Cellulose nanocrystals - thermoset resin systems, applications thereof and articles made therefrom

Patent metadata

Field	Value
Publication number	US-2016002462-A1
Application number	US-201414768137-A
Country	US
Kind code	A1
Filing date	Feb 14, 2014
Priority date	Feb 15, 2013
Publication date	Jan 7, 2016
Grant date	—

Abstract

The present describes wood adhesives reinforced with cellulose nanocrystals (CNC), in liquid and powder forms in which resin system are a phenol-formaldehyde polymer and/or lignin-phenol-formaldehyde polymer and polymeric methylene diphenyl diisocyanate (pMDI), and a method of making this polymer in liquid and powder from and the composite products that can be produced therefrom.

First claim

1 . A thermoset resin system for a wood adhesive comprising:
a thermoset resin, a cellulose nanocrystal, and 30 to 60% weight of moisture, wherein the cellulose nanocrystal is reinforcing the phenolic thermoset resin system, comprising a weight ratio of hydroxide to phenol from 0.03:1 to 0.3:1.

2 . The system of claim 1 , wherein the thermoset resin is a phenolic powder for at least one of wood or molded products.

3 . (canceled)

4 . A thermoset resin system comprising
a phenolic component, a formaldehyde component, and a cellulose nanocrystals, comprising a weight ratio of hydroxide to phenol from 0.03:1 to 0.3:1.

5 . The system of claim 4 , wherein the system comprises from 4 to 6% weight of moisture per resin system.

6 . The system of claim 4 , wherein the system comprises from 0.5 to 4% weight of cellulose nanocrystals per resin system.

7 . The system of claim 4 , wherein the phenolic component is phenol.

8 . The system of claim 4 , wherein the phenolic component is phenol and lignin.

9 . The system of claim 8 , comprising a molar ratio of formaldehyde:phenol component from 1.8:1 to 3:1.

10 . (canceled)

11 . The system of claim 4 , wherein the system comprises 35 to 55% weight of solids in the resin system, a % weight of moisture and the cellulose nanocrystals is incorporated into an intimate contact with the system, whereby the incorporation is through in-situ polymerization.

12 . The system of claim 11 , wherein the system comprises from 40 to 45% weight solids per resin system.

13 . The system of claim 11 , wherein the system comprises from 0.5 to 1% weight of cellulose nanocrystals per resin system.

14 . The system of claim 11 , wherein the phenolic component is phenol.

15 . The system of claim 11 , wherein the phenolic component is phenol and lignin.

16 . The system of claim 15 , comprising a molar ratio of formaldehyde:phenol component of from 1.8:1 to 3:1.

17 . (canceled)

18 . A method of producing a liquid resin adhesive system comprising the steps of:
providing a phenolic compound; providing a formaldehyde compound; providing a cellulose nanocrystals; providing an alkaline hydroxide; mixing the phenolic compound and the cellulose nanocrystals with water and the alkaline hydroxide at a constant temperature making a phenolic blend; methylolation of the phenolic blend by adding the formaldehyde compound to the phenolic blend to start the polymerization through condensation and controlling the temperature producing a reaction mixture; and stopping the polymerization by cooling the reaction mixture until the mixture reaches a specific viscosity.

19 . The method of claim 18 , further comprising adding more formaldehyde and/or alkaline hydroxide to the reaction mixture during the polymerizing step.

20 . A method for producing a powder resin adhesive system comprising the steps of
providing a phenolic compound; providing a formaldehyde compound; providing a cellulose nanocrystals, providing an alkaline hydroxide, mixing the phenolic compound and the formaldehyde compound with water at a constant temperature making a resin mix having a specified solids weight % in the mix; polymerizing the resin mix by adding the alkaline hydroxide to the resin mix to start the polymerization and controlling the temperature producing a reaction mixture; monitoring and adjusting the temperature and pH of the reaction mixture; stopping the polymerization by cooling the reaction mixture until the mixture reaches a specific viscosity and an alkaline pH to produce a phenolic resin, mixing the cellulose nanocrystals with the phenolic resin and drying the phenolic resin to produce the powder.

21 . The method of claim 20 , wherein the phenolic compound is at least one of phenol or lignin.

22 . The method of claim 20 , wherein the formaldehyde is a para-formaldehyde.

23 . An oriented strand board or a plywood produced with the resin system defined in claim 3 .

24 . (canceled)

25 . (canceled)

26 . (canceled)

27 . (canceled)

28 . (canceled)

29 . (canceled)

30 . The system of claim 4 , wherein the system comprises 2 to 8% weight of moisture per resin system.

Assignees

• Fpinnovations

Inventors

• Zhang Yaolin
• Kouisni Lamfeddal
• Wang xiang-ming
• Paleologou Michael
• Feng Martin W
• Brunette Gilles
• He Guangbo
• Wan Hui
• Alemdar-Thomson Ayse

Classifications

• C08L97/02 Primary

  Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)} · CPC title

• C08L1/02

  Cellulose; Modified cellulose · CPC title

• C08L61/12 Primary

  with polyhydric phenols · CPC title

• C09J197/005

  Lignin · CPC title

• C08L1/04

  Oxycellulose; Hydrocellulose {, e.g. microcrystalline cellulose} · CPC title