Methods for making lignocellulose containing composite products

• Main Authors: Hines, John B, Sniady, Adam K, Williamson, Bobby L, Atkinson, Derek L, Hagiopol, Cornel
• Format: Patent
• Language: English
• Published: 31.08.2018
• Subjects: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOIDCHEMISTRY; CHEMISTRY; COMPOSITIONS BASED THEREON; COMPOUNDS THEREOF; DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS; DERIVATIVES THEREOF; FIBREBOARD; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR; INORGANIC CHEMISTRY; LAUNDERING; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS ORFROM PAPIER-MACHE; METALLURGY; NON-METALLIC ELEMENTS; ORGANIC MACROMOLECULAR COMPOUNDS; PAPER-MAKING; PERFORMING OPERATIONS; PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL; POLYSACCHARIDES; PRODUCTION OF CELLULOSE; TEXTILES; THEIR PREPARATION OR CHEMICAL WORKING-UP; THEIR RELEVANT APPARATUS; TRANSPORTING; TREATMENT OF TEXTILES OR THE LIKE; TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS,FABRICS, FEATHERS, OR FIBROUS GOODS MADE FROM SUCH MATERIALS

Methods for making composite products are provided. Embodiments described herein relate to methods for making lignocellulose containing composite products. Conventional binders used in the production of these products frequently contain formaldehyde based resins. However, these binders also release formaldehyde into the environment during the production of the binder, curing of the binder/composite product, as well as, from the final product made using the binder. The present invention provides improved methods for making lignocellulose containing composite products having reduced or no formaldehyde emission. In at least one specific embodiment, the method can include combining a plurality of lignocellulose substrates and one or more free radical precursors that can include a catalyst and an oxidant to produce a mixture of the lignocellulose substrates and the one or more free radical precursors. The method can also include maintaining the mixture at a temperature less than 60°C for at least 10 minutes while retaining at least 11 wt% of the oxidant charged to the mixture. The method can then include heating the mixture comprising at least 11 wt% of the oxidant charged to the mixture to a temperature of at least 60°C to about 300°C to produce a composite product. The composite product can have a density less than 1 g/cm3 and an internal bond strength of at least 0.35 MPa.