Binder composition for manufacture of fiberboard

Claim 2

In a process for the preparation of a synthetic board wherein cellulosic material is contacted with a binder and the treated material is subsequently formed into boards by the application of heat and pressure, the improvement wherein the binder comprises an organic polyisocyanate and a mixture of reactive hydrogen-containing compounds containing an average of more than one reactive hydrogen atom per molecule, said mixture comprising a member selected from the group consisting of (a) a blend of (i) a polyester polyol and (ii) a reaction product of at least one fatty acid and at least one polyol, (b) a reaction product of at least one polyol and at least one coreactant selected from the group consisting of carboxylic acids, carboxylic acid esters and mixtures thereof, each coreactant including at least one fatty acid, (c) a mixture including at least one fatty acid amide, and (d) mixtures thereof.

Claim 3

The process of claim 1 wherein said polyisocyanate is a polymethylene polyphenyl polyisocyanate.

Claim 4

The process of claim 2 wherein said mixture of reactive hydrogen-containing compounds comprises a member selected from the group consisting of (1) blend (a) of claim 2 and said polyester polyol (i) comprises a member selected from the group consisting of (a) a mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of an ester-containing by-product fraction from the manufacture of dimethyl terephthalate, (b) a mixture prepared by the transesterification of polyalkylene terephthalate with a polyol, and (c) mixtures thereof, (2) reaction product (b) of claim 2 and said coreactant comprises a member selected from the group consisting of (a) an ester-containing by-product fraction from the manufacture of dimethyl terephthalate, (b) polyalkylene terephthalate, and (c) mixtures thereof, each coreactant including at least one fatty acid, and (3) mixtures thereof.

Claim 5

The process of claim 2 wherein said mixture of reactive hydrogen-containing compounds comprises a member selected from the group consisting of (1) blend (a) of claim 2 and said polyester polyol (i) comprises a member selected from the group consisting of (a) a mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials, (b) a mixture prepared by the transesterification, with a glycol of molecular weight from about 60 to about 400, of a residue remaining after dimethyl terephthalate and methyl p-toluate have been removed from a dimethyl terephthalate esterified oxidate reaction product, the major portion of said residue comprising a mixture of methyl and benzyl esters of benzene and biphenyl di- and tricarboxylic acids, (c) a mixture prepared by the transesterification of polyalkylene terephthalate with a polyol, and (d) mixtures thereof, (2) reaction product (b) of claim 2 and said coreactant comprises a member selected from the group consisting of (a) a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials, (b) a residue remaining after dimethyl terephthalate and methyl p-toluate have been removed from a dimethyl terephthalate esterified oxidate reaction product, the major portion of said residue comprising a mixture of methyl and benzyl esters of benzene and biphenyl di- and tricarboxylic acids, (c) polyalkylene terephthalate, and (d) mixtures thereof, each coreactant including at least one fatty acid, and (3) mixtures thereof.

Claim 6

The process of claim 2 wherein said mixture of reactive hydrogen-containing compounds comprises a member selected from the group consisting of (1) a blend of (i) a reaction product of at least one fatty acid and at least one glycol, and (ii) a member selected from the group consisting of (a) a mixture prepared by the transesterification, with a glycol, of an ester-containing by-product from the manufacture of dimethyl terephthalate, (b) a mixture prepared by the transesterification of polyalkylene terephthalate with a glycol, and (c) mixtures thereof, (2) a reaction product of at least one glycol, at least one fatty acid, and a member selected from the group consisting of (a) an ester-containing by-product from the manufacture of dimethyl terephthalate, (b) polyalkylene terephthalate, and (c) mixtures thereof, and (3) mixtures thereof, wherein each of said glycols is the same or different and is a member selected from the group consisting of ethylene glycol, diethylene glycol, dipropylene glycol, tripropylene glycol and mixtures thereof, and said mixture of reactive hydrogen-containing compounds has a hydroxyl number within a range of from about 150 to 200 and an acid number of from about 0.2 to 10.

Claim 7

The process of claim 2 wherein said mixture of reactive hydrogen-containing compounds comprises a member selected from the group consisting of (a) a blend of (i) a polyester polyol and (ii) a reaction product of at least one fatty acid and at least one polyol, (b) a reaction product of at least one polyol and at least one coreactant selected from the group consisting of carboxylic acids, carboxylic acid esters and mixtures thereof, each coreactant including at least one fatty acid, with the proviso that when said coreactant solely comprises a fatty member selected from the group consisting of fatty acids, fatty acid esters and mixtures thereof, said fatty member does not contain any hydroxyl group, (c) a mixture including at least one fatty acid amide, and (d) mixtures thereof.

Claim 8

The process of claim 6 wherein the equivalent ratio of said polymethylene polyphenyl polyisocyanate to said mixture of reactive hydrogen-containing compounds is about 10:1 to 2:1, and said fatty acid comprises about 5 to 95 weight percent of the ingredients used to produce said blend (a), and about 5 to 95 weight percent of the ingredients used to produce said reaction product (b).

Claim 9

The process of claim 6 wherein each fatty acid contains from 10 to 54 carbon atoms.

Claim 10

The process of claim 6 wherein said mixture of reactive hydrogen-containing compounds has a hydroxyl number of from about 100 to 700 and a functionality of from about 1 to 8.

Claim 11

The process of claim 6 wherein said mixture of reactive hydrogen-containing compounds has a hydroxyl number of from about 100 to 400 and a functionality of from about 1 to 2.

Claim 12

The process of claim 1 wherein said mixture of reactive hydrogen-containing compounds comprises hydroxyl group-containing compounds.

Claim 13

The process of claim 11 wherein the equivalent ratio of polyisocyanate to polyol is about 10:1 to 2:1.

Claim 14

The process of claim 11 wherein the equivalent ratio of polyisocyanate to polyol is about 8:1 to 3:1.

Claim 15

The process of claim 11 wherein said hydroxyl group-containing compounds comprise aromatic polyester polyols.

Claim 16

The process of claim 14 wherein the equivalent ratio of polyisocyanate to polyol is about 10:1 to 2:1.

Claim 17

The process of claim 14 wherein the equivalent ratio of polyisocyanate to polyol is about 8:1 to 3:1.

Claim 18

The process of claim 11 wherein said hydroxyl group-containing compounds comprise a mixture of polyether and polyester polyols.

Claim 19

The process of claim 17 wherein said polyester polyols comprise aromatic polyester polyols.

Claim 20

The process of claim 18 wherein the equivalent ratio of polyisocyanate to polyol is about 10:1 to 2:1.

Claim 21

The process of claim 18 wherein the equivalent ratio of polyisocyanate to polyol is about 8:1 to 3:1.

Claim 22

The process of claim 3 wherein the equivalent ratio of polyisocyanate to polyol is about 10:1 to 2:1.

Claim 23

The process of claim 3 wherein the equivalent ratio of polyisocyanate to polyol is about 8:1 to 3:1.

Claim 24

The process of claim 5 wherein the equivalent ratio of polyisocyanate to polyol is about 8:1 to 3:1.