High flow urea-formaldehyde powders for particleboard and fiberboard manufacture

Patent metadata

Field	Value
Publication number	US-9975271-B2
Application number	US-201615161864-A
Country	US
Kind code	B2
Filing date	May 23, 2016
Priority date	Mar 14, 2013
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

Particulate binder compositions made with amine-aldehyde resins and methods for making same are provided. The method for making the particulate binder composition can include spray-drying an amine-aldehyde resin having a total aldehyde compound to total amine compound molar ratio of about 1.55:1 to about 1.65:1 to produce a particulate binder composition. The particulate binder composition can have a fusion diameter of about 35 mm to about 70 mm.

First claim

What is claimed is:

1. A composite product, comprising: a plurality of substrates and an at least partially cured binder, wherein the binder, prior to curing, comprises a particulate binder comprising an amine-aldehyde resin having a total aldehyde compound to total amine compound molar ratio of about 1.55:1 to about 1.65:1, and wherein the particulate binder has a fusion diameter of about 35 mm to about 70 mm.

2. The composite product of claim 1 , wherein the particulate binder has a fusion diameter of at least 40 mm to about 70 mm.

3. The composite product of claim 1 , wherein the particulate binder has a stroke cure time of about 30 seconds to about 50 seconds.

4. The composite product of claim 1 , wherein the particulate binder has an average particle size of about 0.1 μm to about 150 μm.

5. The composite product of claim 1 , wherein the particulate binder has a packed bulk density of about 0.3 g/cm 3 to about 0.8 g/cm 3 .

6. The composite product of claim 1 , wherein the amine-aldehyde resin comprises a urea-formaldehyde resin, a melamine-formaldehyde resin, or a melamine-urea-formaldehyde resin.

7. The composite product of claim 1 , wherein the amine-aldehyde resin comprises a urea-formaldehyde resin.

8. The composite product of claim 1 , wherein the plurality of substrates comprises glass, carbon, lignocellulose, a polymer, gypsum, metal, cement, or any mixture thereof.

9. The composite product of claim 1 , wherein the plurality of substrates comprises lignocellulose, and wherein the composite product is a particleboard, a fiberboard, a waferboard, an oriented strand board, a plywood, or a laminated veneer board.

10. A process for making a composite product, comprising: at least partially curing a particulate binder in a mixture comprising the particulate binder and a plurality of substrates to produce the composite product, wherein the particulate binder comprises an amine-aldehyde resin having a total aldehyde compound to total amine compound molar ratio of about 1.55:1 to about 1.65:1, and wherein the particulate binder has a fusion diameter of about 35 mm to about 70 mm.

11. The process of claim 10 , wherein the particulate binder has at least one of:
a fusion diameter of about 40 mm to about 70 mm;
a stroke cure time of about 30 seconds to about 50 seconds;
an average particle size of about 0.1 μm to about 150 μm; and
a packed bulk density of about 0.3 g/cm 3 to about 0.8 g/cm 3 .

12. The process of claim 10 , wherein the amine-aldehyde resin comprises a urea-formaldehyde resin, a melamine-formaldehyde resin, or a melamine-urea-formaldehyde resin.

13. The process of claim 10 , wherein at least a portion of a liquid medium is removed from a liquid mixture comprising the liquid medium and the amine-aldehyde resin to produce the particulate binder, wherein the liquid medium comprises water, methanol, acetonitrile, or any mixture thereof, and wherein the liquid medium is removed from the liquid mixture by spray-drying, freeze drying, vacuum drying, precipitation, air drying, or dry spinning.

14. The process of claim 10 , wherein the plurality of substrates comprises glass, carbon, lignocellulose, a polymer, gypsum, metal, cement, or any mixture thereof.

15. The process of claim 10 , wherein the mixture is heated to a temperature of about 100° C. to about 250° C. to at least partially cure the particulate binder.

16. A composite lignocellulose product, comprising: a plurality of lignocellulose substrates bound together with an at least partially cured binder, wherein the binder, prior to curing, comprises a particulate binder comprising an amine-aldehyde resin having a total aldehyde compound to total amine compound molar ratio of about 1.55:1 to about 1.65:1, and wherein the particulate binder has a fusion diameter of about 35 mm to about 70 mm.

17. The composite lignocellulose product of claim 16 , wherein the composite lignocellulose product is a particleboard, a fiberboard, a waferboard, an oriented strand board, a plywood, or a laminated veneer board.

18. The composite lignocellulose product of claim 17 , wherein the amine-aldehyde resin comprises a urea-formaldehyde resin.

19. The composite lignocellulose product of claim 18 , wherein the particulate binder has a stroke cure time of about 30 seconds to about 50 seconds.

20. The composite lignocellulose product of claim 19 , wherein the particulate binder as a fusion diameter of about 40 mm to about 70 mm.

Assignees

• Georgia Pacific Chemicals Llc

Inventors

• Breyer Robert A
• Krauth Tyler
• Cothran John D
• Baxter Paul S
• Cribb Ashlee

Classifications

• B27N3/002 Primary

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

• C08J2361/24

  with urea or thiourea · CPC title

• B27N3/00

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

• C08J3/122 Primary

  Pulverisation by spraying · CPC title