US4130515A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Lignin-based composition board binder comprising a copolymer of a lignosulfonate, melamine and an aldehyde
Assignee: GP Chemicals Equity LLC
•
Filing: 1977-06-30
•
Granted: 1978-12-19
•
Expires: 1997-06-30
Abstract
Abstract A lignin-based resin binder for use in the manufacture of composition board is produced by the in situ copolymerization of a major portion of a lignosulfonate salt with melamine and formaldehyde. This resin binder employs lignosulfonate levels up to about 70 percent without any of the deleterious effects normally associated with lignin-based resin systems. The resulting binder is completely compatible with conventional composition board processes and produces a board with superior stability under adverse conditions involving high humidity and temperature over a board produced with a standard typical urea-formaldehyde resin as presently in use.
Inventors
- 👤 Leopold F. Bornstein
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 23:37
CPC Classifications
C; C08; C08H; C08H6/00; C08G; C08G16/00; C08G16/02; C08G16/0293; C08L; C08L97/00; C08L97/02; C09; C09J; C09J161/00; C09J161/34; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31942; Y10T428/31949
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
34 words
A thermosetting resin composition board binder comprising a copolymer of lignosulfonate, melamine, and an aldehyde, said copolymer prepared by the in situ reaction under alkaline conditions of a lignosulfonate salt, melamine, and an aldehyde.
Claim 2
Dependent Claim
34 words
A thermosetting resin composition board binder comprising a copolymer of lignosulfonate, melamine, and an aldehyde, said copolymer prepared by the in situ reaction under alkaline conditions of a lignosulfonate salt, melamine, and an aldehyde.
Claim 3
Dependent Claim
52 words
The binder of claim 1 wherein said lignosulfonate is present in an amount of about 25 to 75 percent by weight, said melamine is present in an amount of about 9 to 30 percent by weight and said aldehyde is present in an amount of about 15 to 45 percent by weight.
Claim 4
Dependent Claim
12 words
The binder of claim 1 wherein said lignosulfonate salt is sodium lignosulfonate.
Claim 5
Dependent Claim
16 words
The binder of claim 1 wherein said melamine is partially methylated by the addition of methanol.
Claim 6
Dependent Claim
10 words
The binder of claim 1 wherein said aldehyde is formaldehyde.
Claim 7
Dependent Claim
15 words
The binder of claim 1 wherein said lignosulfonate salt is prereacted with phenol to copolymerization.
Claim 8
Dependent Claim
17 words
The binder of claim 1 wherein said lignosulfonate salt is prereacted with additional aldehyde prior to copolymerization.
Claim 9
Dependent Claim
25 words
The binder of claim 1 comprising about 70 percent by weight lignosulfonate, about 10 percent by weight melamine and about 15 percent by weight formaldehyde.
Claim 10
Dependent Claim
25 words
A process for preparing a thermosetting resin composition board binder which comprises copolymerization in situ, under alkaline conditions a lignosulfonate salt, melamine, and an aldehyde.
Claim 11
Dependent Claim
25 words
A process for preparing a thermosetting resin composition board binder which comprises copolymerization in situ, under alkaline conditions a lignosulfonate salt, melamine, and an aldehyde.
Claim 12
Dependent Claim
52 words
The process of claim 9 wherein said lignosulfonate is present in an amount of about 25 to 75 percent by weight, said melamine is present in an amount of about 9 to 30 percent by weight and said aldehyde is present in an amount of about 15 to 45 percent by weight.
Claim 13
Dependent Claim
12 words
The process of claim 9 wherein said lignosulfonate salt is sodium lignosulfonate.
Claim 14
Dependent Claim
18 words
The process of claim 9 wherein said melamine is partially methylated by adding methanol to the reaction mixture.
Claim 15
Dependent Claim
10 words
The process of claim 9 wherein said aldehyde is formaldehyde.
Claim 16
Dependent Claim
20 words
The process of claim 9 wherein said copolymerization is carried out at a temperature of about 80° to 100° C.
Claim 17
Dependent Claim
19 words
The process of claim 9 wherein said copolymerization is carried out at a pH of about 9 to 10.
Claim 18
Dependent Claim
19 words
The process of claim 9 additionally comprising the step of prereacting said lignosulfonate with phenol prior to said copolymerization.
Claim 19
Dependent Claim
26 words
The process of claim 16 wherein said phenol is added in an amount of about 5 to 15 percent by weight based on said lignosulfonate solids.
Claim 20
Dependent Claim
20 words
The process of claim 9 additionally comprising the step of prereacting said lignosulfonate with additional formaldehyde prior to said copolymerization.
Claim 21
Dependent Claim
27 words
The process of claim 18 wherein said additional formaldehyde is added in amount of from about 2 to 5 percent by weight based on said lignosulfonate solids.
Claim 22
Dependent Claim
73 words
A process for producing cured composition board comprising the steps of (a) mixing a particulate cellulosic material with a thermosetting resin binder, said binder comprising a copolymer of a lignosulfonate, melamine and an aldehyde, said copolymer prepared by the in situ reaction under alkaline conditions of a lignosulfonate salt, melamine, and an aldehyde; and (b) consolidating said mixture under heat and pressure to form a board-like product and to cure said resin binder.
Claim 23
Dependent Claim
73 words
A process for producing cured composition board comprising the steps of (a) mixing a particulate cellulosic material with a thermosetting resin binder, said binder comprising a copolymer of a lignosulfonate, melamine and an aldehyde, said copolymer prepared by the in situ reaction under alkaline conditions of a lignosulfonate salt, melamine, and an aldehyde; and (b) consolidating said mixture under heat and pressure to form a board-like product and to cure said resin binder.
Claim 24
Dependent Claim
22 words
The process of claim 20 wherein said binder is present in an amount of from about 6 to 12 percent by weight.
Claim 25
Dependent Claim
52 words
The process of claim 20 wherein said lignosulfonate is present in an amount of about 25 to 75 percent by weight, said melamine is present is an amount of about 9 to 30 percent by weight and said aldehyde is present in an amount of about 15 to 45 percent by weight.
Claim 26
Dependent Claim
12 words
The process of claim 20 wherein said lignosulfonate salt is sodium lignosulfonate.
Claim 27
Dependent Claim
16 words
The process of claim 20 wherein said melamine is partially methylated by the addition of methanol.
Claim 28
Dependent Claim
10 words
The process of claim 20 wherein said aldehyde is formaldehyde.
Claim 29
Dependent Claim
16 words
The process of claim 20 wherein said lignosulfonate salt is prereacted with phenol prior to copolymerization.
Claim 30
Dependent Claim
17 words
The process of claim 20 wherein said lignosulfonate salt is prereacted with additional aldehyde prior to copolymerization.
Claim 31
Dependent Claim
28 words
The process of claim 20 wherein said binder comprises about 70 percent by weight lignosulfonate, about 10 percent by weight melamine and about 15 percent by weight formaldehyde.
Claim 32
Dependent Claim
44 words
A composition board comprising a plurality of consolidated cellulosic particles bound into board-like form by a cured, crosslinked, infusable resin copolymer of lignosulfonate, melamine and an aldehyde, said copolymer prepared by the reaction under alkaline conditions, of a lignosulfonate salt, melamine and an aldehyde.
Claim 33
Dependent Claim
44 words
A composition board comprising a plurality of consolidated cellulosic particles bound into board-like form by a cured, crosslinked, infusable resin copolymer of lignosulfonate, melamine and an aldehyde, said copolymer prepared by the reaction under alkaline conditions, of a lignosulfonate salt, melamine and an aldehyde.
Claim 34
Dependent Claim
53 words
The composition board of claim 29 wherein said lignosulfonate is present in an amount of about 25 to 75 percent by weight, said melamine is present in an amount of about 9 to 30 percent by weight and said aldehyde is present in an amount of about 15 to 45 percent by weight.
Claim 35
Dependent Claim
13 words
The composition board of claim 29 wherein said lignosulfonate salt is sodium lignosulfonate.
Claim 36
Dependent Claim
17 words
The composition board of claim 29 wherein said melamine is partially methylated by the addition of methanol.
Claim 37
Dependent Claim
11 words
The composition board of claim 29 wherein said aldehyde is formaldehyde.
Claim 38
Dependent Claim
17 words
The composition board of claim 29 wherein said lignosulfonate salt is prereacted with phenol prior to copolymerization.
Claim 39
Dependent Claim
18 words
The composition board of claim 29 wherein said lignosulfonate salt is prereacted with additional aldehyde prior to copolymerization.
Claim 40
Dependent Claim
29 words
The composition board of claim 29 wherein said copolymer comprises about 70 percent by weight lignosulfonate, about 10 percent by weight melamine and about 15 percent by weight formaldehyde.
References Cited (Backward Citations)
US2562898A
Cited
US2622979A
Cited
US2849314A
Cited
US2786008A
Cited
US2794790A
Cited
US3017303A
Cited
US3011998A
Cited
US3076738A
Cited
US3093609A
Cited
US3117098A
Cited
US3093604A
Cited
US3093605A
Cited
US3304346A
Cited
US3597375A
Cited
US3658638A
Cited
US3677884A
Cited
US3864290A
Cited
US3931072A
Cited
GB1404536A
Cited
US3940352A
Cited
US3975319A
Cited
US3990928A
Cited
US3956207A
Cited
US3968294A
Cited
US3886101A
Cited
US4026744A
Cited
US3994850A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-12-18 | 1982-06-19 | 1982-12-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-12-18 | 1986-06-19 | 1986-12-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-12-18 | 1990-06-19 | 1990-12-19 | $7700.00 | Window Closed / Lapsed |