WO2010130411A1 - Resin with reduced formaldehyde emission - Google Patents
Resin with reduced formaldehyde emission Download PDFInfo
- Publication number
- WO2010130411A1 WO2010130411A1 PCT/EP2010/002890 EP2010002890W WO2010130411A1 WO 2010130411 A1 WO2010130411 A1 WO 2010130411A1 EP 2010002890 W EP2010002890 W EP 2010002890W WO 2010130411 A1 WO2010130411 A1 WO 2010130411A1
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- WO
- WIPO (PCT)
- Prior art keywords
- component
- amino
- mixture
- components
- resin
- Prior art date
Links
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 title claims abstract description 198
- 229920005989 resin Polymers 0.000 title claims description 94
- 239000011347 resin Substances 0.000 title claims description 94
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 claims abstract description 64
- 239000011342 resin composition Substances 0.000 claims abstract description 61
- 239000000463 material Substances 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 25
- 238000004132 cross linking Methods 0.000 claims abstract description 20
- 150000001299 aldehydes Chemical class 0.000 claims abstract description 18
- 239000002245 particle Substances 0.000 claims abstract description 14
- ZNZYKNKBJPZETN-WELNAUFTSA-N Dialdehyde 11678 Chemical compound N1C2=CC=CC=C2C2=C1[C@H](C[C@H](/C(=C/O)C(=O)OC)[C@@H](C=C)C=O)NCC2 ZNZYKNKBJPZETN-WELNAUFTSA-N 0.000 claims abstract description 13
- 125000003277 amino group Chemical group 0.000 claims abstract description 8
- LEQAOMBKQFMDFZ-UHFFFAOYSA-N glyoxal Chemical compound O=CC=O LEQAOMBKQFMDFZ-UHFFFAOYSA-N 0.000 claims description 48
- 239000000203 mixture Substances 0.000 claims description 46
- 229920000877 Melamine resin Polymers 0.000 claims description 23
- XSQUKJJJFZCRTK-UHFFFAOYSA-N urea group Chemical group NC(=O)N XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims description 23
- 239000004202 carbamide Substances 0.000 claims description 22
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 22
- 238000006243 chemical reaction Methods 0.000 claims description 15
- 239000011541 reaction mixture Substances 0.000 claims description 14
- -1 cyclic amino compound Chemical class 0.000 claims description 10
- 239000011094 fiberboard Substances 0.000 claims description 10
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical group C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 claims description 9
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical group O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 claims description 6
- ZHNUHDYFZUAESO-OUBTZVSYSA-N aminoformaldehyde Chemical compound N[13CH]=O ZHNUHDYFZUAESO-OUBTZVSYSA-N 0.000 claims description 5
- 125000004122 cyclic group Chemical group 0.000 claims description 5
- 230000015572 biosynthetic process Effects 0.000 claims description 3
- 239000007795 chemical reaction product Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000000123 paper Substances 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 239000011888 foil Substances 0.000 claims description 2
- 239000011236 particulate material Substances 0.000 claims description 2
- 239000011230 binding agent Substances 0.000 abstract description 5
- 239000003365 glass fiber Substances 0.000 abstract description 4
- 239000011490 mineral wool Substances 0.000 abstract description 3
- 239000011120 plywood Substances 0.000 abstract description 3
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 29
- 229920001807 Urea-formaldehyde Polymers 0.000 description 28
- 235000013877 carbamide Nutrition 0.000 description 21
- 238000006482 condensation reaction Methods 0.000 description 11
- 239000004848 polyfunctional curative Substances 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 239000007787 solid Substances 0.000 description 8
- 239000000243 solution Substances 0.000 description 8
- 238000012360 testing method Methods 0.000 description 7
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 6
- 238000009833 condensation Methods 0.000 description 6
- 239000010954 inorganic particle Substances 0.000 description 6
- 230000009467 reduction Effects 0.000 description 6
- PAWQVTBBRAZDMG-UHFFFAOYSA-N 2-(3-bromo-2-fluorophenyl)acetic acid Chemical compound OC(=O)CC1=CC=CC(Br)=C1F PAWQVTBBRAZDMG-UHFFFAOYSA-N 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 5
- 230000005494 condensation Effects 0.000 description 5
- 238000009472 formulation Methods 0.000 description 5
- 239000000835 fiber Substances 0.000 description 4
- 239000003607 modifier Substances 0.000 description 4
- 239000002023 wood Substances 0.000 description 4
- SXRSQZLOMIGNAQ-UHFFFAOYSA-N Glutaraldehyde Chemical compound O=CCCCC=O SXRSQZLOMIGNAQ-UHFFFAOYSA-N 0.000 description 3
- 230000002378 acidificating effect Effects 0.000 description 3
- 150000001412 amines Chemical class 0.000 description 3
- 238000013459 approach Methods 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 229960000587 glutaral Drugs 0.000 description 3
- 239000011121 hardwood Substances 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000000376 reactant Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- UMHJEEQLYBKSAN-UHFFFAOYSA-N Adipaldehyde Chemical compound O=CCCCCC=O UMHJEEQLYBKSAN-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 239000004971 Cross linker Substances 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 2
- ZRALSGWEFCBTJO-UHFFFAOYSA-N Guanidine Chemical compound NC(N)=N ZRALSGWEFCBTJO-UHFFFAOYSA-N 0.000 description 2
- ICYIIEFSHYSYRV-UHFFFAOYSA-N N-Carbamoylcarbamidsaeure-methylester Natural products COC(=O)NC(N)=O ICYIIEFSHYSYRV-UHFFFAOYSA-N 0.000 description 2
- 229920002531 Rubberwood Polymers 0.000 description 2
- PCSMJKASWLYICJ-UHFFFAOYSA-N Succinic aldehyde Chemical compound O=CCCC=O PCSMJKASWLYICJ-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 125000003172 aldehyde group Chemical group 0.000 description 2
- 229920003180 amino resin Polymers 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000003431 cross linking reagent Substances 0.000 description 2
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 2
- HANVTCGOAROXMV-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine;urea Chemical compound O=C.NC(N)=O.NC1=NC(N)=NC(N)=N1 HANVTCGOAROXMV-UHFFFAOYSA-N 0.000 description 2
- 229940015043 glyoxal Drugs 0.000 description 2
- HHLFWLYXYJOTON-UHFFFAOYSA-N glyoxylic acid Chemical compound OC(=O)C=O HHLFWLYXYJOTON-UHFFFAOYSA-N 0.000 description 2
- 230000007062 hydrolysis Effects 0.000 description 2
- 238000006460 hydrolysis reaction Methods 0.000 description 2
- 239000004849 latent hardener Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 230000007935 neutral effect Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 235000020354 squash Nutrition 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000002195 synergetic effect Effects 0.000 description 2
- 239000003039 volatile agent Substances 0.000 description 2
- FIDRAVVQGKNYQK-UHFFFAOYSA-N 1,2,3,4-tetrahydrotriazine Chemical compound C1NNNC=C1 FIDRAVVQGKNYQK-UHFFFAOYSA-N 0.000 description 1
- SMYUKVKOBVLKIB-UHFFFAOYSA-N 1,3-bis(carbamoylcarbamoyl)urea Chemical compound NC(=O)NC(=O)NC(=O)NC(=O)NC(=O)N SMYUKVKOBVLKIB-UHFFFAOYSA-N 0.000 description 1
- KIFSHYFJRXSDPA-UHFFFAOYSA-N 1,3-dicarbamoyl-1-ethylurea Chemical compound CCN(C(N)=O)C(=O)NC(N)=O KIFSHYFJRXSDPA-UHFFFAOYSA-N 0.000 description 1
- RVSGRNSOKLGTFL-UHFFFAOYSA-N 1,3-dicarbamoyl-1-methoxyurea Chemical compound CON(C(N)=O)C(=O)NC(N)=O RVSGRNSOKLGTFL-UHFFFAOYSA-N 0.000 description 1
- VAHORQSNSHTDDP-UHFFFAOYSA-N 1,3-dicarbamoyl-1-methylurea Chemical compound NC(=O)N(C)C(=O)NC(N)=O VAHORQSNSHTDDP-UHFFFAOYSA-N 0.000 description 1
- KJRROGKYAZGYSP-UHFFFAOYSA-N 1-carbamoyl-3-[2-(carbamoylcarbamoylamino)ethyl]urea Chemical compound NC(=O)NC(=O)NCCNC(=O)NC(N)=O KJRROGKYAZGYSP-UHFFFAOYSA-N 0.000 description 1
- KLVNKESMMYNBSW-UHFFFAOYSA-N 1-carbamoyl-3-ethylurea Chemical compound CCNC(=O)NC(N)=O KLVNKESMMYNBSW-UHFFFAOYSA-N 0.000 description 1
- ARXFNPUIMZCMPW-UHFFFAOYSA-N 1-carbamoyl-3-methylurea Chemical compound CNC(=O)NC(N)=O ARXFNPUIMZCMPW-UHFFFAOYSA-N 0.000 description 1
- FCKJWEBXQFCMPZ-UHFFFAOYSA-N 1-carbamoyl-3-propylurea Chemical compound CCCNC(=O)NC(N)=O FCKJWEBXQFCMPZ-UHFFFAOYSA-N 0.000 description 1
- WWMIMRADNBGDHP-UHFFFAOYSA-N 2-hydroxyhexanedial Chemical compound O=CC(O)CCCC=O WWMIMRADNBGDHP-UHFFFAOYSA-N 0.000 description 1
- NICDGFIIDLQPAF-UHFFFAOYSA-N 2-methylhexanedial Chemical compound O=CC(C)CCCC=O NICDGFIIDLQPAF-UHFFFAOYSA-N 0.000 description 1
- VXYSFSCCSQAYJV-UHFFFAOYSA-N 2-methylpropanedial Chemical compound O=CC(C)C=O VXYSFSCCSQAYJV-UHFFFAOYSA-N 0.000 description 1
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 description 1
- ROOJTHWWUWLYCT-UHFFFAOYSA-N 3-(carbamoylcarbamoyl)-1,1-dimethylurea Chemical compound CN(C)C(=O)NC(=O)NC(N)=O ROOJTHWWUWLYCT-UHFFFAOYSA-N 0.000 description 1
- RDFARSDVIWJBII-UHFFFAOYSA-N 3-carbamoyl-1,1-dimethylurea Chemical compound CN(C)C(=O)NC(N)=O RDFARSDVIWJBII-UHFFFAOYSA-N 0.000 description 1
- ZMGMDXCADSRNCX-UHFFFAOYSA-N 5,6-dihydroxy-1,3-diazepan-2-one Chemical compound OC1CNC(=O)NCC1O ZMGMDXCADSRNCX-UHFFFAOYSA-N 0.000 description 1
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 description 1
- BUTKIOWGLJIVJP-UHFFFAOYSA-N COC(=O)NC(=O)NC(=O)N.NC(=O)N.NC(=O)N.C#C Chemical compound COC(=O)NC(=O)NC(=O)N.NC(=O)N.NC(=O)N.C#C BUTKIOWGLJIVJP-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- WSMYVTOQOOLQHP-UHFFFAOYSA-N Malondialdehyde Chemical compound O=CCC=O WSMYVTOQOOLQHP-UHFFFAOYSA-N 0.000 description 1
- CHJJGSNFBQVOTG-UHFFFAOYSA-N N-methyl-guanidine Natural products CNC(N)=N CHJJGSNFBQVOTG-UHFFFAOYSA-N 0.000 description 1
- 229930040373 Paraformaldehyde Natural products 0.000 description 1
- OOLBRPUFHUSCOS-UHFFFAOYSA-N Pimelic dialdehyde Chemical compound O=CCCCCCC=O OOLBRPUFHUSCOS-UHFFFAOYSA-N 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 150000003863 ammonium salts Chemical class 0.000 description 1
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 1
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 1
- 235000011130 ammonium sulphate Nutrition 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- IZALUMVGBVKPJD-UHFFFAOYSA-N benzene-1,3-dicarbaldehyde Chemical compound O=CC1=CC=CC(C=O)=C1 IZALUMVGBVKPJD-UHFFFAOYSA-N 0.000 description 1
- OHJMTUPIZMNBFR-UHFFFAOYSA-N biuret Chemical compound NC(=O)NC(N)=O OHJMTUPIZMNBFR-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- ZNWNWEHQFXOPGK-UHFFFAOYSA-N decanedial Chemical compound O=CCCCCCCCCC=O ZNWNWEHQFXOPGK-UHFFFAOYSA-N 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- QGBSISYHAICWAH-UHFFFAOYSA-N dicyandiamide Chemical compound NC(N)=NC#N QGBSISYHAICWAH-UHFFFAOYSA-N 0.000 description 1
- SWSQBOPZIKWTGO-UHFFFAOYSA-N dimethylaminoamidine Natural products CN(C)C(N)=N SWSQBOPZIKWTGO-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- WGFXYQVNLZXJJG-UHFFFAOYSA-N ethyl n-(carbamoylcarbamoyl)carbamate Chemical compound CCOC(=O)NC(=O)NC(N)=O WGFXYQVNLZXJJG-UHFFFAOYSA-N 0.000 description 1
- PIHPSKJRLDSJPX-UHFFFAOYSA-N ethyl n-carbamoylcarbamate Chemical compound CCOC(=O)NC(N)=O PIHPSKJRLDSJPX-UHFFFAOYSA-N 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 229940083124 ganglion-blocking antiadrenergic secondary and tertiary amines Drugs 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- NDCAAPXLWRAESY-UHFFFAOYSA-N hexa-2,4-dienedial Chemical compound O=CC=CC=CC=O NDCAAPXLWRAESY-UHFFFAOYSA-N 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910017053 inorganic salt Inorganic materials 0.000 description 1
- 239000002085 irritant Substances 0.000 description 1
- 231100000021 irritant Toxicity 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 150000007974 melamines Chemical class 0.000 description 1
- 125000004184 methoxymethyl group Chemical group [H]C([H])([H])OC([H])([H])* 0.000 description 1
- 125000000325 methylidene group Chemical group [H]C([H])=* 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- WONSNAWCCUUEST-UHFFFAOYSA-N n-(carbamoylcarbamoyl)acetamide Chemical compound CC(=O)NC(=O)NC(N)=O WONSNAWCCUUEST-UHFFFAOYSA-N 0.000 description 1
- OADYBSJSJUFUBR-UHFFFAOYSA-N octanedial Chemical compound O=CCCCCCCC=O OADYBSJSJUFUBR-UHFFFAOYSA-N 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 229920002866 paraformaldehyde Polymers 0.000 description 1
- ZWLUXSQADUDCSB-UHFFFAOYSA-N phthalaldehyde Chemical compound O=CC1=CC=CC=C1C=O ZWLUXSQADUDCSB-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920000768 polyamine Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- HJKODFBJSPEFPW-UHFFFAOYSA-N prop-1-ene-1,1,3-triol Chemical group OCC=C(O)O HJKODFBJSPEFPW-UHFFFAOYSA-N 0.000 description 1
- 239000002516 radical scavenger Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- DUIOPKIIICUYRZ-UHFFFAOYSA-N semicarbazide Chemical compound NNC(N)=O DUIOPKIIICUYRZ-UHFFFAOYSA-N 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000009044 synergistic interaction Effects 0.000 description 1
- KUCOHFSKRZZVRO-UHFFFAOYSA-N terephthalaldehyde Chemical compound O=CC1=CC=C(C=O)C=C1 KUCOHFSKRZZVRO-UHFFFAOYSA-N 0.000 description 1
- RVQZQLYGXXOJIM-UHFFFAOYSA-N tetrauret Chemical compound NC(=O)NC(=O)NC(=O)NC(N)=O RVQZQLYGXXOJIM-UHFFFAOYSA-N 0.000 description 1
- 238000009988 textile finishing Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 150000003918 triazines Chemical class 0.000 description 1
- WNVQBUHCOYRLPA-UHFFFAOYSA-N triuret Chemical compound NC(=O)NC(=O)NC(N)=O WNVQBUHCOYRLPA-UHFFFAOYSA-N 0.000 description 1
- 150000003672 ureas Chemical class 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G12/00—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C08G12/02—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes
- C08G12/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
- C08G12/34—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds and acyclic or carbocyclic compounds
- C08G12/36—Ureas; Thioureas
- C08G12/38—Ureas; Thioureas and melamines
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J161/00—Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
- C09J161/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C09J161/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
- C09J161/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
Definitions
- the invention relates to resin binder compositions that may be used for a wide variety of bonded structures including cellulosic materials such as particle board and plywood, veneer sheets, and non-woven materials such as mineral wool and glass fibers.
- the resin compositions of the invention exhibit very low formaldehyde emissions when used in bonded structures in comparison to resin compositions of the prior art.
- the invention further relates to methods of making such resin compositions, methods of making bonded structures using such resin compositions, and bonded structures bound by such resin compositions.
- Urea-formaldehyde (UF) resins and melamine-formaldehyde (MF) resins are known in the prior art. It was also known to combine melamine with UF resins in order to improve their mechanical properties.
- U.S. Patent No. 5,017,641 attempts to address the formaldehyde emission problem in UF resins by adding ethanedial in an amount between 0.1 and 0.5 moles per mole of urea and a triazine.
- ethanedial in an amount between 0.1 and 0.5 moles per mole of urea and a triazine.
- a 3- to 8-fold reduction in formaldehyde emission (17O 0 C for 7 minutes) was observed as compared to UF resins without ethanedial and triazine.
- the preferred fibrous web products according to that patent emitted between 0.1% and 0.2% formaldehyde by weight of the solid resin during curing.
- Patent application number SI 9800068 takes the same approach of adding ethanedial to UF resins. In both cases, the ethanedial was co-condensed with the formaldehyde and urea.
- An approach for reduction of formaldehyde emissions is the use of formaldehyde scavengers, compounds which react with formaldehyde to form non-volatile compounds.
- Patent application WO 2008026056 describes a resin composition deriving from proteinaceous material which has good reactivity and achieves lowered formaldehyde emission by fast cross-linking at a high degree into hydrolysis resistible network and providing an efficient formaldehyde scavenger at the right time in the application. This system can realize a similar low level of formaldehyde emission but a different technology than used in present invention.
- dialdehydes such as ethanedial as a post-condensation reaction additive
- ethanedial a post-condensation reaction additive
- JP-07- 126596 ethanedial was added to UF resins after the urea and formaldehyde were fully condensed. It is believed that the post-condensation addition of ethanedial improves the curing conditions, thus binding more formaldehyde in the cured resin and allowing less free formaldehyde to be emitted.
- US4,039,496 describes a water soluble textile finishing resin composition
- a water soluble textile finishing resin composition comprising fully etherified substantially fully methylolated melamine resins which is reacted in a separate subsequent step with urea, formaldehyde and glyoxal.
- the resin composition has a relatively low free formaldehyde content and good storage stability.
- a resin composition obtainable by forming a reaction mixture by combining different components (Ia) an amino component having 2-6 amino groups; (Ib) an aldehyde component; (2) a trifunctional amino component; and (3) a crosslinking component for the amino components (Ia) and/or (2), and reacting said mixture at a temperature between 6O 0 C and 120 0 C and at a pH lower than 7.
- the present inventors have surprisingly found a synergistic interaction between a crosslinking agent such as ethanedial and a tri-functional amino component, such as melamine in reducing formaldehyde in amino-formaldehyde resins to a much greater extent than would be expected based on using a crosslinking agent such as ethanedial and a tri-functional amino component, such as melamine, alone or than would be expected when using a resin comprising fully condensated tri-functional amino component such as melamine that can no longer react with the crosslinking component for the trifunctional amino component.
- a crosslinking agent such as ethanedial and a tri-functional amino component, such as melamine
- the amino component (Ia) is an non-cyclic amino compound, i.e. not comprising cyclic groups, whereas component (2) is a cyclic trifunctional amino component.
- the resin composition may comprising an amino- formaldehyde resin reacted with an at least trifunctional amino component and a crosslinker for the trifunctional amino component, preferably a dialdehyde.
- the amino resin is an UF resin
- the trifunctional amino component is melamine
- the dialdehyde is ethanedial.
- the resin in the resin composition preferably does not comprise a substantial amount of components other than the mentioned components Ia, Ib, 2 and 3, in particular the resin is not etherified.
- the amount of component (2) is preferably less than 30%, more preferably less than 25, 15 wt% or even less than 10 or 7% and most preferably less than 5 % (wt to total resin composition in aqueous solution having total resin solids content between 40 and 70wt%).
- the amount of amino-formaldehyde (Ia + Ib) is at least 70 wt%, more preferably at least 80wt%, even more preferably at least 90wt%.
- the methods of the invention include mixing of certain components and submitting them to changed pH and/or temperature conditions, which favor covalent reactions, such as condensation reactions such as between an amino resin with an at least trifunctional amino component and a crosslinker, preferably a dialdehyde.
- a method for making the resin composition according to the invention comprises the following steps in order: providing in a reaction mixture components (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component, and (3) a crosslinking component for the trifunctional amino component; wherein the components Ia, Ib, 2 and 3 are provided in uncondensed form or in pre-condensed form, reacting the reaction mixture at a temperature between 6O 0 C and 120 0 C and at a pH of below 7, stopping the reaction by raising the pH of the reaction product to above 7 and cooling to a temperature of below 60 0 C and optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 60 0 C.
- the reaction is stopped when the mixture has reached a viscosity of at least about 100 cP, measured at 30 0 C using the Brookfield spindle 18.
- the components Ia, Ib, 2 and 3 are provided in the reaction mixture in uncondensed form.
- at least two of the components amino component, aldehyde component, trifunctional amino component, and crosslinking component for the trifunctional amino component may be co- condensed before addition of the remaining components, preferably component (Ia) and/or (2) may be co-condensed with component (Ib) or component (2) may be co-condensed with component (3).
- component (Ia) may be co-condensed with component (Ib).
- the co-condensed means condensed to some partial degree but not fully condensed such that the trifunctional amino component (2) and the crosslinking component for the trifunctional amino component (3) can still react.
- the invention also relates to a bonded structure comprising a particulate material, preferably a cellulosic material, and a resin according to the invention wherein the resin is cured and to the use of such a resin composition as a binder for bonded structures, especially cellulosic products including particle board and plywood, veneer sheets, and non-woven materials such as mineral wool and glass fibers.
- the bonded structures are preferably particle board, preferably medium density fiberboard or paper bonded finish foil.
- the bonded structures according to the invention have very low formaldehyde emission levels of less than 0.3 mg/1, preferably less than 0.2 mg/1, most preferably less than 0.1 mg/1 as measured by the Japanese desiccator method.
- the amino (Ia * ) -Aldehyde (Ib) component [0018]
- the basic component of the resin compositions of the invention is an amino (Ia)- aldehyde (Ib) resin.
- the amino component (Ia) is an non- cyclic amino compound, i.e. not comprising cyclic groups, whereas component (2) is a cyclic trifunctional amino component.
- Component (Ia) is preferably chosen form groups of Urea, Biuret, Triuret, Tetrauret, Pentauret, Hexauret, Methoxycarbonylurea, Ethoxycarbonylurea, tert.-Butylurea, Bis- 1,4- butyldiureid, guanidine and Acetylene-diurea Methoxycarbonylbiuret, Ethoxycarbonylbiuret, 1- Methylbiuret, 1-Ethylbiuret, 1-Propylbiuret, Acetylbiuret, Diacetylbiuret, 1,1-Dimethylbiuret, Ethylendibiuret and/or 1 ,2-Diethylbiuret, 3-Methyltriuret, 3-Ethyltriuret, 3-Methoxytriuret and/or 1,1 -Dimethyltriuret and salts and derivatives thereof.
- the Amino-Aldehyde component is preferably a urea-formaldehyde (UF) resin.
- UF resin used as the major component of the resin composition of the invention can be prepared from urea and formaldehyde monomers in any manner known to those skilled in the art.
- UF reactants are commercially available in many forms. Any form that can react with the other reactants and which does not introduce extraneous moieties deleterious to the desired reaction and reaction product can be used in the preparation of the UF resins of the invention.
- the aldehyde component (Ib) of the invention is preferably formaldehyde.
- Formaldehyde for use in UF resins is commercially available in many forms.
- Paraformaldehyde (solid, polymerized formaldehyde) and formalin solutions (aqueous solutions of formaldehyde, sometimes with methanol, in various concentrations) are commonly used forms as well as UFC (Urea-Formaldehyde-Concentrate) solutions.
- Formaldehyde is also available as a gas. Any of these forms is suitable for use in preparing UF resins.
- Formalin solutions are preferred.
- the amino component (Ia), preferably urea is also available in many forms.
- Solid urea such as prill, and urea solutions, typically aqueous solutions, are commonly available. Urea may be combined with another moiety, most typically formaldehyde and urea-formaldehyde adducts, often in aqueous solution. Any form of urea or urea in combination with formaldehyde is suitable for use in the practice of the invention.
- any of a wide variety of procedures used for reacting the principal urea and formaldehyde components to form a UF thermosetting resin composition also can be used, such as staged monomer addition, staged catalyst addition, pH control, amine modification and the like.
- the urea and formaldehyde are reacted at a mole ratio of formaldehyde to urea in the range of about 1.1 :1 to 4:1, and more often at an F:U mole ratio of about 2.1 :1 to 3.2:1.
- the UF resin is highly water dilutable, if not water soluble.
- thermosetting UF resins are commercially available including those sold by Georgia Pacific Resins, Inc. for glass fiber mat applications, and those sold by Hexion and Dynea. These resins contain reactive methylol groups that upon curing form methylene or ether linkages. Such methylol-containing urea adducts may include N,N'-dimethylol, dihydroxy- methylolethylene. N,N'-bis(methoxymethyl), N,N'-dimethylolpropylene, 5,5-dimethyl-N,N'- dimethylolethylene, N,N'-dimelhylolethylene, and the like.
- UF resins useful in the practice of the invention generally contain 45 to 70 weight percent non-volatiles, preferably 55 to 65 weight percent non-volatiles. They generally have a viscosity of 50 to 600 centipoise, preferably 150 to 400 centipoise. They normally exhibit a pH of 7.0 to 9.0, preferably 7.5 to 8.5. And they often have a free formaldehyde level of not more than about 3.0%, and a water dilutability of 1:1 to 100:1, preferably 5: 1 and above.
- US2004/0082697 describes certain UF and/or MF resin modified inorganic particles wherein lamellar inorganic particles like clay are swollen with a very dilute urea or melamine solution and then reacted with formaldehyde and/or glyoxal to form modified inorganic particles having resin interlaminarly inside the particles. It is noted that the resin of the resin composition according to the invention is formed in the absence of such inorganic particles and is much more concentrated (45 - 70 wt%). The resin composition according to the invention when it is formed does not comprise inorganic particles, but inorganic particles may be added after formation of the resin. These particles are however not interlaminar resin modified.
- the reactants for making the UF resin can, optionally, further include a small amount of a resin modifier such as ammonia, an alkanolamine, or a polyamine such as an alkyl primary diamine (e.g., ethylenediamine (EDA)).
- a resin modifier such as ammonia, an alkanolamine, or a polyamine such as an alkyl primary diamine (e.g., ethylenediamine (EDA)).
- Additional modifiers such as melamine, ethylene ureas, and primary and secondary and tertiary amines, for example, dicyanodiamide, can also be incorporated during manufacturing into the resin composition. Concentrations of these modifiers, when present in the reaction mixture, can be 0.05 to 20 weight percent, based on the total resin solids. These types of modifiers promote hydrolysis resistance, polymer flexibility, and lower formaldehyde emissions in the cured resin.
- Component (2) of resin composition of the invention is an at least trifunctional amine, preferably a cyclic urea, preferably having an aromatic structure, like triazines.
- a particularly suitable component is Melamine (m) (also referred to as (2,4,6-Triamino-l,3,5-triazine; Cyanuro-triamide; Cyanurotriamine; Cyanuramide).
- Melamine is a broadly available chemical, and may be use in the present context in any form, as long as the water solubility and water dispersibility is not compromised.
- Suitable tri-functional amino components include melamine derivatives such as 4,6-Diamino-l,3,5-triazin-2(lH)-one; 6-Amino-l,3,5-triazine-2,4(lH,3H)-dione; N2-(4,6- diamino-l,3,5-triazin-2-yl)-l,3,5-triazine-2,4,6-triamine and l,3,4,6,7,9,9b-Heptaazaphenalene- 2,5,8-triamine. If such materials are used, the molar ratios to other ingredients as will be discussed herein below, might need to be adjusted, and the weight ratios may change. Those of ordinary skill in the art would readily appreciate how to adjust these parameters.
- Component (3) in the resin composition of the invention is a component which can undergo cross-linking reactions with the component (2) in the reaction mixture, the tri-functional amino component.
- Suitable components include components comprising at least one reactive aldehyde group and at least a further reactive groups such as an acidic group, such as glyoxylic acid.
- Other suitable components comprise at least two aldehyde groups, such as tri-aldehydes or di-aldehydes
- Preferred aldehydes are aliphatic. More preferred are short chain C2 to C 12 dialdehydes, so as to not negatively impact the solubility properties, for example, Ethanedial, Butanedial, 2-
- the crosslinking component is in liquid form, such as in aqueous solution.
- Other ingredients such as in aqueous solution.
- Hardener or curing agents may be added just after the condensation reaction between the components la/b, 2 and 3 (step f and g) but imminently before the application to a bondable material.
- latent hardener may be added, which will not induce the curing until they are activated, e.g. after shipment of the resin composition with the latent hardener to the place, where this is combined with the bondable material, and the curing is initiated.
- the hardener or curing agent may be shipped separately to the place of application, and be mixed with the curable resin composition just prior to the application to the bondable material.
- the hardener may be any inorganic salt, for example, ammonium nitrate or ammonium sulfate.
- the hardener is ammonium nitrate present in a quantity of about 0.5% by weight.
- the invention includes a method for manufacturing a resin composition according to the invention comprising the following steps in order: (a) providing at least four components comprising: (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component, and (3) a crosslinking component for the trifunctional amino component.
- the components form a reaction mixture wherein the components Ia, Ib, 2 and 3 can be provided in uncondensed form or in part in pre-condensed form.
- the pre-condensed form can be prepared according to steps (b) to (e); (b) combining at least two of the at least four components having amino and aldehyde reactive groups to form a first mixture, (c) adjusting the pH of the first mixture to between 2-10 to allow formation of covalent bonds between the components in the first mixture;(d) heating the first mixture to a temperature between 60 0 C and 100 0 C; (e) adding the remaining of the at least four components that were not added in step (b) to form the second mixture.
- the second mixture is uncondensed or in part pre-condensed but does not comprise fully condensed amino formaldehyde resin,
- the full condensation reaction is done by (f) adjusting the temperature of the second mixture to between 60 0 C and 120 0 C; (g) adjusting the pH of the second mixture to below 7 to start the reaction. When the desired viscosity of preferably at least lOOcP at 3O 0 C is achieved (Brookfield spindle 18); (h) stopping the reaction by raising the pH of the mixture to above 7 and by (i) adjusting the temperature of the mixture to less than about 60 0 C, (j) optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 60°C.
- a first particular execution of this method comprises adding a crosslinking component such as a dialdehyde or a mixture of a crosslinking component such as a dialdehyde and an aldehyde component such as formaldehyde to a solution of an aldehyde such as formaldehyde.
- a crosslinking component such as a dialdehyde or a mixture of a crosslinking component such as a dialdehyde and an aldehyde component such as formaldehyde
- the pH is adjusted to 4-10 before or after subsequent addition of the amino component and a trifunctional amino component such as a triazine.
- step (b) comprises combining the aldehyde and amino components
- step (e) comprises adding the crosslinking component and the trifunctional amino component.
- the condensation reaction in the mixture is done by heating to 60- 120°C. The pH is lowered below 7.0 into acidic/slight acidic range for condensation. The condensation reaction is allowed to proceed until a predetermined viscosity is reached, after which pH is adjusted back above 7.0 to neutral to slightly alkaline condition in order to halt the condensation reaction. A second or third or greater quantity of urea may be added in stages, depending on the desired properties of the final resin product. Finally, the mixture is cooled and the pH is adjusted to basic, for example, 7-1 1. Those who are skilled in the art will readily appreciate that there are alternative orders to add the components.
- the resin compositions of the invention are particularly useful resin compositions, and in particular as resin compositions allowing the manufacturing of bonded structures exhibiting very low formaldehyde emissions, when the four key components as described above (such as urea, formaldehyde, dialdehyde and triazine) are combined and optionally covalently reacted such as co-condensed.
- the condensation and addition reactions before the curing upon the application to the bondable material should not be complete or excessive, but just to a degree that the resin is still water soluble and/or dilutable or capable of forming a stable dispersion.
- the resin compositions of the invention preferably have a free formaldehyde content of less than 0.01- 0.8% by weight of solid content, preferably less than 0.5%, more preferably less than 0.2% and most preferably less than 0.1% as determined by titration on the uncured resin composition.
- a free formaldehyde content of less than 0.01- 0.8% by weight of solid content, preferably less than 0.5%, more preferably less than 0.2% and most preferably less than 0.1% as determined by titration on the uncured resin composition.
- the degree of reaction such as of the condensation is such that essentially all of the resin is reacted into oligomers but not into the completely cured polymeric network as can be found in the final bonded structure.
- the degree of reaction such as of the condensation may be measured by the viscosity of the resin during the reaction or condensation.
- the viscosity at which it is preferable to stop the condensation reaction is at least 100 cP, measured by means of a Brookefield® viscosimeter at 30°C with spindle No 18.
- the physical properties of the resin can typically be readily adjusted to be comparable to the ones of conventional resins.
- the resulting resins exhibit a good water dilutability, and their viscosity may thus be adjusted by adding or evaporating water.
- the resulting resins are storage stable. Other properties of the resin may vary according to the application and the bondable material.
- the present invention includes application of the resin to a bondable material and the forming of the bonded structure.
- Resin compositions as described above which may be produced according to the processes as described in the above may be applied in a broad range of applications to create bonded structures.
- the condensed resin compositions are added in the uncured state to bondable material. Upon curing of the resin, the bonded structure is created.
- the resin composition as described may replace conventional UF resins in any useful application. They may even broaden the application field to areas in which conventional UF resins are not considered for due to their high formaldehyde emissions, even if such emissions are reduced as compared to pure or unmodified UF resins.
- the present invention is particularly useful in the context of bonding cellulosic based materials. Such materials may be wood fibres, chips, particles, sheets or the like, which then may be formed into boards, such as fiber boards, MDF boards, HDF, OSB boards, glue-lam, form-bent, parquet and the like, as well known to a person skilled in the art, and the resin compositions according to the present invention may be the binder in such structures. Such materials may also be essentially solid wood pieces, such as to form beams or form pressing structures or slices, such as veneers, and the resin composition may be the adhesive in such structures.
- the resins of the invention may also be used for resin impregnated webs, such as paper webs and overlays.
- the resins of the present invention are further particularly useful in the context of bonding non-woven structures. Such structures may be based on discrete or essentially endless fibres of thermoplastic or thermoset materials, but may also be based on mineral, glass, or similar materials. Yet a further application is to use the resins according to the present invention with sand or sand-like materials such as in foundry applications.
- the present invention may further be applied to the making of abrasive articles, whereby abrasive particles are bonded to a carrier.
- the present invention can further be applied to the making of foamed structures, where by the resin may brought into a foam structure by conventional means and be cured.
- the present invention includes any combination of such materials, such as when veneers are bonded to a fiber board, and a composition according to the present invention may be the binder of the fiber board and the same or a different composition may be the adhesive.
- the properties of the resin composition may be suitably modified to allow good application.
- modification may relate to adjusting viscosity or concentration depending on the application technology, such as coating, spraying, or soaking.
- the resin penetrates into the structure or components of the structure, such as into solid wood, into wood pieces, chips, strands or fibers, etc.
- the bonded material is typically brought into a form corresponding to the desired form of the bonded structure, and to resin composition is added prior to or after this forming.
- the wooden fibres are mixed with the resin composition, which might already comprise a hardener, and the mixture is brought into a board form and - e.g. by temperature - curing is initiated.
- the curing step accomplishes the forming of the final polymeric network structure and in the resins of the invention causes efficient and relatively complete formaldehyde bonding within the polymeric network structure.
- F:(NH 2 ) 2 indicates the Formaldehyde to amino (urea) ratio, not including the amino groups added with Melamine.
- Mel% indicates the percentage of melamine by weight of the resin composition
- ED% indicates the weight percent added to the liquid resin of ethanedial.
- control resins were used to make samples of particle board using a rubberwood and hardwood particle blend.
- Formaldehyde emissions from the particle board samples were measured using the Japanese standard dessicator method for determining formaldehyde emission
- the resins were prepared as follows. The 50% w/w mixture of ethanedial and formaldehyde was added to a solution of formaldehyde. The pH was adjusted to be slightly basic. Urea and melamine were added to the solution. The mixture was heated to 80°C, and the pH was adjusted to 5.5-5.6. The condensation reaction was allowed to proceed until a viscosity of between 200 and 300 cP (measured at 30 0 C) was reached, after which pH was adjusted back above 7.0 to neutral to slightly alkaline condition in order to halt the condensation reaction. Second and third quantities of urea were added in stages, and the mixture was cooled and the pH was adjusted to basic. Resins were prepared according to the formulations in Table 3.
- each resin was used to prepare a sample of medium density fiberboard (MDF) using rubberwood fibers and 0.5% Ammonium Nitrate was added as a hardener.
- MDF medium density fiberboard
- Ammonium Nitrate was added as a hardener.
- Resin load is weight of resin per total weight of the MDF sample.
- dialdehydes may be used to make the resin compositions of the invention.
- pentanedial was used.
- Resins were prepared according to the formulations in Table 5.
- the resins were prepared according to the method described in Example 1. Each resin was used to prepare a sample of medium density fiberboard (MDF) using mixed tropical hardwood fibers, and 0.5% Ammonium Nitrate was added as a hardener. Formaldehyde emissions and internal bond strength were measured, and the results are presented in Table 6.
- MDF medium density fiberboard
- the resins were prepared according to the method described in Example 1. Each resin was used to prepare a sample of medium density fiberboard (MDF) using mixed tropical hardwood fibers, and 0.5% Ammonium Nitrate was added as a hardener. Formaldehyde emissions and internal bond strength were measured, and the results are presented in Table 8.
- MDF medium density fiberboard
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Abstract
The invention relates to resin compositions that may be used as binder for a wide variety of bonded structures including cellulosic materials such as particle board and plywood, veneer sheets, and non-woven materials such as mineral wool and glass fibers. The resin compositions include an amino component having 2-6 amino groups, an aldehyde, a trifunctional amino component and a crosslinking component for the trifunctional amino component, preferably a dialdehyde, by co-condensing of at least two of the said components. The resin compositions of the invention exhibit very low formaldehyde emissions when used in bonded structures in comparison to resin compositions of the prior art. The invention further relates to methods of making such resin compositions, methods of making bonded structures using such resin compositions, and bonded structures bound by such resin compositions.
Description
Resin With Reduced Formaldehyde Emission
Field of the Invention
[001] The invention relates to resin binder compositions that may be used for a wide variety of bonded structures including cellulosic materials such as particle board and plywood, veneer sheets, and non-woven materials such as mineral wool and glass fibers. The resin compositions of the invention exhibit very low formaldehyde emissions when used in bonded structures in comparison to resin compositions of the prior art. The invention further relates to methods of making such resin compositions, methods of making bonded structures using such resin compositions, and bonded structures bound by such resin compositions.
Background
[002] Urea-formaldehyde (UF) resins and melamine-formaldehyde (MF) resins are known in the prior art. It was also known to combine melamine with UF resins in order to improve their mechanical properties.
[003] A known problem with both UF and MF resins is that during curing and particularly afterwards they tend to emit formaldehyde, a toxic irritant. U.S. Patent No. 5,017,641 attempts to address the formaldehyde emission problem in UF resins by adding ethanedial in an amount between 0.1 and 0.5 moles per mole of urea and a triazine. A 3- to 8-fold reduction in formaldehyde emission (17O0C for 7 minutes) was observed as compared to UF resins without ethanedial and triazine. The preferred fibrous web products according to that patent emitted between 0.1% and 0.2% formaldehyde by weight of the solid resin during curing. Patent application number SI 9800068 takes the same approach of adding ethanedial to UF resins. In both cases, the ethanedial was co-condensed with the formaldehyde and urea.
[004] An approach for reduction of formaldehyde emissions is the use of formaldehyde scavengers, compounds which react with formaldehyde to form non-volatile compounds. Several patents refer to this technology. Patent application WO 2008026056 describes a resin composition deriving from proteinaceous material which has good reactivity and achieves lowered formaldehyde emission by fast cross-linking at a high degree into hydrolysis resistible network and providing an efficient formaldehyde scavenger at the right time in the application. This system can realize a similar low level of formaldehyde emission but a different technology than used in present invention.
[005] Another approach to formaldehyde reduction was to add dialdehydes such as ethanedial as a post-condensation reaction additive to UF resins. For example, in patent application number JP-07- 126596 ethanedial was added to UF resins after the urea and formaldehyde were fully condensed. It is believed that the post-condensation addition of ethanedial improves the curing conditions, thus binding more formaldehyde in the cured resin and allowing less free formaldehyde to be emitted.
[006] US4,039,496 describes a water soluble textile finishing resin composition comprising fully etherified substantially fully methylolated melamine resins which is reacted in a separate subsequent step with urea, formaldehyde and glyoxal. The resin composition has a relatively low free formaldehyde content and good storage stability.
Summary
[007] While significant advances have thus been made in reducing formaldehyde emissions from curing resins, there is a constant need for further reduction of formaldehyde emissions until it can be eliminated altogether without compromising the material properties of the resin.
[008] According to the invention there is provided a resin composition obtainable by forming a reaction mixture by combining different components (Ia) an amino component having 2-6 amino groups; (Ib) an aldehyde component; (2) a trifunctional amino component; and (3) a crosslinking component for the amino components (Ia) and/or (2), and reacting said mixture at a temperature between 6O0C and 1200C and at a pH lower than 7.
[009] The present inventors have surprisingly found a synergistic interaction between a crosslinking agent such as ethanedial and a tri-functional amino component, such as melamine in reducing formaldehyde in amino-formaldehyde resins to a much greater extent than would be expected based on using a crosslinking agent such as ethanedial and a tri-functional amino component, such as melamine, alone or than would be expected when using a resin comprising fully condensated tri-functional amino component such as melamine that can no longer react with the crosslinking component for the trifunctional amino component.
[0010] In a particular embodiment, the components of the invention the amino component (Ia) is an non-cyclic amino compound, i.e. not comprising cyclic groups, whereas component (2) is a cyclic trifunctional amino component. The resin composition may comprising an amino- formaldehyde resin reacted with an at least trifunctional amino component and a crosslinker for the trifunctional amino component, preferably a dialdehyde. Preferably, the amino resin is an UF resin, the trifunctional amino component is melamine, and the dialdehyde is ethanedial. The resin in the resin composition preferably does not comprise a substantial amount of components other than the mentioned components Ia, Ib, 2 and 3, in particular the resin is not etherified.
[0011] It was surprisingly found that a relatively low amount of the tri-functional amino component (2) (in particular melamine) is sufficient to produce a significant synergistic effect with dialdehyde in reducing formaldehyde emissions. The amount of component (2) is preferably less than 30%, more preferably less than 25, 15 wt% or even less than 10 or 7% and most
preferably less than 5 % (wt to total resin composition in aqueous solution having total resin solids content between 40 and 70wt%). Preferably, the amount of amino-formaldehyde (Ia + Ib) (relative to total dry resin weight in the resin composition) is at least 70 wt%, more preferably at least 80wt%, even more preferably at least 90wt%.
[0012] Preferably, for the preferred resin composition based on UF, triazine and dialdehyde, the ranges for the various components (relative to one weight unit of formaldehyde) are F:U = 1 :0.25 to 1 :1.5, more preferably 1 :0.4 to 1: 1.5, most preferably 1:0.6 - 1 :1.3, F:Triazine = 1:0.05 to 1:40, more preferably 1 :0.05 - 1 : 15, most preferably 1 :0.05 - 1 :5, F:Dialdehyde = 1 :0 to 1 :40, more preferably 1 :0.05 - 1 :15, most preferably 1 :0.05 - 1 :5.
[0013] The methods of the invention include mixing of certain components and submitting them to changed pH and/or temperature conditions, which favor covalent reactions, such as condensation reactions such as between an amino resin with an at least trifunctional amino component and a crosslinker, preferably a dialdehyde.
[0014] A method for making the resin composition according to the invention comprises the following steps in order: providing in a reaction mixture components (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component, and (3) a crosslinking component for the trifunctional amino component; wherein the components Ia, Ib, 2 and 3 are provided in uncondensed form or in pre-condensed form, reacting the reaction mixture at a temperature between 6O0C and 1200C and at a pH of below 7, stopping the reaction by raising the pH of the reaction product to above 7 and cooling to a temperature of below 600C and optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 600C.
[0015] In some embodiments, the reaction is stopped when the mixture has reached a viscosity of at least about 100 cP, measured at 300C using the Brookfield spindle 18.
[0016] It is preferred that the components Ia, Ib, 2 and 3 are provided in the reaction mixture in uncondensed form. However, in some embodiments of the resins and methods of the invention, at least two of the components amino component, aldehyde component, trifunctional amino component, and crosslinking component for the trifunctional amino component may be co- condensed before addition of the remaining components, preferably component (Ia) and/or (2) may be co-condensed with component (Ib) or component (2) may be co-condensed with component (3). Preferably component (Ia) may be co-condensed with component (Ib). It is noted that the co-condensed means condensed to some partial degree but not fully condensed such that the trifunctional amino component (2) and the crosslinking component for the trifunctional amino component (3) can still react.
[0017] The invention also relates to a bonded structure comprising a particulate material, preferably a cellulosic material, and a resin according to the invention wherein the resin is cured and to the use of such a resin composition as a binder for bonded structures, especially cellulosic products including particle board and plywood, veneer sheets, and non-woven materials such as mineral wool and glass fibers. The bonded structures are preferably particle board, preferably medium density fiberboard or paper bonded finish foil. The bonded structures according to the invention have very low formaldehyde emission levels of less than 0.3 mg/1, preferably less than 0.2 mg/1, most preferably less than 0.1 mg/1 as measured by the Japanese desiccator method.
Detailed Description
The amino (Ia*) -Aldehyde (Ib) component
[0018] The basic component of the resin compositions of the invention is an amino (Ia)- aldehyde (Ib) resin. Preferably, in the resin composition the amino component (Ia) is an non- cyclic amino compound, i.e. not comprising cyclic groups, whereas component (2) is a cyclic trifunctional amino component.
[0019] Component (Ia) is preferably chosen form groups of Urea, Biuret, Triuret, Tetrauret, Pentauret, Hexauret, Methoxycarbonylurea, Ethoxycarbonylurea, tert.-Butylurea, Bis- 1,4- butyldiureid, guanidine and Acetylene-diurea Methoxycarbonylbiuret, Ethoxycarbonylbiuret, 1- Methylbiuret, 1-Ethylbiuret, 1-Propylbiuret, Acetylbiuret, Diacetylbiuret, 1,1-Dimethylbiuret, Ethylendibiuret and/or 1 ,2-Diethylbiuret, 3-Methyltriuret, 3-Ethyltriuret, 3-Methoxytriuret and/or 1,1 -Dimethyltriuret and salts and derivatives thereof.
[0020] The Amino-Aldehyde component is preferably a urea-formaldehyde (UF) resin. In a preferred embodiment, the UF resin used as the major component of the resin composition of the invention can be prepared from urea and formaldehyde monomers in any manner known to those skilled in the art.
[0021] UF reactants are commercially available in many forms. Any form that can react with the other reactants and which does not introduce extraneous moieties deleterious to the desired reaction and reaction product can be used in the preparation of the UF resins of the invention.
[0022] The aldehyde component (Ib) of the invention is preferably formaldehyde. Formaldehyde for use in UF resins is commercially available in many forms. Paraformaldehyde (solid, polymerized formaldehyde) and formalin solutions (aqueous solutions of formaldehyde, sometimes with methanol, in various concentrations) are commonly used forms as well as UFC (Urea-Formaldehyde-Concentrate) solutions. Formaldehyde is also available as a gas. Any of these forms is suitable for use in preparing UF resins. Formalin solutions are preferred.
[0023] The amino component (Ia), preferably urea, is also available in many forms. Solid urea, such as prill, and urea solutions, typically aqueous solutions, are commonly available. Urea may be combined with another moiety, most typically formaldehyde and urea-formaldehyde adducts, often in aqueous solution. Any form of urea or urea in combination with formaldehyde is suitable for use in the practice of the invention.
[0024] Any of a wide variety of procedures used for reacting the principal urea and formaldehyde components to form a UF thermosetting resin composition also can be used, such as staged monomer addition, staged catalyst addition, pH control, amine modification and the like. Generally, the urea and formaldehyde are reacted at a mole ratio of formaldehyde to urea in the range of about 1.1 :1 to 4:1, and more often at an F:U mole ratio of about 2.1 :1 to 3.2:1. Generally, the UF resin is highly water dilutable, if not water soluble.
[0025] Many suitable thermosetting UF resins are commercially available including those sold by Georgia Pacific Resins, Inc. for glass fiber mat applications, and those sold by Hexion and Dynea. These resins contain reactive methylol groups that upon curing form methylene or ether linkages. Such methylol-containing urea adducts may include N,N'-dimethylol, dihydroxy- methylolethylene. N,N'-bis(methoxymethyl), N,N'-dimethylolpropylene, 5,5-dimethyl-N,N'- dimethylolethylene, N,N'-dimelhylolethylene, and the like.
[0026] UF resins useful in the practice of the invention generally contain 45 to 70 weight percent non-volatiles, preferably 55 to 65 weight percent non-volatiles. They generally have a viscosity of 50 to 600 centipoise, preferably 150 to 400 centipoise. They normally exhibit a pH of 7.0 to 9.0, preferably 7.5 to 8.5. And they often have a free formaldehyde level of not more than about 3.0%, and a water dilutability of 1:1 to 100:1, preferably 5: 1 and above.
[0027] US2004/0082697 describes certain UF and/or MF resin modified inorganic particles wherein lamellar inorganic particles like clay are swollen with a very dilute urea or melamine solution and then reacted with formaldehyde and/or glyoxal to form modified inorganic particles having resin interlaminarly inside the particles. It is noted that the resin of the resin composition according to the invention is formed in the absence of such inorganic particles and is much more concentrated (45 - 70 wt%). The resin composition according to the invention when it is formed does not comprise inorganic particles, but inorganic particles may be added after formation of the resin. These particles are however not interlaminar resin modified.
[0028] The reactants for making the UF resin can, optionally, further include a small amount of a resin modifier such as ammonia, an alkanolamine, or a polyamine such as an alkyl primary diamine (e.g., ethylenediamine (EDA)). Additional modifiers, such as melamine, ethylene ureas, and primary and secondary and tertiary amines, for example, dicyanodiamide, can also be incorporated during manufacturing into the resin composition. Concentrations of these modifiers, when present in the reaction mixture, can be 0.05 to 20 weight percent, based on the total resin solids. These types of modifiers promote hydrolysis resistance, polymer flexibility, and lower formaldehyde emissions in the cured resin.
The tri-functional amino component (2)
[0029] Component (2) of resin composition of the invention is an at least trifunctional amine, preferably a cyclic urea, preferably having an aromatic structure, like triazines. A particularly suitable component is Melamine (m) (also referred to as (2,4,6-Triamino-l,3,5-triazine; Cyanuro-triamide; Cyanurotriamine; Cyanuramide). Melamine is a broadly available chemical, and may be use in the present context in any form, as long as the water solubility and water dispersibility is not compromised.
[0030] Other suitable tri-functional amino components include melamine derivatives such as 4,6-Diamino-l,3,5-triazin-2(lH)-one; 6-Amino-l,3,5-triazine-2,4(lH,3H)-dione; N2-(4,6- diamino-l,3,5-triazin-2-yl)-l,3,5-triazine-2,4,6-triamine and l,3,4,6,7,9,9b-Heptaazaphenalene- 2,5,8-triamine. If such materials are used, the molar ratios to other ingredients as will be discussed herein below, might need to be adjusted, and the weight ratios may change. Those of ordinary skill in the art would readily appreciate how to adjust these parameters.
Crosslinking components (3) for the tri-functional amine
[0031] Component (3) in the resin composition of the invention is a component which can undergo cross-linking reactions with the component (2) in the reaction mixture, the tri-functional amino component. Suitable components include components comprising at least one reactive aldehyde group and at least a further reactive groups such as an acidic group, such as glyoxylic acid. Other suitable components comprise at least two aldehyde groups, such as tri-aldehydes or di-aldehydes
[0032] Preferred aldehydes are aliphatic. More preferred are short chain C2 to C 12 dialdehydes, so as to not negatively impact the solubility properties, for example, Ethanedial, Butanedial, 2-
Butene-l,4-dial, Hexanedial, Pentanedial, 2-Hydroxy-hexanedial, 3-Hydroxymethyl-5-methoxy-
2-methyl-hexanedial, Heptanedial, Octanedial, Propanedial, Propanedial-2-on, 2-
Methylpropanedial, Propanedial-2-on, Butanedial, Hexanedial, Decanedial, 2,4-
Hexadienedialdehyde, 1,4-Benzenedialdehyde, 1 ,2-Benzenedialdehyde, and 1,3- Benzenedialdehyde. Even more preferred are unbranched C2 to C5 di-aldehydes, and most preferred is Ethanedial. Preferably, the crosslinking component is in liquid form, such as in aqueous solution.
Other ingredients
[0033] Other ingredients may be added to the resin compositions of the invention that will beneficially affect the material properties of the resins without detrimentally affecting the formaldehyde reduction. For example, plasticizers or catalysts known in the art to be useful in resin formulations, but also organic and inorganic fillers may be used with the present invention
[0034] Essentially any conventional hardener as useful for UF resins and not contradicting the process conditions as described herein below may be applied in the present invention.
[0035] Hardener or curing agents may be added just after the condensation reaction between the components la/b, 2 and 3 (step f and g) but imminently before the application to a bondable material. Alternatively, latent hardener may be added, which will not induce the curing until they are activated, e.g. after shipment of the resin composition with the latent hardener to the place, where this is combined with the bondable material, and the curing is initiated. Alternatively, the hardener or curing agent may be shipped separately to the place of application, and be mixed with the curable resin composition just prior to the application to the bondable material.
[0036] The hardener may be any inorganic salt, for example, ammonium nitrate or ammonium sulfate. Preferably, the hardener is ammonium nitrate present in a quantity of about 0.5% by weight.
[0037] In one aspect, the invention includes a method for manufacturing a resin composition according to the invention comprising the following steps in order: (a) providing at least four components comprising: (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component, and (3) a crosslinking component for the trifunctional amino component. The components form a reaction mixture wherein the
components Ia, Ib, 2 and 3 can be provided in uncondensed form or in part in pre-condensed form. The pre-condensed form can be prepared according to steps (b) to (e); (b) combining at least two of the at least four components having amino and aldehyde reactive groups to form a first mixture, (c) adjusting the pH of the first mixture to between 2-10 to allow formation of covalent bonds between the components in the first mixture;(d) heating the first mixture to a temperature between 600C and 1000C; (e) adding the remaining of the at least four components that were not added in step (b) to form the second mixture. The second mixture is uncondensed or in part pre-condensed but does not comprise fully condensed amino formaldehyde resin, The full condensation reaction is done by (f) adjusting the temperature of the second mixture to between 600C and 1200C; (g) adjusting the pH of the second mixture to below 7 to start the reaction. When the desired viscosity of preferably at least lOOcP at 3O0C is achieved (Brookfield spindle 18); (h) stopping the reaction by raising the pH of the mixture to above 7 and by (i) adjusting the temperature of the mixture to less than about 600C, (j) optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 60°C.
[0038] A first particular execution of this method comprises adding a crosslinking component such as a dialdehyde or a mixture of a crosslinking component such as a dialdehyde and an aldehyde component such as formaldehyde to a solution of an aldehyde such as formaldehyde. The pH is adjusted to 4-10 before or after subsequent addition of the amino component and a trifunctional amino component such as a triazine.
[0039] In another embodiment step (b) comprises combining the aldehyde and amino components, and step (e) comprises adding the crosslinking component and the trifunctional amino component.
[0040] In both executions the condensation reaction in the mixture is done by heating to 60- 120°C. The pH is lowered below 7.0 into acidic/slight acidic range for condensation. The condensation reaction is allowed to proceed until a predetermined viscosity is reached, after which pH is adjusted back above 7.0 to neutral to slightly alkaline condition in order to halt the condensation reaction. A second or third or greater quantity of urea may be added in stages, depending on the desired properties of the final resin product. Finally, the mixture is cooled and the pH is adjusted to basic, for example, 7-1 1. Those who are skilled in the art will readily appreciate that there are alternative orders to add the components.
Chemical properties of the resin
[0041] The resin compositions of the invention are particularly useful resin compositions, and in particular as resin compositions allowing the manufacturing of bonded structures exhibiting very low formaldehyde emissions, when the four key components as described above (such as urea, formaldehyde, dialdehyde and triazine) are combined and optionally covalently reacted such as co-condensed.
[0042] As with conventional resins, the condensation and addition reactions before the curing upon the application to the bondable material (as described herein below) should not be complete or excessive, but just to a degree that the resin is still water soluble and/or dilutable or capable of forming a stable dispersion.
[0043] The resin compositions of the invention preferably have a free formaldehyde content of less than 0.01- 0.8% by weight of solid content, preferably less than 0.5%, more preferably less than 0.2% and most preferably less than 0.1% as determined by titration on the uncured resin composition. However, for certain hardener or curing compounds such as ammonium salts, it may be desirable to have a certain amount of residual formaldehyde in the resin.
[0044] Without wishing to be bound by a theory, it is believed, that the degree of reaction such as of the condensation is such that essentially all of the resin is reacted into oligomers but not into the completely cured polymeric network as can be found in the final bonded structure. The degree of reaction such as of the condensation may be measured by the viscosity of the resin during the reaction or condensation. For the resins of the invention, the viscosity at which it is preferable to stop the condensation reaction is at least 100 cP, measured by means of a Brookefield® viscosimeter at 30°C with spindle No 18.
[0045] The physical properties of the resin can typically be readily adjusted to be comparable to the ones of conventional resins. Preferably, the resulting resins exhibit a good water dilutability, and their viscosity may thus be adjusted by adding or evaporating water. Preferably, the resulting resins are storage stable. Other properties of the resin may vary according to the application and the bondable material.
[0046] The present invention includes application of the resin to a bondable material and the forming of the bonded structure. Resin compositions as described above which may be produced according to the processes as described in the above may be applied in a broad range of applications to create bonded structures. To this end, the condensed resin compositions are added in the uncured state to bondable material. Upon curing of the resin, the bonded structure is created.
[0047] In general terms, the resin composition as described may replace conventional UF resins in any useful application. They may even broaden the application field to areas in which conventional UF resins are not considered for due to their high formaldehyde emissions, even if such emissions are reduced as compared to pure or unmodified UF resins.
[0048] The present invention is particularly useful in the context of bonding cellulosic based materials. Such materials may be wood fibres, chips, particles, sheets or the like, which then may be formed into boards, such as fiber boards, MDF boards, HDF, OSB boards, glue-lam, form-bent, parquet and the like, as well known to a person skilled in the art, and the resin compositions according to the present invention may be the binder in such structures. Such materials may also be essentially solid wood pieces, such as to form beams or form pressing structures or slices, such as veneers, and the resin composition may be the adhesive in such structures.
[0049] The resins of the invention may also be used for resin impregnated webs, such as paper webs and overlays. The resins of the present invention are further particularly useful in the context of bonding non-woven structures. Such structures may be based on discrete or essentially endless fibres of thermoplastic or thermoset materials, but may also be based on mineral, glass, or similar materials. Yet a further application is to use the resins according to the present invention with sand or sand-like materials such as in foundry applications. The present invention may further be applied to the making of abrasive articles, whereby abrasive particles are bonded to a carrier. The present invention can further be applied to the making of foamed structures, where by the resin may brought into a foam structure by conventional means and be cured.
[0050] The present invention includes any combination of such materials, such as when veneers are bonded to a fiber board, and a composition according to the present invention may be the binder of the fiber board and the same or a different composition may be the adhesive.
[0051] In order to create a bonded structure, the properties of the resin composition may be suitably modified to allow good application. Such modification may relate to adjusting viscosity or concentration depending on the application technology, such as coating, spraying, or soaking.
For certain applications, it may be highly preferred that the resin penetrates into the structure or
components of the structure, such as into solid wood, into wood pieces, chips, strands or fibers, etc. The bonded material is typically brought into a form corresponding to the desired form of the bonded structure, and to resin composition is added prior to or after this forming. Thus, when forming e.g. fiber boards, the wooden fibres are mixed with the resin composition, which might already comprise a hardener, and the mixture is brought into a board form and - e.g. by temperature - curing is initiated.
[0052] The curing step accomplishes the forming of the final polymeric network structure and in the resins of the invention causes efficient and relatively complete formaldehyde bonding within the polymeric network structure.
EXAMPLE 1 (Particle board)
[0053] A fully condensed melamine-urea-formaldehyde control resin (Prefere 10L023 El resin available from Dynea Austria) was used to show the effect of addition of ethanedial (see Table
1).
Table 1
[0054] In this table, F:(NH2)2 indicates the Formaldehyde to amino (urea) ratio, not including the amino groups added with Melamine. Mel% indicates the percentage of melamine by weight of the resin composition ED% indicates the weight percent added to the liquid resin of ethanedial.
[0055] The control resins were used to make samples of particle board using a rubberwood and hardwood particle blend. Formaldehyde emissions from the particle board samples were measured using the Japanese standard dessicator method for determining formaldehyde emission
(JIS A 1460), and the European perforator value method (EN 120) was used to measure the free
formaldehyde in the samples at 6.5% moisture. Internal bond strength was also measured using European standard EN 319 to determine the perpendicular tensile strength with a Zwick ® testing unit. The results of these tests are presented in Table 2.
Table 2
[0056] These tests demonstrate that formaldehyde emission both in desiccator and perforator method was reduced in the particle board samples prepared with a resin of control example IA to control example 1. The internal bond strength remained largely unchanged.
EXAMPLES 2-5 (Medium Density Fiberboard - Rubber-wood)
[0057] The resins were prepared as follows. The 50% w/w mixture of ethanedial and formaldehyde was added to a solution of formaldehyde. The pH was adjusted to be slightly basic. Urea and melamine were added to the solution. The mixture was heated to 80°C, and the pH was adjusted to 5.5-5.6. The condensation reaction was allowed to proceed until a viscosity of between 200 and 300 cP (measured at 300C) was reached, after which pH was adjusted back above 7.0 to neutral to slightly alkaline condition in order to halt the condensation reaction. Second and third quantities of urea were added in stages, and the mixture was cooled and the pH was adjusted to basic. Resins were prepared according to the formulations in Table 3.
Table 3
[0058] Each resin was used to prepare a sample of medium density fiberboard (MDF) using rubberwood fibers and 0.5% Ammonium Nitrate was added as a hardener. The sample density and resin loads for each of examples 2-5 are as indicated in Table 3. Resin load is weight of resin per total weight of the MDF sample.
[0059] Each MDF sample was tested using the Japanese dessicator method to measure formaldehyde emissions and the internal bond strengths were measured. The results of these measurements are presented in Table 4.
Table 4
[0060] In each case, the addition of the formaldehyde/ethanedial mixture (the "b" control examples) reduced the formaldehyde emission by about half. But the compositions of the invention, which add the formaldehyde/ethanedial mixture and 2% by weight of melamine led to a surprisingly drastic reduction in formaldehyde emission, leading to MDF samples with almost no formaldehyde emission. Such a synergistic reaction of melamine and ethanedial was a completely unexpected result.
Example 6
[0061] Other dialdehydes may be used to make the resin compositions of the invention. In this example, pentanedial was used. Resins were prepared according to the formulations in Table 5.
Table 5
[0062] The resins were prepared according to the method described in Example 1. Each resin was used to prepare a sample of medium density fiberboard (MDF) using mixed tropical hardwood fibers, and 0.5% Ammonium Nitrate was added as a hardener. Formaldehyde emissions and internal bond strength were measured, and the results are presented in Table 6.
Table 6
[0063] Thus the combination of pentanedial and melamine are effective to reduce formaldehyde emissions by more than half in this example.
Example 7
[0064] Several tests were conducted to determine the most beneficial amount of ethanedial in the Melamine-Urea-Formaldehyde resin formulations of the invention. Further tests were conducted to determine the most beneficial time to add ethanedial, pre- or post-condensation. To conduct these tests, resins were prepared according to the formulations in Table 7.
[0065] The resins were prepared according to the method described in Example 1. Each resin was used to prepare a sample of medium density fiberboard (MDF) using mixed tropical hardwood fibers, and 0.5% Ammonium Nitrate was added as a hardener. Formaldehyde emissions and internal bond strength were measured, and the results are presented in Table 8.
Table 8
[0066] These tests show that this example (inventive example 6a) resulted in very low formaldehyde emissions.
Claims
1) A resin composition obtainable by forming a reaction mixture by combining different components
(Ia) an amino component having 2-6 amino groups; ( 1 b) an aldehyde component;
(2) a trifunctional amino component; and
(3) a crosslinking component for the amino components (Ia) and/or (2), and reacting said mixture at a temperature between 6O0C and 1200C and at a pH lower than 7.
2) A resin composition according to claim 1 wherein the component (Ia) is an non-cyclic amino compound and component (2) is a cyclic trifunctional amino component.
3) The resin composition according to claims 1 or 2, wherein the amino component is urea, the aldehyde is formaldehyde, the trifunctional amino component is a triazine, preferably melamine and the crosslinking component for the trifunctional amino component is a dialdehyde, preferably ethanedial.
4) The resin composition according to claims 1 to 3, wherein in the reaction mixture the components Ia, Ib, 2 and 3 are provided in uncondensed form.
5) The resin composition according to claims 1 - 3, wherein in the reaction mixture some components are provided to the reaction mixture in pre-condensed form, preferably component (Ia) and/or (2) with component (Ib) or component (2) with component (3), preferably component (Ia) with component (Ib).
6) The resin composition according to claims 1 - 5, wherein the ranges for the various components, relative to one weight unit of formaldehyde, are F:U = 1 :0.25 to 1 :1.5, more preferably 1 :0.4 to 1 :1.5, most preferably 1:0.6 - 1 :1.3, F:Triazine = 1 :0.05 to 1:40, , more
preferably 1:0.05 - 1 :15, most preferably 1 :0.05 - 1 :5, F:Dialdehyde = 1 :0 to 1 :40, more preferably 1 :0.05 - 1:15, most preferably 1:0.05 - 1 :5.
7) The resin composition according to claims 1 - 6, wherein the amount of amino-formaldehyde (Ia + Ib) is at least 70 wt%, more preferably at least 80 wt%, even more preferably at least 90 wt% (relative to total dry resin weight in the resin composition).
8) A method for making the resin composition according to claims 1 to 7 comprising the steps:
- providing in a reaction mixture components (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component and (3) a crosslinking component for the trifunctional amino component, wherein the components Ia, Ib, 2 and 3 are provided in uncondensed form or in pre-condensed form,
- reacting the reaction mixture at a temperature between 600C and 12O0C and at a pH of below 7,
- stopping the reaction by raising the pH of the reaction product to above 7 and cooling to a temperature of below 600C, - optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 600C.
9) A method for making the resin composition according to claim 8 comprising the steps:
(a) providing in a reaction mixture components (Ia) an amino component having 2-6 amino groups, (Ib) an aldehyde component, (2) a trifunctional amino component, and (3) a crosslinking component for the trifunctional amino component; wherein the components Ia,
Ib, 2 and 3 are provided in uncondensed form or in part in pre-condensed form as prepared according to steps (b) to (e),
(b) combining at least two of the at least four components having amino and aldehyde reactive groups to form a first mixture,
(c) adjusting the pH of the first mixture to between 2-10 to allow formation of covalent bonds between the components in the first mixture;
(d) heating the first mixture to a temperature between 600C and 1000C;
(e) adding the remaining of the at least four components that were not added in step (b) to form the second mixture;
(f) start the reaction by adjusting the temperature of the second mixture to between 6O0C and 12O0C and;
(g) adjusting the pH of the second mixture to below 7;
(h) stopping the reaction by raising the pH of the mixture to above 7 and by (i) adjusting the temperature of the mixture to less than about 600C,
(J) optionally adding additional amounts of the amino component (of type Ia) after the temperature of the mixture has been adjusted to less than 6O0C.
10) The method according to claim 8 or 9, wherein the reaction is stopped (step (h)) after the mixture has reached a viscosity of at least about 100 cP, measured at 300C using the
Brookfield spindle 18.
11) The method according to claims 8 - 10, wherein step (b) comprises combining the aldehyde and amino components, and step (e) comprises adding the crosslinking component and the trifunctional amino component.
12) The method according to any of claims 8 to 11, wherein the amino component is urea, the aldehyde is formaldehyde, the trifunctional amino component is a triazine, preferably melamine and the crosslinking component for the trifunctional amino component is a dialdehyde, preferably ethanedial.
13) A bonded structure comprising a particulate material, preferably a cellulosic material, and a resin according to any of claims 1 to 7 wherein the resin is cured.
14) The bonded structure according to claim 13, wherein the bonded structure is particle board, preferably medium density fiberboard or paper bonded finish foil.
15) A bonded structure according to any of claims 13 or 14, having a formaldehyde emission level of less than 0.3 mg/1 as measured by the Japanese desiccator method.
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GB0908135A GB0908135D0 (en) | 2009-05-12 | 2009-05-12 | Resin with reduced formaldehyde emissions |
GB0908135.7 | 2009-05-12 |
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Cited By (2)
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CN102490217A (en) * | 2011-12-02 | 2012-06-13 | 朱江福 | Thin board veneering method for bamboo floor |
CN113336908A (en) * | 2021-07-20 | 2021-09-03 | 西南林业大学 | Branched polymer-urea-glyoxal copolycondensation resin, preparation method and application thereof |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102490217A (en) * | 2011-12-02 | 2012-06-13 | 朱江福 | Thin board veneering method for bamboo floor |
CN113336908A (en) * | 2021-07-20 | 2021-09-03 | 西南林业大学 | Branched polymer-urea-glyoxal copolycondensation resin, preparation method and application thereof |
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