Binder compositions comprising lignin derivatives

• US 9,982,174 B2
• Filed: 10/27/2016
• Issued: 05/29/2018
• Est. Priority Date: 02/15/2010
• Status: Active Grant

• Current Assignee: Suzano Canada Inc. (Suzano S.A.)
• Original Assignee: Fibria Innovations Inc. (Suzano S.A.)
• Inventors: Berlin, Alex
• Primary Examiner(s): Uselding, John E
• Application Number:
  US15/336,526
• Publication Number:
  US 20170044409A1
• Time in Patent Office: 579 Days
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B29C 70/12 using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29C 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2311/14 Wood, e.g. woodboard or fibreboard
• CPC Class Codes: C08G 18/4081 Mixtures of compounds of group C08G18/64 with other macromolecular compounds
• CPC Class Codes: C08G 18/7671 containing only one alkylene bisphenyl group
• CPC Class Codes: C08L 61/06 of aldehydes with phenols
• CPC Class Codes: C08L 97/00 Compositions of lignin-containing materials of polysaccharides C08L1/00 - C08L5/00
• CPC Class Codes: C08L 97/005 Lignin
• CPC Class Codes: C09J 161/06 of aldehydes with phenols
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: C09J 197/005 Lignin
• CPC Class Codes: D21J 1/04 Pressing

Abstract

The present disclosure provides an adhesive composition comprising derivatives of native lignin and an isocyanate-based binder such as methylene diphenyl diisocyanate. The present compositions may further comprise formaldehyde-based resins such as PF, UF, and MF. While not wishing to be bound by theory, it is believed that incorporating derivatives of native lignin in isocyanate compositions will reduce incidence of pre-curing.

Claims

1. An adhesive system comprising:

(a) a resin composition comprising a mixture of at least about 30% by weight of a phenol-formaldehyde resin and at least about 30% by weight of a derivative of native lignin; and

(b) a liquid isocyanate-based binder, wherein the adhesive system does not have any other liquid solvent.

2. The system according to claim 1, wherein the system comprises at least about 35% by weight of the derivative of native lignin.

3. The system according to claim 1, wherein the derivative of the native lignin has an ethoxy content of 0.45 mmol/g or greater.

4. The system according to claim 1, wherein the isocyanate-based binder comprises methylene diphenyl diisocyanate.

5. The system according to claim 1, wherein the isocyanate-based binder comprises methylene diphenyl diisocyanate and a second derivative of native lignin.

6. The system according to claim 5, wherein the second derivative of native lignin of the isocyanate-based binder has an aliphatic hydroxyl content of from about 0.6 mmol/g to about 6.5 mmol/g.

7. A method of producing a fibreboard, the method comprising:

(a) providing fibres to a blowline;

(b) providing the adhesive system according to claim 1;

(c) treating the fibres with the adhesive system;

(d) pressing the treated fibres to form the fibreboard.

8. The method according to claim 7, wherein the treated fibres are at least partially dried prior to pressing the treated fibres to form the fibreboard.

9. The method according to claim 7, wherein the fibreboard is selected from the group consisting of a low density fibreboard, a medium density fibreboard, a high density fibreboard, a strawboard, and agricultural fibre/particle board, an oriented strand board, a particle board, a wood fibre insulation board, and a polyurethane board.

10. The system according to claim 1, wherein the derivative of native lignin has a phenolic hydroxyl content of from about 2 mmol/g to about 8 mmol/g.

11. The system according to claim 10, wherein the derivative of native lignin further has a polydispersity of from about 1 to about 5.

12. The system according to claim 1, wherein the derivative of native lignin further has a polydispersity of from about 1 to about 5.

13. The system according to claim 1, wherein the derivative of native lignin has an aliphatic hydroxyl content of from about 0.1 mmol/g to about 8 mmol/g.

14. The system according to claim 13, wherein the aliphatic hydroxyl content is from about 0.6 mmol/g to about 6.5 mmol/g.

15. The system according to claim 1, wherein the derivative of native lignin has an alkoxy content of from 0.001 mmol/g to 2 mmol/g.