Everboard

Recycled content board that visually features its source material: polyethylene coated beverage cartons, cups and other paper products. These products, usually containing juice or milk, are made of mostly cellulose fiber 70%, and are reinforced with thin films of low density polyethylene (LDPE) 25% and sometimes foils of aluminum 5%. As carton board is constructed of multiple materials laminated together, it is notoriously hard to recycle. The finished boards have high impact resistance with a rupture modulus of 357 psi (2.5 MPa), high bending strength with a 14,926 (y-axis), 24,815 (x-axis) psi (103 (y-axis), 171 (x-axis) MPa) flexural modulus, high mold resistance rating of 10 out of 10, and no VOC’s (volatile organic compounds). Recycled cartons are cleaned, shredded, and then laid into a sheet form. The sheets of material are stress melted, using heat and pressure to melt the LDPE layers in the carton so that they liquefy and flow throughout the board, bonding the cellulosic fibers together upon solidifying. The finished boards can be processed with standard woodworking tools; and have a load strength of 831 lbf (3696.5 N) with a #6 screw in the 1/2 in (12.7 mm) board. Boards are offered in 4×12 sheets (1.2×3.6 m) at ¼ and ½ in thicknesses (6.4 and 12.7 mm). Only one finish is offered, revealing the core of shredded LDPE coated materials, featuring a combination of both printed or color paper and aluminum in a light beige/orange resin, exact coloration varies based on composition. Varied content sourcing creates multiple finishes, and custom size boards are available upon request. Physical property testing of the 1/4 in (9.5 mm) board has resulted in water vapor transmission of 2.53 perms (1.7 metric perms); and Class C flame spread and smoke index, Class A available upon request. Additionally, the boards are a USDA Certified Biobased Product, and contribute toward LEED Credits. Applications include decorative wallboard, interior wallboards, furniture and point of purchase displays.