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Ultra-lightweight foam core particleboards have been produced in a novel one-step process with resinated wood particles for the faces and expandable polystyrene (EPS) as core layer material. The mechanical and physical properties of panels were investigated in terms of the different foam core densities and press parameters (temperature, pressing and foaming time). The bending strength properties of the panels were not significantly changed with increasing foam core density from 80 to 120 kg m -3 . Panels produced at a press temperature of 130°C (1-EPS) have an improved core-face interface and also a denser surface layer, which positively influences the internal bond and thickness swelling. The panels produced at a press temperature of 160°C (2-EPS) have smaller and more foam cells and an improved fusion of foam beads and properties, which have a positive influence on the edge screw withdrawal resistance and water absorption.

Physiomechanical properties of ultra-lightweight foam core particleboard: different core densities