Formaldehyde-free high-strength low-density wood biocomposites via corrugation and self-bonding of wooden cell

In alignment with global sustainable development strategies and the growing demand for green manufacturing practices in engineered wood production, an innovative method has been developed for incorporating hot pressing techniques, minimal energy consumption, and the complete elimination of adhesives. This approach achieved a 100% conversion of waste palm wood into sustainable natural biocomposites suitable for use in structures and furniture. Analysis shows that the biocomposites forms strong internal bonding through mechanical “nail like” nanomaterials, ester bonds, and ether bonds. Unlike conventional furniture materials, which rely on hazardous formaldehyde-based adhesives, this biocomposites boasts an internal bonding strength of 1.652 MPa—four times higher than typical materials. Additionally, it is lightweight, with a density of less than 1 g/cm³, offers excellent friction resistance, and is dense with only 0.67% internal porosity. The composite materials eliminate the use of toxic adhesives, addressing concerns regarding potential harmful emissions from formaldehyde-based VOCs and ensuring higher indoor air quality. This surpasses the performance of existing structures and furniture materials that rely on synthetic adhesives. The method achieves a 100% conversion of waste palm wood into biocomposites, offering a cost-effective and profitable alternative. This provides a novel solution for developing new structural and furniture materials.