Composite products made with lewis acid catalyzed binder compositions that include tannins and multifunctional aldehydes

• Main Authors: JING FENG, WILLIAMSON BOBBY L
• Format: Patent
• Language: English
• Published: 28.10.2016
• Subjects: ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; ADHESIVES; CHEMISTRY; COMPOSITIONS BASED THEREON; DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS; DYES; MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUTORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTINGOF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL; METALLURGY; MISCELLANEOUS APPLICATIONS OF MATERIALS; MISCELLANEOUS COMPOSITIONS; NAILING OR STAPLING MACHINES IN GENERAL; NATURAL RESINS; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ORGANIC MACROMOLECULAR COMPOUNDS; PAINTS; PERFORMING OPERATIONS; POLISHES; THEIR PREPARATION OR CHEMICAL WORKING-UP; TRANSPORTING; USE OF MATERIALS AS ADHESIVES; WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL

The technical problem of the invention relates to a need for improved binder compositions for making composite products having reduced or no formaldehyde emission. The solution to the problem involves a composite product and a method for making the same. The method for making a composite product comprises: contacting a plurality of lignocellulose substrates with a binder composition, wherein the binder composition comprises: one or more tannins; one or more Lewis acids; and one or more multifunctional aldehyde compounds, wherein the one or more multifunctional aldehyde compounds comprises 2-hydroxyglutaraldehyde, -methylglutaraldehyde, malondialdehyde, succinaldehyde, pimelaldehyde, suberaldehyde, malealdehyde, fumaraldehyde, sebacaldehyde, adipaldehyde, phthalaldehyde, isophthalaldehyde, terephthalaldehyde, 5-(hydroxymethyl)furfural, or any combination thereof, and wherein the binder composition has about 1 wt% to about 40 wt% of the one or more multifunctional aldehyde compounds, based on a combined weight of the one or more tannins, the one or more Lewis acids, and the one or more multifunctional aldehyde compounds; and at least partially curing the binder composition to provide a composite product comprising the at least partially cured binder composition and the plurality of lignocellulose substrates, wherein a carbon atom of at least one aldehyde functional group in the at least partially cured binder composition has a first bond with a first tannin molecule of the one or more tannins and a second bond with (a) the first tannin molecule, (b) a second tannin molecule of the one or more tannins, or (c) an oxygen atom of the at least one aldehyde functional group.