Method of applying a binder composition to a lignocellulosic substrate

Patent metadata

Field	Value
Publication number	US-9771460-B2
Application number	US-201414771829-A
Country	US
Kind code	B2
Filing date	Feb 27, 2014
Priority date	Apr 1, 2013
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

The present invention is directed to a method for adjusting the tack value of a binder material formed from a composition comprising an emulsion that comprises an emulsifiable prepolymer that is the reaction product of (i) an isocyanate compound, (ii) a polyol compound, and (iii) a monol compound, and wherein the method comprises: (a) determining a desired tack profile for the emulsion, wherein the tack profile comprises a tack value ranging from 1 to 4 as measured by the TACK TEST METHOD for a particular time value, and adjusting the reactive group ratio of component (i) to (ii) to achieve the desired tack value profile; (b) introducing water to components (i), (ii), and (iii) to form the emulsion composition; and (c) applying the emulsion composition to a lignocellulosic substrate thereby forming a mixture having a moisture water content ranging from 7% to 25% based on the total weight of the mixture.

First claim

What is claimed is:

1. A method for adjusting the tack value of a binder material formed from a composition comprising an emulsion wherein the emulsion comprises water and an emulsifiable prepolymer and wherein the emulsifiable pre-polymer is the reaction product of (i) an isocyanate compound, (ii) a polyol compound, and (iii) a monol compound, the method comprising: (a) determining a desired tack profile for the emulsion, wherein the tack profile comprises a plurality of tack values over a period of time ranging from 0 minutes to 40 minutes and wherein the tack values have a rating ranging from 1 to 4 as measured by the TACK TEST METHOD; adjusting the reactive group ratio of component (i) to (ii) to achieve the desired tack value profile; (b) introducing water to components (i), (ii), and (iii) to form the emulsion composition and forming the emulsifiable prepolymer in situ in the water; (c) applying the emulsion composition to a lignocellulosic substrate thereby forming a mixture having a moisture water content ranging from 7% to 25% based on the total weight of the mixture; and wherein the TACK TEST METHOD comprises the steps of blending wood particles with the emulsion to form a blended material and compressing the blended material to measure the tack value rating; and wherein a tack value rating of 1 represents no tack, 2represents slight tack, 3 represents tack, and 4 represents high tack.

2. The method according to claim 1 , wherein the reactive group ratio of component (i) to (ii) is adjusted prior to step (b).

3. The method according to claim 1 , wherein the method further comprises (d) curing the mixture after step (c).

4. The method according to claim 3 , wherein the method further comprises blending the mixture prior to curing.

5. The method according to claim 4 , wherein the method further comprises adding a secondary additive compound to the mixture prior to curing the mixture.

6. The method according to claim 5 , wherein the secondary additive comprises a release agent, a diluent, or combinations thereof.

7. The method according to claim 1 , wherein the polyol compound comprises a hydrocarbon backbone comprising 4 to 2000 carbon atoms, and wherein no heteroatoms are dispersed between such carbon atoms.

8. The method according to claim 1 , wherein the polyol compound comprises a polyether polyol, polyester polyol, polyalkadiene polyol, or combinations thereof.

9. The method according to claim 1 , wherein component (i) comprises 60 weight % to 95 weight %, component (ii) comprises 1 weight % to 35 weight %, and, when present, component (iii) comprises 1 weight % to 10 weight % based on the total weight of components (i), (ii), and (iii).

10. The method according to claim 1 , wherein the ratio of water to emulsifiable prepolymer ranges from 7:1 to 1:1 based on the total weight of the emulsfiable prepolymer and water.

11. The method according to claim 1 , wherein the emulsifiable prepolymer has an NCO content ranging from 18% to 28% weight percent based on the total weight of the emulsifiable prepolymer.

12. The method according to claim 1 , wherein component (iii) comprises the following chemical structure:
CH 3 —(OCH 2 CH 2 ) n —OH

wherein n is 1 to 34.

Assignees

• Huntsman Int Llc

Inventors

• Moriarty Christopher J

Classifications

• C08G18/7664 Primary

  containing alkylene polyphenyl groups · CPC title

• C08J3/2053 Primary

  the additives only being premixed with a liquid phase · CPC title

• C08G18/6492

  Lignin containing materials; Wood resins; Wood tars; Derivatives thereof · CPC title

• C08G18/12 Primary

  using two or more compounds having active hydrogen in the first polymerisation step · CPC title

• C08G18/48

  Polyethers · CPC title