Modified polyphenol binder compositions and methods for making and using same

Patent metadata

Field	Value
Publication number	US-10738025-B2
Application number	US-201615289521-A
Country	US
Kind code	B2
Filing date	Oct 10, 2016
Priority date	Oct 1, 2012
Publication date	Aug 11, 2020
Grant date	Aug 11, 2020

Abstract

Modified polyphenol binder compositions and methods for making and using same are provided. In at least one specific embodiment, the binder composition can include at least one unsaturated monomer and at least one polyphenolic compound. The polyphenolic compound can include a lignin, a tannin, a novolac resin, a modified phenol formaldehyde resin, bis-phenol A, humic acid, or any mixture thereof.

First claim

What is claimed is:

1. A binder composition, comprising:
a reaction product of an unsaturated monomer and at least two polyphenolic compounds, wherein:
each polyphenolic compound comprises a tannin, a lignin, a novolac resin, a modified phenol formaldehyde resin, bis-phenol A, or humic acid, and
the unsaturated monomer comprises an unsaturated glycidyl ether, an unsaturated glycidyl ester, an unsaturated mono-epoxide, an unsaturated methylol compound, or a mixture thereof, such that:
an ether linkage is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated glycidyl ether, the unsaturated glycidyl ester, or the unsaturated mono-epoxide, or
a carbon-carbon bond is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated methylol compound.

2. The binder composition of claim 1 , wherein the unsaturated monomer comprises an unsaturated glycidyl ether.

3. The binder composition of claim 1 , wherein the unsaturated monomer comprises an unsaturated glycidyl ester.

4. The binder composition of claim 1 , wherein the unsaturated monomer comprises an unsaturated mono-epoxide.

5. The binder composition of claim 1 , wherein the unsaturated monomer comprises an unsaturated methylol compound.

6. The binder composition of claim 1 , wherein the unsaturated monomer further comprises maleic anhydride.

7. The binder composition of claim 1 , wherein a weight ratio of the unsaturated monomer to the at least two polyphenolic compounds, on a solids basis, is about 0.1:100 to about 1:2.

8. The binder composition of claim 1 , wherein a weight ratio of the unsaturated monomer to the at least two polyphenolic compounds, on a solids basis, is about 0.1:100 to about 1:7.

9. The binder composition of claim 1 , wherein each polyphenolic compound comprises a lignin, a novolac resin, a modified phenol formaldehyde resin, or bis-phenol A, and wherein the unsaturated monomer comprises an unsaturated mono-epoxide, an unsaturated methylol compound, or a mixture thereof.

10. The binder composition of claim 1 , wherein the binder composition comprises about 0.05 wt % to about 50 wt % of the unsaturated monomer, based on a solids weight of the at least two polyphenolic compounds.

11. The binder composition of claim 1 , wherein the binder composition comprises about 0.1 wt % to about 15 wt % of the unsaturated monomer, based on a solids weight of the at least two polyphenolic compounds.

12. The binder composition of claim 1 , wherein at least one of the polyphenolic compounds comprises a lignin, a novolac resin, or bis-phenol A.

13. The binder composition of claim 1 , further comprising about 1 wt % to about 80 wt % of water, based on a solids weight of the at least two polyphenolic compounds.

14. A binder composition, comprising water and a reaction product of an unsaturated monomer and at least two polyphenolic compounds, wherein:
each polyphenolic compound comprises a tannin, a lignin, a novolac resin, a modified phenol formaldehyde resin, bis-phenol A, or humic acid, and
the unsaturated monomer comprises an unsaturated glycidyl ether, an unsaturated glycidyl ester, an unsaturated mono-epoxide, an unsaturated methylol compound, or a mixture thereof, such that:
an ether linkage is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated glycidyl ether, the unsaturated glycidyl ester, or the unsaturated mono-epoxide, or
a carbon-carbon bond is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated methylol compound, and
the binder composition comprises about 0.05 wt % to about 50 wt % of the unsaturated monomer and about 1 wt % to about 80 wt % of the water, based on a solids weight of the at least two polyphenolic compounds.

15. The binder composition of claim 14 , wherein at least one of the polyphenolic compounds comprises a lignin, a novolac resin, or bis-phenol A.

16. The binder composition of claim 14 , wherein the binder composition comprises about 0.1 wt % to about 15 wt % of the unsaturated monomer and about 40 wt % to about 70 wt % of the water, based on the solids weight of the at least two polyphenolic compounds.

17. A composite product, comprising:
a plurality of lignocellulose substrates and an at least partially cured binder composition, wherein the binder composition, prior to curing, comprises:
a reaction product of an unsaturated monomer and at least two polyphenolic compounds, wherein:
each polyphenolic compound comprises a tannin, a lignin, a novolac resin, a modified phenol formaldehyde resin, bis-phenol A, or humic acid, and
the unsaturated monomer comprises an unsaturated glycidyl ether, an unsaturated glycidyl ester, an unsaturated mono-epoxide, an unsaturated methylol compound, or a mixture thereof, such that:
an ether linkage is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated glycidyl ether, the unsaturated glycidyl ester, or the unsaturated mono- epoxide, or
a carbon-carbon bond is formed between the unsaturated monomer and one of the at least two polyphenolic compounds when the unsaturated monomer comprises the unsaturated methylol compound.

18. The composite product of claim 17 , wherein the binder composition, prior to curing, comprises about 0.05 wt % to about 50 wt % of the unsaturated monomer, based on a solids weight of the at least two polyphenolic compounds.

19. The composite product of claim 17 , wherein the binder composition, prior to curing, further comprises water, and wherein the binder composition comprises about 0.1 wt % to about 15 wt % of the unsaturated monomer and about 40 wt % to about 70 wt % of the water, based on a solids weight of the at least two polyphenolic compounds.

20. The composite product of claim 17 , wherein the composite product is a particleboard, a fiberboard, a plywood, an oriented strand board, or a laminated veneer board.

Assignees

• Georgia Pacific Chemicals Llc

Inventors

• Hagiopol Cornel
• Atkinson Derek L

Classifications

• C09J163/00

  Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins · CPC title

• C09J161/06

  of aldehydes with phenols · CPC title

• C08G61/12

  Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule · CPC title

• B27N1/02 Primary

  Mixing the material with binding agent (mixing in general B01F) · CPC title

• C07D311/54 Primary

  substituted in the carbocyclic ring · CPC title