Wood adhesive formulation

Patent metadata

Field	Value
Publication number	US-10844223-B2
Application number	US-201514923590-A
Country	US
Kind code	B2
Filing date	Oct 27, 2015
Priority date	Jan 26, 2012
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

A formulation containing (i) a first component formed from at least one isocyanate and at least one polyether and (ii) a second component including at least one amino resin, wherein the amino resin is the condensation product of an aldehyde and at least one of urea, melamine, benzoguanamine, glycoluril, and acetoguanamine. A process for binding lignocellulosic materials using the formulation is also described.

First claim

The invention claimed is:

1. A process for binding a plurality of lignocellulosic materials, comprising combining:
a plurality of lignocellulosic materials; and
(ii) a liquid adhesive formulation obtained by mixing:
(1) a first component which is formed by mixing at least one isocyanate and at least one polyether, wherein said polyether is an alkoxypolyalkylene glycol compound having a molecular weight in the range of 250 to 4000 and contains at least 15% by weight of ethylene oxide groups, based on 100% by weight of the polyether; and wherein the liquid adhesive formulation has an ethylene oxide content of at least 10% based on 100% by weight of the at least one isocyanate and the at least one polyether combined; with
(2) at least one amino resin comprising a condensation product of an aldehyde with a compound selected from the group consisting of urea, melamine, benzoguanamine, glycoluril, acetoguanamine and mixtures thereof, wherein said amino resin is present in an amount of at least 50% by weight based on the weight of the liquid adhesive formulation; and

wherein the polyether is a reaction product of ethylene oxide, propylene oxide and a polyfunctional initiator comprising ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, cyclohexane dimethanol, resorcinol, bisphenol A, glycerol, trimethylolopropane, 1,2,6-hexantriol, pentaerythritol, or mixtures thereof.

2. The process according to claim 1 , wherein said aldehyde is selected from the group consisting of formaldehyde, acetaldehyde, crotonaldehyde, acrolein, benzaldehyde, furfural, or combinations thereof.

3. The process according to claim 1 , wherein the at least one isocyanate is selected from the group consisting of hexamethylene diisocyanate, m- and p-phenylene diisocyanate, tolylene-2,4- and tolylene-2,6-diisocyanate, diphenylmethane diisocyanate in the form of its 2,4′-, 2,2′- and 4,4′-isomers and mixtures thereof, the mixtures of diphenylmethane diisocyanates and oligomers thereof, chlorophenylene-2,4-diisocyanate, naphthylene-1,5-diisocyanate, diphenylene-4,4′-diisocyanate, 4,4′-diisocyanate-3, 3′-dimethyl-diphenyl, 3-methyl-diphenylmethane-4,4′-diisocyanate, diphenyl ether diisocyanate, cyclohexane-2,4- and -2,3-diisocyanate, 1-methylcyclohexyl-2,4- and -2,6-diisocyanate, bis-(isocyanate-cyclohexyl)methane, 2,4,6-triisocyanatotoluene, 2,4,4-triisocyanatodiphenylether, isophorone diisocyanate, butylene diisocyanate, trimethylhexamethylene diisocyanate, isocyanatomethyl-1,8-octane diisocyanate, tetramethylxylene diisocyanate, 1,4-cyclohexanediisocyanate, tolidine diisocyanate, and mixtures thereof.

4. The process according to claim 1 , wherein the at least one isocyanate is present in an amount of at least 0.5% by weight based on the weight of the liquid adhesive formulation.

5. The process according to claim 1 , wherein the at least one polyether is present in an amount of at least 0.01% by weight based on the weight of the liquid adhesive formulation.

6. The process according to claim 1 , wherein the liquid adhesive formulation further comprises at least one additive selected from the group consisting of a hardener, a surfactant, a release agent, a wax, and a pigment.

7. The process according to claim 1 , wherein the liquid adhesive formulation is aqueous.

8. The process according to claim 1 , wherein particles of the plurality of lignocellulosic materials are in the form of granulates, shavings, chips, fibers, strands, spheres, powders, or a combination thereof.

9. The process according to claim 1 , wherein the plurality of lignocellulosic materials include wood, paper, bagasse, straw, flax, sisal, bamboo, coconut, fibers, hemp, rushes, reeds, rice hulls, husks, grass, nutshells, or a combination thereof.

10. The process according to claim 1 , wherein the plurality of lignocellulosic materials comprises wood strands, woodchips, wood fibers, wood shavings, wood veneers, wood wool, cork, bark, sawdust, or a combination thereof.

11. A process for binding a plurality of lignocellulosic materials, comprising:
(i) mixing (1) a first component including at least one isocyanate and at least one polyether and (2) at least one amino resin to form a liquid adhesive formulation, wherein the polyether is a reaction product of ethylene oxide, a polyfunctional initiator, and propylene oxide, and
wherein said polyether is an alkoxypolyalkylene glycol compound having a molecular weight in the range of 250 to 4000 and contains at least 15% by weight ethylene oxide groups, based on 100% by weight of the polyether; and wherein the liquid adhesive formulation has an ethylene oxide content of at least 10% by weight based on based on 100% by weight of the at least one isocyanate and the at least one polyether combined, and
wherein said amino resin is a reaction product of an aldehyde with a compound selected from the group consisting of urea, melamine, benzoguanamine, glycouril, acetoguanamine, and mixtures thereof, and
wherein said amino resin is present in an amount of at least 50% by weight based on the total weight of the liquid adhesive formulation and

(ii) combining the liquid adhesive formulation with a plurality of lignocellulosic materials.

12. The process according to claim 11 , wherein said aldehyde is selected from the group consisting of formaldehyde, acetaldehyde, crotonaldehyde, acrolein, benzaldehyde, and furfural.

13. The process according to claim 11 , wherein the polyether comprises 50% to 73.5% by weight ethylene oxide groups, based on the total weight of the polyether.

14. The process according to claim 11 , wherein the polyfunctional initiator is selected from the group consisting of ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, cyclohexane dimethanol, resorcinol, bisphenol A, glycerol, trimethylolpropane, 1,2,6-hexantriol, pentaerythritol, or combinations thereof.

15. The process according to claim 14 , wherein the polyether is a reaction product of the polyfunctional initiator, ethylene oxide, propylene oxide, and water.

16. The process according to claim 11 , wherein the liquid adhesive formulation is aqueous.

17. The process according to claim 11 , wherein the liquid adhesive formulation further comprises at least one additive selected from the group consisting of a hardener, a surfactant, a release agent, a wax, and a pigment, or combinations thereof.

18. A process for binding a plurality of lignocellulosic materials, comprising combining:
a plurality of lignocellulosic materials; and
(ii) a liquid adhesive formulation obtained by mixing:
(1) a first component which is formed by mixing at least one isocyanate and at least one polyether, wherein said polyether is an alkoxypolyalkylene glycol compound having a molecular weight in the range of 250 to 4000 and contains at least 15% by weight of ethylene oxide groups, based on 100% by weight of the polyether; and wherein the liquid adhesive formulation has an ethylene oxide content of at least 10% based on 100% by weight of the at least one isocyanate and the at least one polyether combined; with
(2) at least one amino resin comprising a condensation product of an aldehyde with a compound selected from the group consisting of urea, melamine, benzoguanamine, glycoluril, acetoguanamine and mixtures thereof, wherein said amino resin is present in an amount of at least 50% by weight based on the weight of the liquid adhesive formulation; and

wherein the polyether comprises 50% to 73.5% by weight ethylene oxide groups, based on 100% by weight of the polyether.

19. A

Assignees

• Huntsman Int Llc

Inventors

• Holvoet Servaas
• Pratelli Daniele

Classifications

• C09J197/02

  Lignocellulosic material, e.g. wood, straw or bagasse · CPC title

• C08G18/4837 Primary

  and other oxyalkylene units · CPC title

• C08G18/10 Primary

  Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step · CPC title

• C08G18/7664

  containing alkylene polyphenyl groups · CPC title

• C08L75/08

  from polyethers · CPC title