US4409293A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Wood composites of low formaldehyde emission
Assignee: Hexion Inc
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Filing: 1982-09-10
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Granted: 1983-10-11
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Expires: 2002-09-10
Abstract
Abstract A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying a binder to said lignocellulosic material, said binder comprising a urea-formaldehyde base resin having a ratio of formaldehyde to urea of 1.0:1-1.2:1, said base resin having essentially no free formaldehyde and said base resin when cured containing substantially more methylene groups than methylene ether groups, consolidating said lignocellulosic material and curing the binder.
Inventors
- 👤 James H. Williams
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 03:44
CPC Classifications
B; B32; B32B; B32B21/00; B32B21/02; B32B21/04; C; C08; C08G; C08G12/00; C08G12/02; C08G12/04; C08G12/10; C08G12/12; C08G12/26; C08G12/34; C08G12/36; C08G12/38; C09; C09J; C09J161/00; C09J161/20; C09J161/22; C09J161/24; Y; Y10; Y10T; Y10T428/00; Y10T428/25; Y10T428/253; Y10T428/31504; Y10T428/31942
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
80 words
A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying a binder to said lignocellulosic material, said binder comprising a urea-formaldehyde base resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said base resin having essentially no free formaldehyde and said base resin when cured containing substantially more methylene groups than methylene ether groups, consolidating said lignocellulosic material and curing the binder.
Claim 2
Dependent Claim
80 words
A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying a binder to said lignocellulosic material, said binder comprising a urea-formaldehyde base resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said base resin having essentially no free formaldehyde and said base resin when cured containing substantially more methylene groups than methylene ether groups, consolidating said lignocellulosic material and curing the binder.
Claim 3
Dependent Claim
16 words
The process of claim 1 wherein the molar ratio of the base resin is substantially 1:1.
Claim 4
Dependent Claim
19 words
The process of claim 2 wherein said base resin comprises 24.89 weight percent formaldehyde and 49.78 weight percent urea.
Claim 5
Dependent Claim
30 words
The process of claim 3 wherein said base resin further comprises 0.06 weight percent sulfuric acid, 0.05 weight percent sodium hydroxide and 0.33 weight percent triethanolamine, the balance comprising water.
Claim 6
Dependent Claim
15 words
The process of claim 1 or 2 wherein said binder further comprises a cross-linking agent.
Claim 7
Dependent Claim
27 words
The process of claim 5 wherein the cross-linking agent is selected from the group comprising trimethoxymethylmelamine, hexamethoxymethylmelamine, ##STR4## where n=1-6; dimethoxymethyldihydroxyethylene urea, tetraethoxymethylglycoluril, dibutoxymethylurea, 5-ethyl-1-aza-3,7-dioxabicyclo[3,3,0]octane and 5-hydroxymethyl-1-aza-3,7-dioxabicyclo[3,3,0]-octane.
Claim 8
Dependent Claim
13 words
The process of claim 6 wherein the cross-linking agent is trimethoxymethylmelamine or hexamethoxymethylmelamine.
Claim 9
Dependent Claim
11 words
The process of claim 7 which additionally contains an acid catalyst.
Claim 10
Dependent Claim
66 words
An improved pressed composite of lignocellulosic material bound together by a urea-formaldehyde binder, which composite is characterized by reduced emission of formaldehyde, wherein the improvement comprises using as said binder a urea-formaldehyde base resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said base resin having no free formaldehyde and said base resin when cured contains substantially more methylene groups then methylene ether groups.
Claim 11
Dependent Claim
66 words
An improved pressed composite of lignocellulosic material bound together by a urea-formaldehyde binder, which composite is characterized by reduced emission of formaldehyde, wherein the improvement comprises using as said binder a urea-formaldehyde base resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said base resin having no free formaldehyde and said base resin when cured contains substantially more methylene groups then methylene ether groups.
Claim 12
Dependent Claim
17 words
The improved process of claim 9 wherein the molar ratio of said base resin is substantially 1:1.
Claim 13
Dependent Claim
19 words
The composite of claim 10 wherein said base resin comprises 24.89 weight percent formaldehyde and 49.78 weight percent urea.
Claim 14
Dependent Claim
30 words
The composite of claim 11 wherein said base resin further comprises 0.06 weight percent sulfuric acid, 0.05 weight percent sodium hydroxide and 0.33 weight percent triethanolamine, the balance comprising water.
Claim 15
Dependent Claim
15 words
The composite of claim 9 or 10 wherein said binder further comprises a cross-linking agent.
Claim 16
Dependent Claim
27 words
The composite of claim 13 wherein said cross-linking agent is selected from the group comprising trimethoxymethylmelamine, hexamethoxymethylmelamine, ##STR5## where n=1-6, dimethoxymethyldihydroxyethylene urea, tetraethoxymethylglycoluril, dibutoxymethylurea, 5-ethyl-1-aza-3,7-dioxabicyclo[3,3,0]octane and 5-hydroxymethyl-1-aza-3,7-dioxabicyclo[3,3,0]-octane.
Claim 17
Dependent Claim
13 words
The composite of claim 14 wherein said cross-linking agent is trimethoxymethylmelamine or hexamethoxymethylmelamine.
Claim 18
Dependent Claim
13 words
The composite of claim 15 wherein said binder additionally contains an acid catalyst.
Claim 19
Dependent Claim
72 words
A process for adhesively securing a first item to a second using a curable urea-formaldehyde resin, comprising disposing between a first item and a second item a curable urea-formaldehyde resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said resin containing essentially no free formaldehyde and being curable to a structure containing substantially more methylene groups than methylene ether groups, and then curing said resin to bind said items together.
Claim 20
Dependent Claim
72 words
A process for adhesively securing a first item to a second using a curable urea-formaldehyde resin, comprising disposing between a first item and a second item a curable urea-formaldehyde resin having a molar ratio of formaldehyde to urea of 1.0:1-1.2:1, said resin containing essentially no free formaldehyde and being curable to a structure containing substantially more methylene groups than methylene ether groups, and then curing said resin to bind said items together.
Claim 21
Dependent Claim
15 words
The process of claim 17 wherein the molar ratio of said resin is substantially 1:1.
Claim 22
Dependent Claim
63 words
The process of claim 18 wherein said resin is the reaction product of about 0.55 mole of urea per mole of formaldehyde with a neutral urea-formaldehyde solution having a pH of 7.2-7.5, said urea-formaldehyde solution prepared by reacting about 0.28 moles of urea per mole of formaldehyde with an acidified formaldehyde solution having a pH of 0.5-2.5 and then neutralizing the reaction solution.
Claim 23
Dependent Claim
36 words
The process of claim 19 wherein said resin comprises 24.89 weight percent formaldehyde, 49.78 weight percent urea, 0.06 weight percent sulfuric acid, 0.05 weight percent sodium hydroxide and 0.33 weight percent triethanolamine, the balance comprising water.
Claim 24
Dependent Claim
24 words
The process of claim 17 or 18 including a preliminary step, prior to dispersing said resin, of mixing a cross-linking agent with said resin.
Claim 25
Dependent Claim
27 words
The process of claim 21 wherein said cross-linking agent is selected from the group comprising trimethoxymethylmelamine, hexamethoxymethylmelamine, ##STR6## where n=1-6, dimethoxymethyldihydroxyethylene urea, tetraethoxymethylglycoluril, dibutoxymethylurea, 5-ethyl-1-aza-3,7-dioxabicyclo[3,3,0]octane and 5-hydroxymethyl-1-aza-3,7-dioxabicyclo[3,3,0]octane.
Claim 26
Dependent Claim
81 words
A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying a binder to said lignocellulosic material, said binder comprising a amino-formaldehyde base resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said base resin having essentially no free formaldehyde and said base resin when cured containing substantially more methylene groups than methylene ether groups, consolidating said lignocellulosic material and curing the binder.
Claim 27
Dependent Claim
81 words
A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying a binder to said lignocellulosic material, said binder comprising a amino-formaldehyde base resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said base resin having essentially no free formaldehyde and said base resin when cured containing substantially more methylene groups than methylene ether groups, consolidating said lignocellulosic material and curing the binder.
Claim 28
Dependent Claim
14 words
The process of claim 23 wherein the base resin is an urea-melamine-formaldehyde base resin.
Claim 29
Dependent Claim
15 words
The process of claim 23 or 24 wherein said binder further comprises a cross-linking agent.
Claim 30
Dependent Claim
67 words
An improved pressed composite of lignocellulosic material bound together by a urea-formaldehyde binder, which composite is characterized by reduced emission of formaldehyde, wherein the improvement comprises using as said binder a amino-formaldehyde base resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said base resin having no free formaldehyde and said base resin when cured contains substantially more methylene groups then methylene ether groups.
Claim 31
Dependent Claim
67 words
An improved pressed composite of lignocellulosic material bound together by a urea-formaldehyde binder, which composite is characterized by reduced emission of formaldehyde, wherein the improvement comprises using as said binder a amino-formaldehyde base resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said base resin having no free formaldehyde and said base resin when cured contains substantially more methylene groups then methylene ether groups.
Claim 32
Dependent Claim
14 words
The composite of claim 26 wherein the base resin is an urea-melamine-formaldehyde base resin.
Claim 33
Dependent Claim
15 words
The composite of claim 26 or 27 wherein said binder further comprises a cross-linking agent.
Claim 34
Dependent Claim
73 words
A process for adhesively securing a first item to a second using a curable urea-formaldehyde resin, comprising disposing between a first item and a second item a curable amino-formaldehyde resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said resin containing essentially no free formaldehyde and being curable to a structure containing substantially more methylene groups than methylene ether groups, and then curing said resin to bind said items together.
Claim 35
Dependent Claim
73 words
A process for adhesively securing a first item to a second using a curable urea-formaldehyde resin, comprising disposing between a first item and a second item a curable amino-formaldehyde resin having a molar ratio of formaldehyde to amino compound of 1.0:1-1.2:1, said resin containing essentially no free formaldehyde and being curable to a structure containing substantially more methylene groups than methylene ether groups, and then curing said resin to bind said items together.
Claim 36
Dependent Claim
12 words
The process of claim 29 wherein the resin is a urea-melamine-formaldehyde resin.
Claim 37
Dependent Claim
24 words
The process of claim 29 or 30 including a preliminary step, prior to dispersing said resin, of mixing a cross-linking agent with said resin.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-10-10 | 1987-04-11 | 1987-10-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-10-10 | 1991-04-11 | 1991-10-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-10-10 | 1995-04-11 | 1995-10-11 | $7700.00 | Window Closed / Lapsed |