Method of bonding using a lignosulfonate-phenol-formaldehyde resin binder

Claim 1

A method of manufacturing a sheet material formed from a plurality of discrete members adhered together, including contacting a plurality of discrete sheet material members with a binding resin; disposing each of said sheet material members in contact with at least one other of said sheet material members and pressing said sheet material members together with sufficient heat and pressure to form a sheet material, the improvement comprising said binding resin, wherein said resin is formed by mixing phenol, formaldehyde, an alkali and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process to form a reaction mixture and heating said mixture to polymerize said mixture, said lignosulfonate being added to said reaction mixture before a substantial amount of reaction between said phenol and said formaldehyde.

Claim 2

A method of manufacturing a sheet material formed from a plurality of discrete members adhered together, including contacting a plurality of discrete sheet material members with a binding resin; disposing each of said sheet material members in contact with at least one other of said sheet material members and pressing said sheet material members together with sufficient heat and pressure to form a sheet material, the improvement comprising said binding resin, wherein said resin is formed by mixing phenol, formaldehyde, an alkali and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process to form a reaction mixture and heating said mixture to polymerize said mixture, said lignosulfonate being added to said reaction mixture before a substantial amount of reaction between said phenol and said formaldehyde.

Claim 6

A method of manufacturing a sheet material formed from a plurality of discrete members adhered together, including contacting a plurality of discrete sheet material members with a binding resin; disposing each of said sheet material members in contact with at least one other of said sheet material members and pressing said sheet material members together with sufficient heat and pressure to form a sheet material, the improvement comprising said binding resin, wherein said resin is formed by heating a mixture of phenol, formaldehyde, and lignosulfonate wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before a substantial amount of reaction between said phenol and said formaldehyde; and heating said mixture at a temperature of 60° C. to 100° C. to form a lignosulfonate-phenol-formaldehyde polymer.

Claim 7

A method of manufacturing a sheet material formed from a plurality of discrete members adhered together, including contacting a plurality of discrete sheet material members with a binding resin; disposing each of said sheet material members in contact with at least one other of said sheet material members and pressing said sheet material members together with sufficient heat and pressure to form a sheet material, the improvement comprising said binding resin, wherein said resin is formed by heating a mixture of phenol, formaldehyde, and lignosulfonate wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before a substantial amount of reaction between said phenol and said formaldehyde; and heating said mixture at a temperature of 60° C. to 100° C. to form a lignosulfonate-phenol-formaldehyde polymer.

Claim 10

A method of manufacturing a cohesive article of a desired configuration comprising contacting a plurality of fibers with a lignosulfonate-phenol-formaldehyde resin and hot pressing said resin contacted fibers together to cause said fibers to adhere to each other wherein said resin is formed by heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 11

A method of manufacturing a cohesive article of a desired configuration comprising contacting a plurality of fibers with a lignosulfonate-phenol-formaldehyde resin and hot pressing said resin contacted fibers together to cause said fibers to adhere to each other wherein said resin is formed by heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 13

A method of molding an object having a predetermined configuration from a plurality of smaller objects comprising disposing an object-resin composition in a mold cavity, closing said mold cavity and pressing said composition to adhere said composition together into said predetermined configuration, wherein said object-resin composition comprises a plurality of said smaller objects and a lignosulfonate-phenol-formaldehyde resin formed by mixing phenol, formaldehyde and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process to form a reaction mixture, adding alkali incrementally to control the temperature rise of the mixture during reaction and heating said mixture to polymerize said mixture, said lignosulfonate being added to said mixture before a substantial amount of reaction between said said phenol and said formaldehyde.

Claim 14

A method of molding an object having a predetermined configuration from a plurality of smaller objects comprising disposing an object-resin composition in a mold cavity, closing said mold cavity and pressing said composition to adhere said composition together into said predetermined configuration, wherein said object-resin composition comprises a plurality of said smaller objects and a lignosulfonate-phenol-formaldehyde resin formed by mixing phenol, formaldehyde and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process to form a reaction mixture, adding alkali incrementally to control the temperature rise of the mixture during reaction and heating said mixture to polymerize said mixture, said lignosulfonate being added to said mixture before a substantial amount of reaction between said said phenol and said formaldehyde.

Claim 18

A method of manufacturing a solid article comprising a plurality of solid members bound with a lignosulfonate-phenol-formaldehyde resin comprising: heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in waste sulfite or sulfited cooking liquor as recovered from a pulping process and alkali wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before substantial reaction between said phenol and said formaldehyde; reacting said mixture to form a lignosulfonate-phenol-formaldehyde polymer; coating at least a portion of said solid members with said polymer; and pressing said solid members together under conditions to adhere said solid members together with said resin and thereby manufacture said solid article.

Claim 19

A method of manufacturing a solid article comprising a plurality of solid members bound with a lignosulfonate-phenol-formaldehyde resin comprising: heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in waste sulfite or sulfited cooking liquor as recovered from a pulping process and alkali wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before substantial reaction between said phenol and said formaldehyde; reacting said mixture to form a lignosulfonate-phenol-formaldehyde polymer; coating at least a portion of said solid members with said polymer; and pressing said solid members together under conditions to adhere said solid members together with said resin and thereby manufacture said solid article.

Claim 24

A method of manufacturing a plywood article including applying a binder comprising a polymer between two layers of wood and pressing said wood layers together under conditions sufficient to adhere said layers together, the improvement comprising said polymer wherein said polymer is formed by heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 25

A method of manufacturing a plywood article including applying a binder comprising a polymer between two layers of wood and pressing said wood layers together under conditions sufficient to adhere said layers together, the improvement comprising said polymer wherein said polymer is formed by heating a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 26

A method of manufacturing an oriented strand board including at least partially coating a plurality of wood fiber strand members with a polymeric binder; disposing said coated strand members in contact with at least one other of said strand members; and pressing said wood fiber strand members to adhere said strand members together; the improvement comprising said polymeric binder wherein said polymer is formed by a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 27

A method of manufacturing an oriented strand board including at least partially coating a plurality of wood fiber strand members with a polymeric binder; disposing said coated strand members in contact with at least one other of said strand members; and pressing said wood fiber strand members to adhere said strand members together; the improvement comprising said polymeric binder wherein said polymer is formed by a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 28

A method of manufacturing a waferboard including binding together a plurality of discrete, relatively thin wood pieces with a polymer binder under pressure sufficient to adhere said wood pieces together into sheet form, the improvement comprising the polymer binder wherein said polymer is formed by a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process lignosulfonate, phenol and formaldehyde, under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.

Claim 29

A method of manufacturing a waferboard including binding together a plurality of discrete, relatively thin wood pieces with a polymer binder under pressure sufficient to adhere said wood pieces together into sheet form, the improvement comprising the polymer binder wherein said polymer is formed by a mixture of phenol, formaldehyde, and a lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process lignosulfonate, phenol and formaldehyde, under alkaline conditions, said lignosulfonate being added to said phenol and formaldehyde before a substantial amount of reaction between said phenol and said formaldehyde and reacting said mixture to form said polymer.