21.9 20.3 18.5

Edge Crush Test @ 90%RH

gross fail stress (kPa) 2.3 4.6 3.3 2.9
facing stress (MPa) 11.9 21.5 15.9 14.6

Flat Crush Test @ 50%RH

gross fail stress (kPa)
combined panel 403 442 280 338
sub-panel 398 634 470 521

Linear Expansion (%) 0.15 0.21 0.18 0.16

Thickness Swell (%) 1.5 1.5 1.4 1.3

348 / TAPPI Proceedings

1995 Recycling Symposium / 349
 TM
Fig. 2. GRIDCORE hex mold and panel.

350 / TAPPI Proceedings

Fig. 3. Spaceboard forming process: (a) fiber is deposited on the mold as water drains through the wire screen;
(b) hexagonal pads deform laterally, densifying the webbing when normal pressure is applied.

1995 Recycling Symposium / 351

 Technologoy Park/Atlanta
P.O. Box 105113
Atlanta, GA 30348-5113, USA