Isocyanate-carboxyl group-containing fatty compounds for manufacture of lignocellulosic composites

Claim 2

In the process for the production of a molded article wherein particulate material selected from the group consisting of organic material, inorganic material and mixtures thereof is contacted with a binder and the treated material is subsequently formed into the molded article by the application of heat and pressure provided by a molding device, the improvement wherein the binder comprises (a) an organic polyisocyanate and (b) a fatty material selected from the group consisting of a polyfunctional polymeric fatty acid, a chain-extended polycarboxyl compound containing a polymeric fatty radical and mixtures thereof, the acid number of the fatty material being in the range from about 30-250, and the chain-extended polycarboxyl compound being the reaction product of a polyfunctional polymeric fatty acid with at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 3

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

Claim 4

The process of claim 2 wherein the particulate material comprises a lignocellulosic material.

Claim 5

The process of claim 3 wherein the binder includes at least one additional compound having at least one group which is reactive with isocyanate.

Claim 6

The process of claim 3 wherein the fatty material comprises a polymeric fatty acid selected from the group consisting of dimerized fatty acids, trimerized fatty acids, higher polymers of fatty acids and mixtures thereof.

Claim 7

The process of claim 5 wherein the binder components are applied neat or in the form of a solution or dispersion to the lignocellulosic material.

Claim 8

The process of claim 5 wherein the polymeric fatty acid is derived from unsaturated C 18 fatty acids and comprises about 0 to 15 weight percent of C 18 monobasic acids, 50 to 96 weight percent of C 36 dibasic acids and 4 to 35 weight percent of higher polybasic acids.

Claim 9

The process of claim 3 wherein the fatty material comprises a chain-extended polycarboxyl compound containing a polymeric fatty radical, the chain-extended polycarboxyl compound being the reaction product of (a) a polymeric fatty acid selected from the group consisting of dimerized fatty acids, trimerized fatty acids, higher polymers of fatty acids and mixtures thereof, and (b) at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 10

The process of claim 8 wherein the polymeric fatty acid is derived from unsaturated C 18 fatty acids and comprises about 0 to 15 weight percent of C 18 monobasic acids, 50 to 96 weight percent of C 36 dibasic acids and 4 to 35 weight percent of higher polybasic acids.

Claim 11

The process of claim 8 wherein reactant (b) comprises a member selected from the group consisting of glycols, diamines, aminoalcohols, mixtures thereof, and mixtures of the glycols, diamines and aminoalcohols with acidic compounds selected from the group consisting of dicarboxylic acids, dicarboxylic acid anhydrides and dicarboxylic acid esters.

Claim 12

The process of claim 8 wherein reactant (b) comprises a glycol.

Claim 13

The process of claim 1 wherein the surface of the molding device or the surface of the binder-contacted material or both are treated before the pressing with a fatty material selected from the group consisting of a polyfunctional polymeric fatty acid, a chain-extended polycarboxyl compound containing a polymeric fatty radical and mixtures thereof, the acid number of the fatty material being in the range from about 30-250, and the chain-extended polycarboxyl compound being the reaction product of a polyfunctional polymeric fatty acid with at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 14

In a process for the production of a molded article wherein particulate material selected from the group consisting of organic material, inorganic material and mixtures thereof is contacted with a binder and the treated material is subsequently formed into the molded article by the application of heat and pressure provided by a molding device, the improvement wherein the binder comprises an organic polyisocyanate and the surface of the molding device or the surface of the binder-contacted material or both are treated before the pressing with a fatty material selected from the group consisting of a polyfunctional fatty acid, a chain-extended polycarboxyl compound containing a polymeric fatty radical and mixtures thereof, the acid number of the fatty material being in the range from about 30-250, and the chain-extended polycarboxyl compound being the reaction product of a polyfunctional polymeric fatty acid with at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 15

In a process for the production of a molded article wherein particulate material selected from the group consisting of organic material, inorganic material and mixtures thereof is contacted with a binder and the treated material is subsequently formed into the molded article by the application of heat and pressure provided by a molding device, the improvement wherein the binder comprises an organic polyisocyanate and the surface of the molding device or the surface of the binder-contacted material or both are treated before the pressing with a fatty material selected from the group consisting of a polyfunctional fatty acid, a chain-extended polycarboxyl compound containing a polymeric fatty radical and mixtures thereof, the acid number of the fatty material being in the range from about 30-250, and the chain-extended polycarboxyl compound being the reaction product of a polyfunctional polymeric fatty acid with at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 16

The process of claim 13 wherein the polyisocyanate is a polymethylene polyphenyl polyisocyanate.

Claim 17

The process of claim 14 wherein the particulate material comprises a lignocellulosic material.

Claim 18

The process of claim 15 wherein the binder includes at least one compound having at least one group which is reactive with isocyanate.

Claim 19

The process of claim 15 wherein the fatty material comprises a polymeric fatty acid selected from the group consisting of dimerized fatty acids, trimerized fatty acids, higher polymers of fatty acids and mixtures thereof.

Claim 20

The process of claim 17 wherein the binder is applied neat or in the form of a solution or dispersion to the lignocellulosic material.

Claim 21

The process of claim 17 wherein the polymeric fatty acid is derived from unsaturated C 18 fatty acids and comprises about 0 to 15 weight percent of C 18 monobasic acids, 50 to 96 weight percent of C 36 dibasic acids and 4 to 35 weight percent of higher polybasic acids.

Claim 22

The process ov claim 15 wherein the fatty material comprises a chain-extended polycarboxyl compound containing a polymeric fatty radical, the chain-extended polycarboxyl compound being the reaction product of (a) a polymeric fatty acid selected from the group consisting of dimerized fatty acids, trimerized fatty acids, higher polymers of fatty acids and mixtures thereof, and (b) at least one other compound having at least two active hydrogen groups, the acid equivalents employed in the preparation of the chain-extended polycarboxyl compound being in excess relative to the equivalents of the other active hydrogen group-containing compound or compounds employed in the preparation.

Claim 23

The process of claim 20 wherein the polymeric fatty acid is derived from unsaturated C 18 fatty acids and comprises about 0 to 15 weight percent of C 18 monobasic acids, 50 to 96 weight percent of C 36 dibasic acids and 4 to 35 weight percent of higher polybasic acids.

Claim 24

The process of claim 20 wherein reactant (b) comprises a member selected from the group consisting of glycols, diamines, aminoalcohols, mixtures thereof, and mixtures of the glycols, diamines and aminoalcohols with acidic compounds selected from the group consisting of dicarboxylic acids, dicarboxylic acid anhydrides and dicarboxylic acid esters.

Claim 25

The process of claim 20 wherein reactant (b) comprises a glycol.

Claim 26

The process of claim 12 wherein the fatty material is applied in the form of an aqueous emulsion which contains an emulsifying agent.

Claim 27

The process of claim 24 wherein the emulsifying agent is triethanolamine.

Claim 28

The process of claim 13 wherein the fatty material is applied in the form of an aqueous emulsion which contains an emulsifying agent.

Claim 29

The process of claim 26 wherein the emulsifying agent is triethanolamine.

Claim 30

The process of claim 15 wherein the fatty material is applied in the form of an aqueous emulsion which contains an emulsifying agent.

Claim 31

The process of claim 28 wherein the emulsifying agent is triethanolamine.

Claim 32

The process of claim 16 wherein the fatty material is applied in the form of an aqueous emulsion which contains an emulsifying agent.

Claim 33

The process of claim 30 wherein the emulsifying agent is triethanolamine.

Claim 34

The process of claim 19 wherein the polymeric fatty acid is applied in the form of an aqueous emulsion which contains an emulsifying agent.

Claim 35

The process of claim 32 wherein the emulsifying agent is triethanolamine.