Compositions that include hydrophobizing agents and stabilizers and methods for making and using same

Patent metadata

Field	Value
Publication number	US-9404221-B2
Application number	US-201314135459-A
Country	US
Kind code	B2
Filing date	Dec 19, 2013
Priority date	Jan 24, 2013
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

Compositions that include hydrophobizing agents and stabilizers and methods for making and using same are provided. In at least one specific embodiment, a composition can include about 40 wt % to about 60 wt % lignosulfonic acid or a salt thereof, about 1 wt % to about 20 wt % of a hydrophobizing agent, and about 20 wt % to about 59 wt % of a liquid medium, where all weight percents are based on the combined weight of the lignosulfonic acid or salt thereof, the hydrophobizing agent, and the liquid medium.

First claim

What is claimed is:

1. A method for making a composite product, comprising:
mixing a plurality of lignocellulose substrates, a binder, and a mixture comprising a lignosulfonic acid or a salt thereof, a hydrophobizing agent, and a liquid medium to produce a resinated furnish, wherein the mixture comprises about 40 wt % to about 60 wt % of the lignosulfonic acid or salt thereof, about 1 wt % to about 20 wt % of the hydrophobizing agent, and about 20 wt % to about 59 wt % of the liquid medium, wherein all weight percents are based on the combined weight of the lignosulfonic acid or salt thereof, the hydrophobizing agent, and the liquid medium; and
heating the resinated furnish to produce a composite product.

2. The method of claim 1 , wherein the binder comprises a free radical precursor.

3. The method of claim 2 , wherein the free radical precursor comprises a mixture of hydrogen peroxide and one or more iron containing catalysts.

4. The method of claim 1 , wherein the binder comprises an isocyanate resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a melamine-formaldehyde resin, a melamine-urea-phenol-formaldehyde resin, or any mixture thereof.

5. The method of claim 2 , further comprising:
maintaining the resinated furnish at a temperature of less than 60° C. for at least 10 minutes; and
heating the resinated furnish to a temperature of at least 60° C. to about 300° C. to produce a composite product having a density less than 1 g/cm 3 and an internal bond strength of at least 0.35 MPa, wherein at least 1 wt % of the one or more free radical precursors is present when the resinated furnish is heated to at least 60° C., based on a dry weight of the plurality of lignocellulose substrates.

6. The method of claim 1 , wherein the hydrophobizing agent comprises one or more rosins, one or more alkyl ketene dimers, one or more alkenylsuccinic anhydrides, one or more paraffin oils, one or more silicone oils, one or more vegetable oils, one or more animal fats, one or more hydrocarbon resins, turpentine, carene, thujene, sabinene, or any mixture thereof.

7. The method of claim 1 , wherein the hydrophobizing agent comprises petroleum wax, montan wax, synthetic wax, carnauba wax, or any mixture thereof.

8. The method of claim 1 , wherein the mixture comprises the salt of the lignosulfonic acid, and wherein the salt of the lignosulfonic acid comprises ammonium lignosulfonate, sodium lignosulfonate, potassium lignosulfonate, calcium lignosulfonate, magnesium lignosulfonate, or any mixture thereof.

9. The method of claim 1 , wherein the binder comprises one or more azo compounds.

10. The method of claim 1 , wherein the liquid medium comprises water, methanol, ethanol, propanol, isopropanol, n-butanol, sec-butanol, isobutanol, tert-butanol, ethylene glycol, dimethyl ether, diethyl ether, tetrahydrofuran, or any mixture of thereof, and wherein the mixture comprises about 48 wt % to about 55 wt % of the lignosulfonic acid or salt thereof, about 1.3 wt % to about 5.5 wt % of the hydrophobizing agent, and about 40 wt % to about 50 wt % of the liquid medium, wherein all weight percents are based on the combined weight of the lignosulfonic acid or salt thereof, the hydrophobizing agent, and the liquid medium.

11. The method of claim 1 , wherein the binder comprises a free radical precursor comprising a mixture of hydrogen peroxide and an iron containing catalyst, wherein the salt of the lignosulfonic acid is present and comprises ammonium lignosulfonate, sodium lignosulfonate, potassium lignosulfonate, calcium lignosulfonate, magnesium lignosulfonate, or any mixture thereof, wherein the hydrophobizing agent comprises a rosin, an alkyl ketene dimer, an alkenylsuccinic anhydride, a paraffin oil, a silicone oil, a vegetable oil, an animal fat, a hydrocarbon resin, turpentine, carene, thujene, sabinene, or any mixture thereof, and wherein the liquid medium comprises water.

12. The method of claim 1 , wherein the binder comprises an isocyanate resin.

13. The method of claim 1 , wherein the lignosulfonic acid or salt thereof comprises ammonium lignosulfonate, the hydrophobizing agent comprises a wax, and the liquid medium comprises water, and wherein the mixture is an emulsion.

14. The method of claim 1 , wherein the mixture comprises at least 50 wt % of the lignosulfonic acid or salt thereof and less than 45 wt % of the liquid medium, based on the combined weight of the lignosulfonic acid or salt thereof, the hydrophobizing agent, and the liquid medium.

15. A method for making a composite product, comprising:
mixing a plurality of lignocellulose substrates, a binder, and an emulsion comprising a lignosulfonic acid or a salt thereof, a hydrophobizing agent, and a liquid medium to produce a resinated furnish, wherein:
the binder comprises an isocyanate resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a melamine-formaldehyde resin, a melamine-urea-phenol-formaldehyde resin, a free radical precursor, or any mixture thereof, and
the emulsion comprises about 40 wt % to about 60 wt % of the lignosulfonic acid or salt thereof, about 1 wt % to about 20 wt % of the hydrophobizing agent, and about 20 wt % to about 59 wt % of the liquid medium, based on the combined weight of the lignosulfonic acid or salt thereof, the hydrophobizing agent, and the liquid medium; and

at least partially curing the binder in the resinated furnish to produce a composite product.

16. The method of claim 15 , wherein:
the binder comprises the free radical precursor, and wherein the free radical precursor comprises a mixture of hydrogen peroxide and an iron containing catalyst,
the hydrophobizing agent comprises one or more rosins, one or more alkyl ketene dimers, one or more alkenylsuccinic anhydrides, one or more paraffin oils, one or more silicone oils, one or more vegetable oils, one or more animal fats, one or more hydrocarbon resins, turpentine, carene, thujene, sabinene, or any mixture thereof,
the emulsion comprises the salt of the lignosulfonic acid,
the salt of the lignosulfonic acid comprises ammonium lignosulfonate, sodium lignosulfonate, potassium lignosulfonate, calcium lignosulfonate, magnesium lignosulfonate, or any mixture thereof, and
the liquid medium comprises water, methanol, ethanol, propanol, isopropanol, n-butanol, sec-butanol, isobutanol, tert-butanol, ethylene glycol, dimethyl ether, diethyl ether, tetrahydrofuran, or any mixture of thereof.

17. A method for making a composite product, comprising:
mixing a plurality of lignocellulose substrates, a binder, and a mixture comprising ammonium lignosulfonate, a hydrophobizing agent, and water to produce a resinated furnish, wherein the mixture comprises about 40 wt % to about 60 wt % of the ammonium lignosulfonate, about 1 wt % to about 20 wt % of the hydrophobizing agent, and about 20 wt % to about 59 wt % of the water, based on the combined weight of the ammonium lignosulfonate, the wax, and the water; and
heating the resinated furnish to produce a composite product.

18. The method of claim 17 , wherein:
the hydrophobizing agent comprises slack wax, paraffin wax, or a mixture thereof,
the binder comprises a free radical precursor comprising a mixture of hydrogen peroxide and an iron containing catalyst, and
the mixture comprises about 45 wt % to about 55 wt % of the ammonium lignosulfonate, about 1 wt % to about 10 wt % of the hydrophobizing agent, and about 40 wt % to about 50 wt % of the water, based on the combined weight of the ammoni

Assignees

• Georgia Pacific Chemicals Llc

Inventors

• Hagiopol Cornel
• Sniady Adam K
• Townsend David F
• Williamson Bobby L

Classifications

• B27N3/00

  Manufacture of substantially flat articles, e.g. boards, from particles or fibres · CPC title

• D21H21/16 Primary

  Sizing or water-repelling agents · CPC title

• D21C9/001

  Modification of pulp properties (purification D21C9/08) · CPC title

• C08L97/02

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

• B27N3/002

  characterised by the type of binder (compositions of macromolecular compounds C08L) · CPC title