Performance Evaluation of Carbon Fiber Fabric-Reinforced Formaldehyde-Free High-Strength Plywood

Plywood is lightweight, strong, and durable, making it a widely used material in building decoration and furniture areas. In this study, formaldehyde-free, high-strength plywood was prepared through the incorporation of carbon fiber fabrics (CFFs) as reinforcement layers and their bonding with maleic anhydride polyethylene (MAPE) films. Various tests were performed to assess the impact of the carbon fiber fabric positioning on the physical and mechanical properties of plywood, including tensile shear strength, flexural strength, water absorption, thickness swelling, and electro-thermal properties. The results revealed that the plywood with CFFs exhibited significantly higher mechanical properties than plywood without CFFs. Particularly, the addition of CFFs increased the tensile strength of the plywood by nearly 54.43%, regardless of the CFFs' position. The symmetric placement of CFFs near the bottom and upper layers of the plywood resulted in a maximum modulus of rupture of 85.6 MPa. These findings were validated by numerical simulations. Scanning electron microscopy analysis of the plywood microstructures revealed that MAPE penetrated both the vessels and xylem of the wood veneers and the pores of the CFFs, thereby improving the mechanical properties of the plywood. Plywood reinforced with CFFs exhibited increased water absorption and thickness swelling after immersion. Additionally, the placement of CFFs influenced the electro-thermal properties of the plywood. Plywood with CFFs positioned near the bottom and upper surfaces exhibited superior thermal conductivity. Overall, this study presents a feasible method for developing high-performance, formaldehyde-free plywood and sustainable wood-based structural materials with potential applications in geothermal flooring.