SE543465C2 - Process for preparing a bonding resin - Google Patents

Abstract

The present invention relates to a process for preparing a bonding resin, wherein a first resin prepared from lignin, formaldehyde and optionally phenol is mixed with a second resin prepared from lignin, formaldehyde and optionally phenol, wherein the first resin is different from the second resin, to achieve a mixture useful as a bonding resin useful in the manufacture of laminates, mineral wool insulation and wood products such as plywood, laminated veneer lumber (LVL), medium density fiberboards (MDF) and particle boards.

Description

PROCESS FOR PREPARING A BONDING RESIN Field of the invention The present invention relates to a process for preparing a bonding resin,wherein a first resin prepared from Iignin, formaldehyde and optionally phenolis mixed with a second resin prepared from Iignin, formaldehyde andoptionally phenol, wherein the first resin is different from the second resin, toachieve a mixture useful as a bonding resin useful in the manufacture ofIaminates, mineral wool insulation and wood products such as plywood,laminated veneer lumber (LVL), medium density fiberboards (MDF) andparticle boards.

Background Lignin, an aromatic polymer is a major constituent in e.g. wood, being themost abundant carbon source on Earth second only to cellulose. ln recentyears, with development and commercialization of technologies to extractlignin in a highly purified, solid and particularized form from the pulp-makingprocess, it has attracted significant attention as a possible renewablesubstitute to primarily aromatic chemical precursors currently sourced from the petrochemical industry.

Lignin, being a polyaromatic network has been extensively investigated as asuitable substitute for phenol during production of phenol-formaldehydeadhesives. These are used during manufacturing of laminate and structuralwood products such as plywood, oriented strand board and fiberboard. Duringsynthesis of such adhesives, phenol, which may be partially replaced byIignin, is reacted with formaldehyde in the presence of either basic or acidiccatalyst to form a highly cross-linked aromatic resins termed novolacs (whenutilizing acidic catalysts) or resoles (when utilizing basic catalysts). Currently, only limited amounts of the phenol can be replaced by lignin due to the lowerreactivity of lignin.

One problem when preparing resins comprising lignin is to optimize theproperties of the final resin for different products. ln an industrial setting, it isessential to be able to quickly adapt the properties of resins, to ensureoptimal performance of the resins in the manufacture of the final products,such as laminate and structural wood products such as plywood, orientedstrand board and fiberboard. At the same time, it is desirable to use as muchlignin, a renewable material, as possible in the resins and at the same timeminimize the use of phenol. Since resins need to have different propertiesdepending on end use, numerous different resins, i.e. individual resins havingdifferent properties, need to be produced and sometimes stored, to allow theproduction of a range of final end products. Significant storage space may berequired, alternatively different types of resin recipes need to be used either inparallel, requiring additional mixing equipment, or serially which requirescleaning of reaction vessels between resin batches and a risk that whenproduction requirements change, the resin preparation is too slow and isunable to meet the needs of the required end use, thereby reducing overallefficiency of production of final products and thereby a significant costincrease of such production.

Summary of the invention lt has now surprisingly been found that it is possible to optimize the propertiesof a resin mixture without producing a separate resin for each intended enduse. lnstead, a first resin and a second resin is prepared, optionally stored,and then mixed in a ratio adapted to achieve defined and required resinproperties. Thereby, the speed of production of products manufactured using resins, and particularly the efficiency of shifting between producing resins having properties adapted for different end -products, can be significantly improved.

The present invention is thus directed to a method for preparing a resin in theform of a mixture comprising the steps ofa) preparing a first resin comprising lignin, formaldehyde and optionallyphenohb) preparing a second resin comprising lignin, formaldehyde andoptionally pheno|, wherein the second resin is different from the firstresin;c) mixing the first resin and the second resin in a weight ratio of from0.5:10 to 10:0.5 based on weight of the mixture of the first resin and second resin.

The first resin can be prepared using methods known in the art. For example,lignin can be dissolved into an aqueous medium comprising alkali. Thedisso|ution of the lignin may be carried out with or without heating. ln asubsequent step, formaldehyde and optionally pheno| is added to thesolution, separately or simultaneously. The reaction mixture is heated toapproximately 40-95°C until the reaction is completed and desirableproperties, such as viscosity, have been achieved. The amount of lignin usedin the preparation of the resin is typically such that lignin has replaced pheno|to a replacement level of 40-100% in the first resin used in the context of the present invention.

Lignin may be utilized as a powder at the time that it is incorporated into theresin formulation. Lignin can also be utilized in “liquid form” in an alkali solution in order to avoid lignin dust.

The second resin can be prepared using methods known in the art. Thesecond resin can be prepared in the same way as the first resin. The secondresin is different from the first resin. ln the second resin, the lignin hastypically replaced pheno| to a replacement level of 5-100%.

The difference between the first resin and the second resin can for examplebe the lignin content, such as the degree to which lignin has replaced phenol.The difference between the first and the second resin can also be the solid content, viscosity, pH or any other property.

The first resin and the second resin may prepared in any order prior to beingmixed with each other.

The step of mixing the first resin and the second resin can be carried out atroom temperature. However, it is preferable to carry out the mixing step at atemperature of from 20°C to 35°C. The mixing can be carried using traditionalmixing equipment and the mixing can be carried out batch-wise orcontinuously. The mixing is preferably carried out such that the stirring isperformed at less than 10000 rpm, more preferably in the range of from 10 to5000 rpm, such as from 10 to 1000 rpm, particular 20 to 500 rpm. The mixingis typically carried out for at least one minute, such as from 1 minute to 2 hours, depending on the volume of the mixture being prepared.

When mixing the first resin and the second resin, the viscosity of the mixtureof the first resin and the second resin is preferably monitored, either on a continuous basis or by taking samples at defined time intervals.

The amount of each of the first resin and the second resin that is added toprovide the mixture of the first resin and the second resin depends on theintended use of the mixture and the required properties necessary for thatuse. Typically, the amount of each of the first resin and second resin is addedaccording to a predetermined recipe such that the mixture of the first resinand the second resin yields the desired properties.

The step of mixing the first resin and the second resin is carried out until thefirst resin and the second resin have been adequately mixed, such that the composition of the mixture is essentially homogenous throughout the mixtureobtained. ln step c) or in a subsequent step, the properties of the mixture of the firstresin and the second resin can be adjusted by adding additives to themixture. Such additives are for example acids or bases, to adjust the pH ofthe mixture of the first resin and the second resin to a desired pH. Theadditives may also be colorants, pigments, fire retardants or other additivestypically used in the preparation of resins. These additives can also be added in one of the resin before mixing. ln addition to the first resin and the second resin, the mixture may compriseadditives and/or additional resins.

The present invention is thus also directed to the use of the mixture of the firstresin and the second resin in the manufacture of laminates, mineral woolinsulation and wood products such as plywood, laminated veneer lumber(LVL), medium density fiberboards (MDF) and particle boards. The presentinvention is also directed to such laminates, mineral wool insulation and woodproducts such as plywood, laminated veneer lumber (LVL), medium densityfiberboards (MDF) and particle boards manufactured using the mixture of the first resin and the second resin.

The present invention is also directed to a method for selecting an optimizedresin mixture for a specific end use, comprising the steps ofa) defining desirable properties of a resin;b) preparing a first resin comprising lignin, formaldehyde and optionallyphenohc) preparing a second resin comprising lignin, formaldehyde andoptionally phenol, wherein the second resin is different from the first resin; d) mixing the first resin and the second resin in a defined weight ratio offrom 0.5:10 to 10:0.5 based on weight of the mixture of the first resinand second resin; e) in an empty vessel, repeating step d) with a different weight ratio; f) repeating step e) at least five times with additional different weightratios in step d) in each repetition; g) evaluating the properties of each mixture of the first resin and thesecond resin, said evaluation being carried out based on the propertiesof the resin as such or based on the properties of a final productprepared using each mixture of the first resin and the second resinobtained in step f); h) selecting the optimized mixture of the first resin and the second resinobtained in step f), based on the results of the evaluation carried out instep g), said selection step comprising the determination of whichmixture of the first resin and second resin obtained in step f) hasproperties closest to the desired properties of a resin defined in step a).

The evaluation of the properties if the resin mixture or product manufacturedusing the resin mixture can be carried out using methods known in the art.Examples of such properties of the resin include viscosity, pH, storage time,solid content etc and of the product manufactured using the resin includepressing time, assembly time, reactivity etc. The properties concerned can bedetermined by the skilled person.

Detailed description lt is intended throughout the present description that the expression "lignin"embraces any kind of lignin, e.g. lignin originated from hardwood, softwood or annular plants. Preferably the lignin is an alkaline lignin generated in e.g. the Kraft process. The lignin may then be separated from the black Iiquor byusing the process disclosed in WO2006031175.

The pH of the mixture of the first resin and the second resin may be adjustedby addition of acid or base, depending on the final use of the mixture of thefirst resin and the second resin. To the extent alkali is added, it is preferablysodium hydroxide, potassium hydroxide, calcium hydroxide, magnesiumhydroxide or a mixture thereof. To the extent acid is added, it is preferablysulphuric acid or paratoluenesulphonic acid.

The mixture of the first resin and the second resin according to the presentinvention is useful for example in the manufacture of laminate. The mixture ofthe first resin and the second resin is then impregnated into paper that shouldform the laminate and said sheets are pressed together and heated at atemperature of about 130-150 °C.

The mixture of the first resin and the second resin according to the presentinvention is also useful for example in the manufacture of plywood. Themixture of the first resin and the second resin is then applied to the surfacesof the plies or veneers that should form the plywood and said plies or veneersare pressed together and heated at a temperature of about 110-180 °C.

Examples Example 1 Lignin-phenol-formaldehyde (LPF) resin was synthesized for plywoodapplication with a phenol replacement level of 50% with lignin. ln the first step, 918 g powder lignin (solid content 91%) and 1225 g of waterwere added to a 5L glass reactor at ambient temperature and were stirreduntil the lignin was fully and evenly dispersed. Then, 426 g of sodiumhydroxide solution (50%) was added to the lignin dispersion. The compositionwas heated to 73°C and stirred for 60 minutes to make sure that lignin was completely dissolved in the alkaline media. Then, the temperature of the lignincomposition was lowered to 45 °C. ln the second step, 846g of phenol and 1802g of formalin solution (40%) wereadded into the reaction mixture. The temperature of the reaction mixture wasincreased to 80°C and the reaction mixture was continuously stirred for 115minutes. Then, 315g of sodium hydroxide solution (50%) was added and thereaction temperature was cooled to 75°C. Then, the reaction mixture wascontinuously stirred at 75°C for further 95 minutes before cooling down toroom temperature. The reaction was monitored by measuring the viscosity at25 °C using a Brookfield DV-ll + LV viscometer.

Example 2 Lignin-phenol-formaldehyde (LPF) resin was synthesized with a phenolreplacement level of 20% with lignin. ln the first step, the 66 g of powder lignin (solid content 91%) and 115 g ofwater were added to a 1L glass reactor at ambient temperature and werestirred until the lignin was fully and evenly dispersed. Then, 39 g of sodiumhydroxide solution (50%) was added to the lignin dispersion. The compositionwas heated to 80°C and stirred for 60 minutes to make sure that lignin wascompletely dissolved in the alkaline media. Then, the temperature of the lignincomposition was lowered to 45 °C. ln the second step, 242 g of phenol, 43 g of sodium hydroxide solution (50%),225 g of water and 327 g of formalin solution (52.5%) were added into thereaction mixture. The temperature of the reaction mixture was increased to80°C and the reaction mixture was continuously stirred for 130 minutes. Then,61 g of sodium hydroxide solution (50%) was added and the reactiontemperature was cooled to 75°C. Then, the reaction mixture was continuouslystirred at 75°C for further 130 minutes before cooling down to roomtemperature. The reaction was monitored by measuring the viscosity at 25 °C using a Brookfield DV-ll + LV viscometer.

Example 3The resin blend was prepared by mixing LPF resin from example 1 and LPFresin from example 2 in a ratio of 1:1 by weight.

The resin blend was analyzed and the results of the analysis are givenin Table 1.

Resin from Resin from Resin from Example 1 Example 2 Example 3Viscosity [cP] at 223 253 24025°CpH at23°C 11.5 11.6 11.5Solid Content [%] 45.5 42.9 44.2155°C Table 1: Resin properties Example 4 - Plywood ApplicationBirch veneers were sawn to 300 x 300 mm2 size and conditioned in 20°C,65% RH prior to manufacture. Glue comprising resin from example 3 was formulated according to Table 2.

Component Amount [wt. %]Resin from examples 3 71 5Filler/Hardener (contains limestone, 14 2cellulose, sodium carbonate, starch) ' Water 14 3 Table 2: Composition of glue for plywood boards Target glue content was 165 g/m2 which were spread on one side. Pre-pressing was performed at a pressure of 1.8 MPa for 15 minutes. The closeassembly time was 30 minutes. Hot pressing was performed at 127°C with apressure of 1.8 MPa. The total pressing time was 6 minutes 25 seconds.

Prior to evaluation, all samples were conditioned according to EN636 class 3test method. Shear strength was evaluated according to EN314 test method.

Average data from 20 test specimens is presented in Table 3.

Shear strength [N/mm2] Resin fromExample 35 Table 3: Plywood shear strength 1.65 ln view of the above detailed description of the present invention, other10 modifications and variations will become apparent to those skilled in the art.However, it should be apparent that such other modifications and variations may be effected without departing from the spirit and scope of the invention.

Claims (1)

1. Claims 11 A method for preparing a resin in the form of a mixture comprisingthe steps of a) preparing a first resin comprising lignin, formaldehyde andoptionally phenol; wherein lignin has replaced phenol to areplacement level of 40-100% and wherein the Iiqnin isqenerated in the Kraft process; preparing a second resin comprising Iignin, formaldehyde andoptionally phenol, wherein the second resin is different fromthe first resin, wherein the difference between the first resinand the second resin is the amount of Iiqnin in each resin;wherein lignin has replaced phenol to a replacement level of5-100% and wherein the Iiqnin is qenerated in the Kraftprocess; and mixing the first resin and the second resin in a weight ratio offrom 0.5:1O to 10:0.5 based on weight of the mixture of thefirst resin and second resin. A method according to claim 1, wherein the mixing in step c) iscarried out at from 20 to 1000 rpm. A method according to claim 1 or 2, wherein duration of themixing step is at least one minute. m I | F. . H | . . |H. . . | ._ åí._A method for selecting an optimized resin mixture for a specificend use, comprising the steps of a)b) defining desirable properties of a resin; preparing a first resin comprising lignin, formaldehyde andoptionally phenol; wherein lignin has replaced phenol to areplacement level of 40-100% and wherein the Iiqnin is qenerated in the Kraft process; C) d) 9) h) 12 preparing a second resin comprising lignin, formaldehyde andoptionally phenol, wherein the second resin is different fromthe first resin; wherein the difference between the first resinand the second resin is the amount of Iiqnin in each resin;wherein Iignin has replaced phenol to a replacement level of5-100% and wherein the Iiqnin is qenerated in the Kraftprocess; mixing the first resin and the second resin in a defined weightratio of from 0.5:10 to 10:0.5 based on weight of the mixture ofthe first resin and second resin; in an empty vessel, repeating step d) with a different weightratio; repeating step e) at least five times with additional differentweight ratios in step d) in each repetition; evaluating the properties of each mixture of the first resin andthe second resin, said evaluation being carried out based onthe properties of the resin as such or based on the propertiesof a final product prepared using each mixture of the first resinand the second resin obtained in step f); selecting the optimized mixture of the first resin and thesecond resin obtained in step f), based on the results of theevaluation carried out in step g), said selection stepcomprising the determination of which mixture of the first resinand second resin obtained in step f) has properties closest to the desired properties of a resin defined in step a).