Patent ID: 9133374
Filing Date: 2015-09-15
Classification: C08L,C09D,C09J,Y10T

Abstract:
1. A method for making a composite product, comprising: contacting a plurality of lignocellulose substrates with a resin system comprising: a first aqueous resin comprising at least two polymerized monomers and a second aqueous resin comprising at least two polymerized monomers, wherein: the first aqueous resin is present in an amount of about 5 wt % to about 95 wt %, based on the total weight of the resin system, the second aqueous resin is present in an amount of about 5 wt % to about 95 wt %, based on the total weight of the resin system, the at least two polymerized monomers of the first and second aqueous resins are the same monomers, the first aqueous resin is selected from the group consisting of: a first phenol-formaldehyde resin having a molar ratio of formaldehyde to phenol of about 1.5 to about 2.2, a first urea-formaldehyde resin having a molar ratio of formaldehyde to urea of about 0.25 to about 1.5, a first melamine-formaldehyde resin having a molar ratio of formaldehyde to melamine of about 0.25 to about 1.5, a first resorcinol-formaldehyde resin having a molar ratio of formaldehyde to resorcinol of about 0.4 to about 2, and a first melamine-urea-formaldehyde resin having a molar ratio of F:(M+U), wherein F is the moles of formaldehyde, M is the moles of melamine, U is the moles of urea, and the molar ratio of F:(M+U) is about 0.25 to about 2.1, the second aqueous resin is selected from the group consisting of: a second phenol-formaldehyde resin having a molar ratio of formaldehyde to phenol of about 2 to about 2.6, a second urea-formaldehyde resin having a molar ratio of formaldehyde to urea of about 0.25 to about 2.1, a second melamine-formaldehyde resin having a molar ratio of formaldehyde to melamine of about 0.8 to about 2, a second resorcinol-formaldehyde resin having a molar ratio of formaldehyde to resorcinol of about 1.6 to about 2, a third resorcinol-formaldehyde resin having a molar ratio of formaldehyde to resorcinol of about 0.4 to about 1, and a second melamine-urea-formaldehyde resin having a molar ratio of F:(M+U), wherein F is the moles of formaldehyde, M is the moles of melamine, U is the moles of urea, and the molar ratio of F:(M+U) is about 0.8 to about 2.1; and at least partially curing the resin system to produce a composite product.