US3903041A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composition board and process
Assignee: GP Chemicals Equity LLC
•
Filing: 1974-03-19
•
Granted: 1975-09-02
•
Expires: 1994-03-19
Abstract
Abstract The caulless system of composition board manufacture comprising a resin binder which is prepared by a controlled reaction of phenol with formaldehyde in the presence of small amounts of sodium hydroxide catalyst. One mole of phenol is reacted with from about 2.5 to 3.5 moles of formaldehyde in the presence of caustic soda catalyst to form a first stage resin having a viscosity of 150 - 300 cps at 77* F. Additional phenol in the range of 0.25 moles to 0.5 moles per mole of phenol in the initial reaction is then added as a second stage and the resin is again reacted to a viscosity of 150 to 750 centipoises. The amount of phenol added is that amount necessary to impart to particles of wood coated with the resin sufficient tack to cause them to adhere to each other and form a sheet of sufficient structural integrity and firmness to normal transfer operations in the caulless system of particle board manufacture. The resin has a pH of about 8.5 to about 10. Its cure may be accelerated by adding about 2 - 4 percent resorcinol formaldehyde resin.
Inventors
- 👤 Leopold F Bornstein
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 16:37
CPC Classifications
C; C08; C08G; C08G8/00; C08G8/04; C08G8/08; C08G8/10; C08L; C08L97/00; C08L97/02
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
22 words
IN A COMPOSITION BOARD COMPRISING WOOD PARTICLES AND A RESIN BINDER THE IMPROVEMENT COMPRISING AS SAID BINDER A PHENOLIC RESIN PREPARED BY:
Claim 2
Dependent Claim
22 words
IN A COMPOSITION BOARD COMPRISING WOOD PARTICLES AND A RESIN BINDER THE IMPROVEMENT COMPRISING AS SAID BINDER A PHENOLIC RESIN PREPARED BY:
Claim 3
Dependent Claim
57 words
REACTING PHENOL WITH A MOLAR EXCESS OF FORMALDEHYDE IN THE RANGE OF ABOUT 2.5 TO 3.5 MOLES OF FORMALDEHYDE PER MOLE OF PHENOL IN AN AQUEOUS MEDIUM UTLIZING AN ALKALINE CATALYST UNTIL THE RESULTING AQUEOUS RESIN HAS A BROOK FIELD VISCOSITY AT 77*F WITHIN THE RANGE 150 CPS TO 300 CPS TO FORM A FIRST STAGE RESIN,
Claim 4
Dependent Claim
57 words
REACTING PHENOL WITH A MOLAR EXCESS OF FORMALDEHYDE IN THE RANGE OF ABOUT 2.5 TO 3.5 MOLES OF FORMALDEHYDE PER MOLE OF PHENOL IN AN AQUEOUS MEDIUM UTLIZING AN ALKALINE CATALYST UNTIL THE RESULTING AQUEOUS RESIN HAS A BROOK FIELD VISCOSITY AT 77*F WITHIN THE RANGE 150 CPS TO 300 CPS TO FORM A FIRST STAGE RESIN,
Claim 5
Dependent Claim
36 words
ADDING FROM ABOUT 0.25 TO ABOUT 0.5 MOLES OF PHENOL PER MOLE OF PHENOL IN THE REACTION OF STEP (1) SAID ADDED PHENOL BEING SUFFICIENT TO IMPART TACK CHARACTERISTIC TO WOOD PARTICLES COATED WITH THE RESIN,
Claim 6
Dependent Claim
36 words
ADDING FROM ABOUT 0.25 TO ABOUT 0.5 MOLES OF PHENOL PER MOLE OF PHENOL IN THE REACTION OF STEP (1) SAID ADDED PHENOL BEING SUFFICIENT TO IMPART TACK CHARACTERISTIC TO WOOD PARTICLES COATED WITH THE RESIN,
Claim 7
Dependent Claim
36 words
adding from about 0.25 to about 0.5 moles of phenol per mole of phenol in the reaction of step (1), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin,
Claim 8
Dependent Claim
36 words
adding from about 0.25 to about 0.5 moles of phenol per mole of phenol in the reaction of step (1), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin,
Claim 9
Dependent Claim
26 words
The composition board of claim 1 wherein from about 2 to about 4 percent of a resorcinol-formaldehyde resin is added to the cooled phenol formaldehyde resin.
Claim 10
Dependent Claim
205 words
In the caulless process for preparing particle board comprising spraying wood particles with resin, forming the resin coated particles as a mat on an endless belt as either homogeneous or layered board, prepressing the mat and cutting the prepressed mat into a sheet of sufficient structural integrity and firmness to be transportable using standard caulless equipment, transferring the sheets to loading belts and loading the sheets into presses for cure, the improvement comprising employing a resin prepared by: a. reacting phenol with a molar excess of formaldehyde in the range of about 2.5 to 3.5 moles of formaldehyde per mole of phenol in an aqueous medium utilizing an alkaline catalyst until the resulting aqueous resin has a Brookfield viscosity at 77*F within the range 150 cps to 300 cps to form a first stage resin, b. adding from about 0.25 to about 0.5 moles of phenol per mole of phenol in the reaction of step (a), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin. c. continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and d. rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 11
Dependent Claim
205 words
In the caulless process for preparing particle board comprising spraying wood particles with resin, forming the resin coated particles as a mat on an endless belt as either homogeneous or layered board, prepressing the mat and cutting the prepressed mat into a sheet of sufficient structural integrity and firmness to be transportable using standard caulless equipment, transferring the sheets to loading belts and loading the sheets into presses for cure, the improvement comprising employing a resin prepared by: a. reacting phenol with a molar excess of formaldehyde in the range of about 2.5 to 3.5 moles of formaldehyde per mole of phenol in an aqueous medium utilizing an alkaline catalyst until the resulting aqueous resin has a Brookfield viscosity at 77*F within the range 150 cps to 300 cps to form a first stage resin, b. adding from about 0.25 to about 0.5 moles of phenol per mole of phenol in the reaction of step (a), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin. c. continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and d. rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 12
Dependent Claim
20 words
continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and
Claim 13
Dependent Claim
20 words
continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and
Claim 14
Dependent Claim
20 words
CONTINUING THE REACTION UNTIL THE AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY WITHIN THE RANGE 150 CPS TO 750 CPS AND
Claim 15
Dependent Claim
20 words
CONTINUING THE REACTION UNTIL THE AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY WITHIN THE RANGE 150 CPS TO 750 CPS AND
Claim 16
Dependent Claim
11 words
RAPIDLY COOLING THE AQUEOUS RESIN TO A TEMPERATURE LESS THAN 80*F.
Claim 17
Dependent Claim
11 words
RAPIDLY COOLING THE AQUEOUS RESIN TO A TEMPERATURE LESS THAN 80*F.
Claim 18
Dependent Claim
11 words
rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 19
Dependent Claim
11 words
rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 20
Dependent Claim
23 words
The process of claim 3 in which the resin further includes from about 2 to about 4 percent of resorcinol-formaldehyde resin as catalyst.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-09-01 | 1979-03-03 | 1979-09-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-09-01 | 1983-03-03 | 1983-09-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-09-01 | 1987-03-03 | 1987-09-02 | $7700.00 | Window Closed / Lapsed |