Abstract: A method of forming a composite panel or board includes the step of adding phyllosilicate clay to a thermosetting resin and natural fibres. The natural fibres include hardwood fibre, softwood fibre, grain straw, hemp fibre, kenaf fibre, bagasse fibre, palm fibre, canola straw fibre, flax straw fibre, rapeseed straw fibre, wheat straw fibre, oat straw fibre, barley straw fibre, rice straw fibre or rye straw fibre. The thermosetting resin may include phenol formaldehyde, urea formaldehyde, melamine formaldehyde, melamine urea formaldehyde, or methylenediphenyl diisocynanate. The phyllosilicate clay may include nanoparticulate clay and may include natural, modified or synthetic forms of sodium montmorillonite, montmorillonite, nontronite, beidellite, volkonskoite, laponite, hectorite, saponite, sauconite, magadite, kenyaite, stevensite, vermiculite, halloysite, or hydrotactite.

Abstract: About 78.0-91.4% refined lignocellulosic fibres were blended with 8.0-12.0% formaldehyde-based resin, 0.5-2.0% wax and 0.1-8.0% oil in a blowline or a blender before mat forming and panel pressing. Fibres can be from cereal straws or wood species. Wax can be slack or emulsified wax. Oil is selected from different groups including, but not being limited to, vegetable oils, tree oils and any kinds of oils and oil mixtures which consist of fatty acids with 12 to 24 carbon atoms. Inverse Gas Chromatography (IGC) measurement and MDF panel test results have shown that fibre adhesion characteristics have changed significantly, leading to significant panel internal bond (IB) and dimensional stability improvements.