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Utilization of kraft lignin in phenol/formaldehyde bonding resins for OSB

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  • Publication Date:
    August 06, 2013
  • معلومة اضافية
    • Patent Number:
      8,501,841
    • Appl. No:
      13/671218
    • Application Filed:
      November 07, 2012
    • نبذة مختصرة :
      A resin for OSB comprising an aqueous resole reaction product of phenol, formaldehyde, alkaline metal hydroxide or carbonate, urea and a degraded lignin polymer having 35-65% solids, a pH of 8-13 and a viscosity 50-1000 centipoises. The phenol and formaldehyde are present in a molar ratio of 1.5 to 3.4 moles formaldehyde to 1 mole phenol and are 40 to 85% of the total solids added to the mixture. In one embodiment they are 50 to 75% of the total solids added to the mixture. The alkaline metal hydroxide or carbonate are 5 to 20% of the total solids added to the mixture. Urea is 5 to 35% of the total solids added to the mixture. The degraded lignin is 5 to 20% of the total solids added to the mixture. A method for making the resin and a product using the resin.
    • Inventors:
      Weyerhaeuser NR Company (Federal Way, WA, US)
    • Assignees:
      Weyerhaeuser NR Company (Federal Way, WA, US)
    • Claim:
      1. A method of manufacturing an aqueous bonding resin, the method comprising: in a first stage, reacting phenol with formaldehyde in the presence of a kraft liquor degraded lignin polymer that is substantially free of sulfonic acid groups, water, and a group 1 alkaline metal hydroxide; wherein the reaction product of the phenol and formaldehyde are 40 to 85% of the weight of the solids in the aqueous bonding resin and the mole ratio of formaldehyde to phenol is 1.5-3.5:1; the group 1 alkaline metal hydroxide is 5 to 20% of the weight of the solids in the aqueous bonding resin; and the kraft liquor degraded lignin polymer is 5 to 20% of the weight of the solids in the aqueous bonding resin; reacting the ingredients at a temperature of 60-100° C. until the viscosity of the mixture is 200-5000 cps; in a subsequent second stage, cooling the mixture to a temperature less than 60° C.; and thereafter adding urea to the first stage reaction product until the viscosity is 50-1000 cps while maintaining the reaction temperature at less than 60° C.
    • Claim:
      2. The method of claim 1 in which the degraded lignin polymer has a moisture content of 15% or more.
    • Claim:
      3. The method of claim 1 in which the degraded lignin polymer has been washed and dewatered.
    • Claim:
      4. The method of claim 1 in which the degraded lignin polymer is readily soluble in a mixture of phenol, formaldehyde and water at a pH greater than 7.5 and temperature greater than 60° C.
    • Claim:
      5. The method of claim 1 in which the final viscosity of the second stage reaction is 100-500 cps.
    • Claim:
      6. The method of claim 1 in which the final viscosity of the second stage reaction is 120-350 cps.
    • Claim:
      7. The method of claim 1 in which water, a group 1 alkaline metal hydroxide, or a combination thereof, is also added in the second stage.
    • Current U.S. Class:
      524/73
    • Patent References Cited:
      2282518 May 1942 Hockwalt
      3076772 February 1963 Christ
      3285801 November 1966 Sarjeant
      5866642 February 1999 McVay et al.
      6632912 October 2003 Sudan
      2002/0065400 May 2002 Raskin et al.
    • Primary Examiner:
      Uselding, John
    • Attorney, Agent or Firm:
      Whalen, Timothy M.
    • الرقم المعرف:
      edspgr.08501841