THERMOSETTING ADHESIVES COMPRISING A RESIN HAVING AZETIDINIUM FUNCTIONAL GROUPS

• US 20070054144A1
• Filed: 08/28/2006
• Published: 03/08/2007
• Est. Priority Date: 09/02/2005
• Status: Active Grant

• Current Assignee: Georgia-Pacific Chemicals LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia-Pacific Resins, Inc. (KOCH Industries Incorporated)
• Inventors: Hagiopol, Cornel, Rivers, Jason, Dopico, Pablo, Rammon, Richard
• Granted Patent: US 7,781,501 B2
• Time in Patent Office: Days
• US Class Current: 428/537.100
• CPC Class Codes: C08L 2666/16 Addition or condensation polymers of aldehydes or ketones according to C08L59/00 - C08L61/00; Derivatives thereof
• CPC Class Codes: C08L 61/06 of aldehydes with phenols
• 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: C09J 179/02 Polyamines
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

Termosetting adhesives for use in e.g., particleboard or fiberboard, wherein the adhesives comprise a resin having azetidinium functional groups, can provide fast tack-building and curing, as well as ultimately excellent bonding characteristics. Preferably, the azetidinium-functional resin is formed from the reaction product of a polyamidoamine and epichlorohydrin.

Claims

1. A composition for preparing wood composites, said composition comprising (1) a thermosetting adhesive comprising predominantly a resin having azetidinium functional groups and (2) a cellulosic material, wherein said thermosetting adhesive is substantially free of protein.

2. The composition of claim 1, wherein said cellulosic material comprises a wood element selected from the group consisting of wood flakes, wood strands, wood fibers, wood particles, wood layers, and mixtures thereof.

3. The composition of claim 1, wherein said thermosetting adhesive comprises protein in an amount of less than 5% by weight, on a dry solids basis.

4. The composition of claim 1, wherein said resin is the reaction product of a polyamidoamine and a halohydrin.

5. The composition of claim 4, wherein said halohydrin is epichlorohydrin.

6. The composition of claim 4, wherein said polyamidoamine is the reaction product of a polyamine and a polycarboxylic acid.

7. The composition of claim 1, wherein said resin is present in an amount of at least 60% by weight, on a dry solids basis, of said thermosetting adhesive.

8. The composition of claim 1, wherein said cellulosic material is present in an amount from about 85% to about 98% by weight, on a dry solids basis, of said composition.

9. A wood composite comprising the composition of claim 1, after said resin is cured.

10. The wood composite of claim 9, wherein said wood composite is particleboard or fiberboard.

11. A method of making a wood composite, the method comprising:

(a) forming the composition of claim 1 into substantially the shape of said wood composite, and

(b) consolidating a shaped composition obtained in step (a) using heat and pressure into said wood composite.

12. The method of claim 11, wherein step (a) comprises forming a mat from said composition and step (b) comprises pressing said mat at a temperature from about 150°

C. (300°

F.) to about 218°

C. (425°

F.) for a time from about 3 to about 20 minutes.

13. The method of claim 11, wherein said wood composite is particleboard or fiberboard.

14. A thermosetting adhesive for bonding wood, said adhesive comprising a resin having azetidinium functional groups and further comprising (1) a cross-linking agent selected from the group consisting of a polyamine, a polyamide, urea, a diisocyanate, and a polyol, (2) an aldehyde-based or an isocyanate-based resin, or (3) a combination of (1) and (2).

15. The thermosetting adhesive of claim 14, comprising predominantly said resin having azetidinium functional groups.

16. The thermosetting adhesive of claim 14, wherein said thermosetting adhesive is substantially free of protein.

17. The thermosetting adhesive of claim 14, wherein said (1) cross-linking agent selected from the group consisting of a polyamine, a polyamide, urea, a diisocyanate, and a polyol, (2) aldehyde-based or an isocyanate-based resin, or (3) combination of (1) and (2) comprise one or more additives that are present in an amount such that a dry solids weight ratio of resin having azetidinium functional groups:

one or more additives is from about 10;

1 to about 1;

10.

18. The thermosetting adhesive of claim 14, wherein said cross-linking agent is selected from the group consisting of a polyamidoamine, a polyacrylamide, diphenylmethane diisocyanate, and a polyvinylalcohol.

19. The thermosetting adhesive of claim 18, wherein said polyacrylamide is a co-polymerization reaction product of acrylamide and a co-monomer.

20. The thermosetting adhesive of claim 19, wherein said co-monomer is a diallyldialkylammonium halide.

21. The thermosetting adhesive of claim 14, wherein said aldehyde-based resin is selected from the group consisting of urea-formaldehyde, melamine-formaldehdye, phenol-formaldehyde, and acetone-formaldehyde.

22. An adhesive for bonding cellulosic materials, said adhesive comprising a reaction product of a mixture comprising a resin having azetidinium functional groups and further comprising (1) an amine-functional or amide-functional cross-linking agent, (2) an aldehyde-based or an isocyanate-based resin, or (3) a combination of (1) and (2).

23. The adhesive of claim 22, wherein said resin having azetidinium functional groups is present in an amount of at least 60% by weight, on a dry solids basis, of said mixture and said cross-linking agent is a polyacrylamide.