CYCLIC UREA-FORMALDEHYDE PREPOLYMER FOR USE IN PHENOL-FORMALDEHYDE AND MELAMINE-FORMALDEHYDE RESIN-BASED BINDERS

• US 20020054994A1
• Filed: 09/07/2001
• Published: 05/09/2002
• Est. Priority Date: 12/19/1997
• Status: Active Grant

• Current Assignee: Georgia-Pacific Chemicals LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia-Pacific Resins, Inc. (KOCH Industries Incorporated)
• Inventors: Shoemake, Kelly A., Gapud, Benjamin D., Tutin, Kim K., Wright, James T., Freese, William P., Dupre, F. C., Rediger, Richard A., Gabrielson, Kurt D., Foucht, Millard E., Ingram, W. Hayes, McVay, Ted M.
• Granted Patent: US 6,379,814 B1
• Time in Patent Office: Days
• US Class Current: 428/349
• CPC Class Codes: C08G 12/422 based on urea or thiourea
• CPC Class Codes: C08G 14/12 Chemically modified polycondensates
• CPC Class Codes: C08L 2666/20 Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof
• CPC Class Codes: C08L 61/06 of aldehydes with phenols
• CPC Class Codes: C08L 61/20 Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen with aminophenols C08L61/04
• CPC Class Codes: C08L 61/28 with melamine
• CPC Class Codes: C08L 75/02 Polyureas
• CPC Class Codes: Y10T 428/2826 Synthetic resin or polymer
• CPC Class Codes: Y10T 428/31888 Addition polymer of hydrocarbon[s] only
• CPC Class Codes: Y10T 428/31895 Paper or wood
• CPC Class Codes: Y10T 428/31957 Wood

Abstract

The preparation of phenol-formaldehyde and melamine-formaldehyde resin-based binders extended with a cyclic urea-formaldehyde prepolymer and to products prepared using the binders. More particularly, the invention relates to a cyclic urea prepolymer comprising urea, formaldehyde, and ammonia or a primary amine which, when added to a phenol-formaldehyde or melamine-formaldehyde based resin, results in a useful binder for the manufacturer numerous articles.

Claims

1. A binder comprising a phenol-formaldehyde or melamine-formaldehyde resin modified with 1 to 95 wt % based on resin solids of a cyclic urea prepolymer either during manufacture of the resin or post added to the resin wherein the cyclic urea prepolymer has a mole ratio of urea:

formaldehyde;

ammonia or a primary amine of about 0.1 to 1.0;

0.1 to 3.0;

0.1 to 1.0.

2. The binder of claim 1 wherein the mole ratios of urea:

formaldehyde;

ammonia or a primary amine are about 2.0;

2.0;

1.0 to 1.0;

4.0;

1.0.

3. The binder of claim 2 wherein the mole ratios of urea:

formaldehyde;

ammonia or a primary amine are about 2.0;

4.0;

1.0.

4. The binder of claim 1 wherein the cyclic urea prepolymer is prepared from urea, formaldehyde and ammonia.

5. The binder of claim 1 wherein the resin is a thermosetting resin.

6. The binder of claim 1 wherein the cyclic urea prepolymer is prepared by:

mixing urea, formaldehyde, and ammonia or a primary amine, and heating the mixture at an alkaline pH to about 60 to 105°

C. for a time sufficient to complete the reaction.

7. The binder of claim 6 wherein the pH is between about 5 and 11.

8. The binder of claim 1 wherein the binder comprises 10 to 70 wt % of the cyclic urea prepolymer based on resin solids.

9. The binder of claim 8 wherein the binder comprises 20 to 60 wt % of the cyclic urea prepolymer based on resin solids.

10. The binder of claim 1 wherein the resin is a phenol-formaldehyde resin.

11. The binder of claim 10 wherein the cyclic urea prepolymer is added to the phenol-formaldehyde resin during manufacture of the resin.

12. The binder of claim 10 wherein the cyclic urea prepolymer is added to the phenol-formaldehyde resin after manufacture of the resin.

13. The binder of claim 1 wherein the binder further comprises a latent catalyst.

14. Insulation comprising fibers and the binder of claim 10.

15. The insulation of claim 14 wherein the binder comprises 10 to 70 wt % of the cyclic urea prepolymer based on resin solids.

16. The insulation of claim 15 wherein the binder comprises 20 to 60 wt % of the cyclic urea prepolymer based on resin solids.

17. The insulation of claim 16 wherein the mole ratios of urea:

formaldehyde;

ammonia or a primary amine are about 1.0;

1.0;

0.5 to 1.0;

4.0;

1.0.

18. The insulation of claim 16 wherein the phenol-formaldehyde resin is prereacted with urea prior to combination with the cyclic urea prepolymer.

19. The insulation of claim 16 wherein the binder further comprises a latent catalyst.

20. The insulation of claim 16 wherein the fibers are glass fibers or mineral wool fibers.

26. The binder of claim 12 wherein the phenol-formaldehyde resin is a paper saturating resin.

27. The binder of claim 10 wherein the resin is a high pressure laminating resin.

28. The binder of claim 11 wherein the resin is a high pressure laminating resin.

29. The binder of claim 12 wherein the resin is a high pressure laminating resin.

31. The binder of claim 10 wherein the binder is a coated abrasive binder or a friction material binder.

33. The binder of claim 1 wherein the resin is a melamine-formaldehyde resin.

34. Ceiling tiles comprising cellulose or mineral fiber materials and a coating comprising the binder according to claim 33.

35. The ceiling tiles of claim 34 wherein the coating further comprises clay.

36. The binder of claim 33 wherein the resin comprises 1 to 25 wt % of the cyclic urea prepolymer based on resin solids.

37. Overlay paper laminates comprising a paper substrate and a coating comprising the binder according to claim 33.

38. A molded article comprising pulp and a binder according to claim 33.

39. A molded article comprising glass fiber or filler and a binder according to claim 33.

41. The binder of claim 1 wherein the binder is a coated foundry sand binder.

42. The binder of claim 1 wherein the binder is a phenolic foam resin.

21. A consolidated wood product comprising a substrate and an adhesive comprising a phenol-formaldehyde resin modified with 1 to 95 wt % based on resin solids of a cyclic urea prepolymer either during manufacture of the resin or post added to the resin wherein the cyclic urea prepolymer has a mole ratio of urea:

formaldehyde;

ammonia or a primary amine of about 0.1 to 1.0;

0.1 to 3.0;

0.1 to 1.0, wherein said consolidated wood product is selected from the group consisting of plywood, oriented strand board, wafer board, engineered lumber, particle board, hardboard and medium density fiber boards.

22. The consolidated wood product of claim 21 wherein the consolidated wood product is plywood comprising at least three plies.

23. The consolidated wood product of claim 21 wherein the consolidated wood product is laminated veneer lumber.

24. The consolidated wood product of claim 21 wherein the consolidated wood product is oriented strand board or wafer board.

25. The consolidated wood product of claim 21 wherein the binder is spray dried onto the substrate.

30. A laminate comprising a paper substrate and the binder of claim 27.

32. A binder comprising a novolac resin and a cyclic urea prepolymer wherein the cyclic urea prepolymer has a mole ratio of urea:

formaldehyde;

ammonia or a primary amine of about 0.1 to 1.0;

0.1 to 3.0;

0.1 to 1.0.

40. The binder of claim 32 wherein the binder is a coated foundry sand binder.