Derivatives of native lignin, lignin-wax compositions, their preparation, and uses thereof

• US 10,435,562 B2
• Filed: 04/27/2017
• Issued: 10/08/2019
• Est. Priority Date: 05/28/2009
• Status: Active Grant

• Current Assignee: Suzano Canada Inc. (Suzano S.A.)
• Original Assignee: Fibria Innovations Inc. (Suzano S.A.)
• Inventors: Berlin, Alex, Mulyk, Paul
• Primary Examiner(s): Hill, Nicholas E
• Application Number:
  US15/499,585
• Publication Number:
  US 20170226344A1
• Time in Patent Office: 894 Days
• CPC Class Codes: A23K 10/32 from hydrolysates of wood or straw
• CPC Class Codes: A23L 33/105 Plant extracts, their artificial duplicates or their derivatives
• CPC Class Codes: A61K 36/15 Pinaceae (Pine family), e.g. pine or cedar
• CPC Class Codes: A61K 36/48 Fabaceae or Leguminosae (Pea or Legume family); Caesalpiniaceae; Mimosaceae; Papilionaceae
• CPC Class Codes: A61K 36/54 Lauraceae (Laurel family), e.g. cinnamon or sassafras
• CPC Class Codes: A61K 36/76 Salicaceae (Willow family), e.g. poplar
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: C07G 1/00 Lignin; Lignin derivatives
• CPC Class Codes: C08H 6/00 Macromolecular compounds derived from lignin, e.g. tannins, humic acids
• CPC Class Codes: C08J 2397/00 Characterised by the use of lignin-containing materials
• CPC Class Codes: C08J 3/00 Processes of treating or compounding macromolecular substances
• CPC Class Codes: C08K 5/13 Phenols; Phenolates
• CPC Class Codes: C08L 2201/52 Aqueous emulsion or latex, e.g. containing polymers of a glass transition temperature (Tg) below 20°C
• CPC Class Codes: C08L 2207/04 Thermoplastic elastomer
• CPC Class Codes: C08L 23/02 not modified by chemical after-treatment
• CPC Class Codes: C08L 57/00 Compositions of unspecified polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C08L 91/06 Waxes
• CPC Class Codes: C08L 97/005 Lignin
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: C09K 15/06 containing oxygen
• CPC Class Codes: D21C 11/0007 : Recovery of by-products, i.e. compounds other than those necessary for pulping, for multiple uses or not otherwise provided for volatile compounds obtained by decomposition of spent liquors in order to regenerate them D21C11/125; compounds obtained by fractionating the liquors in order to regenerate them D21C11/0042
• CPC Class Codes: D21H 11/00 : Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
• CPC Class Codes: Y02P 20/582 : Recycling of unreacted starting or intermediate materials
• CPC Class Codes: Y02P 60/87 : Re-use of by-products of food processing for fodder production

Abstract

A wax composition comprising a lignin derivative wherein the derivative has a total hydroxyl content of from about 0.1 mmol/g to about 7 mmol/g.

Claims

1. A composite wood product comprising a wax emulsion comprising:

a lignin derivative extracted from a lignocellulosic biomass, wherein the lignin derivative comprises a total hydroxyl content of from about 0.1 mmol/g to about 7 mmol/g; and

a wax;

wherein the wax emulsion comprises, on a solid content basis, about 10% or greater by weight of the lignin derivative.

2. The composite wood product according to claim 1, wherein the total hydroxyl content is from about 3 mmol/g to about 6.4 mmol/g.

3. The composite wood product according to claim 1, wherein the lignin derivative further comprising alkoxy groups.

4. The composite wood product according to claim 1, wherein the lignocellulosic biomass is from a hardwood biomass, a softwood biomass, or an annual fibre biomass.

5. The composite wood product according to claim 1, wherein the lignocellulosic biomass is from Populus spp., Eucalyptus spp., Acacia spp., or any combination/hybrid thereof.

6. The composite wood product according to claim 1, wherein the lignocellulosic biomass is from pine, spruce, or any combination/hybrid thereof.

7. The composite wood product according to claim 1, wherein the lignocellulosic biomass is from wheat straw, bagasse, corn cobs, or any combination/hybrid thereof.

8. The composite wood product according to claim 1, wherein the wax is a slack wax.

9. The composite wood product according to claim 1, wherein the wax emulsion comprises, on a solid content basis, from about 20% to about 90%, by weight of the lignin derivative.

10. The composite wood product according to claim 1, comprising, on a solid content basis, from about 1% to about 90%, by weight of the wax.

11. The composite wood product according to claim 8, comprising, on a solid content basis, from about 20% to about 90%, by weight of the slack wax.

12. The composite wood product according to claim 1, the lignin derivative having a weight average molecular weight from about 500 g/mol to about 5000 g/mol.

13. The composite wood product according to claim 1, further comprising a surface tension reducing agent or an interfacial tension reducing agent, and a lignin solubilizing agent.

14. The composite wood product according to claim 13, wherein the surface tension reducing agent or the interfacial tension reducing agent is a lignosulphate, an isogenic lignin derivative, an ionogenic detergent or a combination thereof.

15. The composite wood product according to claim 14, wherein the ionogenic detergent is sodium dodecyl sulfate.

16. A method of producing the composite wood product according to claim 1, the method comprising:

(a) preparing an aqueous solution comprising one of a surface tension reducing agent and an interfacial tension reducing agent;

(b) co-mingling with the aqueous solution a selected amount of a base, thereby forming a basic aqueous solution;

(c) co-mingling with the basic aqueous solution a selected amount of a lignin derivative having a total hydroxyl content of from about 0.1 mmol/g to about 7 mmol/g, thereby forming a mixture;

(d) separating the mixture into a filtrate and a retentate, wherein the lignin derivative is co-mingled with the filtrate;

(e) co-mingling a selected volume of the filtrate with a selected volume of a wax to form a wax emulsion; and

(f) blending and pressing the wax emulsion with a wood feedstock and a phenol-formaldehyde resin to form the composite wood product.

17. The method according to claim 16, wherein the one of a surface tension reducing agent and an interfacial tension reducing agent is selected from the group consisting of lingo-sulphonates, isogenic lignin derivatives, ionogenic detergents, and any combination thereof.