Abstract:
An adhesive suitable for bonding wood is both heat curable and radio frequency (RF) curable. This adhesive is composed of an isocyanate-terminated prepolymer and hydrolyzed soy protein having a pH of at least about 9 and advantageously from about 9 to 11.5. The weight ratio of prepolymer to soy protein hydrolyzate ranges from about 70:30 to 90:10.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to adhesives for joining wood products, and more particularly to two-part polyurethane adhesives modified with soy protein which adhesives are both heat and radio frequency (RF) curable. 
     Glued wood products have been traditionally used in this country in a variety of applications. The adhesives for such bonded or laminated wood products conventionally are based on phenol-formaldehyde, urea-formaldehyde, polyvinyl acetate, resorcinol-formaldehyde, polymeric diphenylmethane diisocyanate (MDI), and hot met adhesives. The glued wood products include plywood, particleboard, oriented strand board (OSB), medium density fiberboard (MDF), laminated veneer lumber (LVL), laminated beams, and a variety of other engineered wood products. Among them, laminated beams, I-beams, LVL, and a variety of engineered wood products are used for structural wood applications. Generally, these engineered wood products require an initial finger jointing of short pieces of wood or parallel laminated veneers (PLV) before they can be constructed into long and/or thick beams or lumbers. Consequently, it is important that the finger-jointed area must have good strength to be used for structural wood applications. For present purposes, all of the foregoing products are known as “laminated wood products.” 
     At present, phenol-resorcinol-formaldehyde (PRF) is widely used in industry for finger joint applications. When adhesive is applied to the fingers, the finger jointed wood or PLV is crowded together using an end pressure until a “tip gap” of 1-40 mils is achieved. Its is essential that the fingers do not “bottom out.” The finger joints then are moved into a curing zone where hot platens or dielectric plates are used to cure the finger joints under heat or radio frequency and pressure for typically less than 30 seconds and then the joints are removed away from the curing zone. The adhesives must be able to fill the gaps or voids between the fingers when curing is complete in order for the product to exhibit good strength and a smooth appearance. 
     One the other hand, the speed of curing must be fast under these conditions in order to hold the finger-jointed pieces together for further processing, such as beam lamination and I-joint assembly. This is especially true in a high-speed commercial finger jointing process. Generally, adhesives with high solids and fast curing profiles are regarded as appropriate for such an application. 
     It should be mentioned also that two-part PRF and melamine-formaldehyde (MF) adhesives generally are used in industry as adhesives in preparation of radio frequency (RF) cured finger joint assemblies. Both of these adhesives are highly polar, which makes them respond well to RF curing. RF curing drives the bondline temperature sufficiently high to permit the MF or PRF to condense quickly. Due to the rigid ring structure of both PRF and MF, these adhesives cure to give a high T g , rigid, three-dimensional network in a short time; thus, producing acceptable immediate handling strength (proof-loading). 
     Soy protein products have been utilized as adhesives for wood bonding since the 1930&#39;s. Their use soon declined as a result of the development of petroleum derived adhesives. Economic and ecological pressures in the 1990&#39;s renewed interest in the practical use of soy protein products in wood adhesives. Heretofore, soybean protein has been proposed for use with phenolic resin, urea resin, or resorcinol resin, such as is described in JP 06200226, 58034877, 50034632, and 04057881. In JP 50034632 and 04057881, adhesives are proposed that consist of soy protein as the major component and isocyanate as a minor component because the soy protein, like wheat flour, is capable of thickening the mixture by absorbing moisture in the wood to give an adhesive with fast drying capability. In recent years, soybean-based adhesives were developed and used primarily in a “honeymoon” system, such as those described by Scheid, “Finger-Jointing and Other Uses of Environmentally Friendly Soy-Based Adhesives”,  Wood Technology Clinic and Show,  Conference Proceeding, Portland, Oreg., Mar. 25-27, 1998; and Steele, et al., “Finger Jointing Green Southern Yellow Pine With A Soy-Based Adhesive”,  Wood Technology Clinic and Show,  Conference Proceeding, Portland, Oreg., March 25-27, 1998. 
     BRIEF SUMMARY OF THE INVENTION 
     An adhesive suitable for bonding wood is both heat curable and radio frequency (RF) curable. This adhesive is composed of an isocyanate-terminated prepolymer and a hydrolyzed soy protein having a pH of at least about 9. The weight ratio of prepolymer to soy protein hydrolyzate ranges from about 70-90 to 30-10. Further increases in the ratio of the soy protein hydrolyzate in the mix would lead to a high viscosity, paste-like material that would not be acceptable for most, if not all, applications contemplated herein, such as, for example, gluing wood, such as, for example finger joints. 
     DETAILED DESCRIPTION OF THE INVENTION 
     It is well known that woods are porous materials that contain different moisture contents, depending upon type of wood, storage environment, etc. Moisture contents can vary from as low as 5 wt-% to greater than 30 wt-%. For adhesives to properly bond wood, it is important that the adhesive penetrates deep into the wood and interlock with the cellulose structure upon cross-linking. If the adhesive cures too fast, however, such desirable penetration is not achieved. An adhesive predominating with soy protein hydrolyzate would react and dry very rapidly, thus decreasing the ability of the adhesive to penetrate into the wood&#39;s structure to provide a strong bond. 
     To strike a balance, then an isocyanate-terminated prepolymer becomes the predominant component of the adhesive composition and an aqueous hydrolyzed soy protein a minor component. Such a composition would substantially decrease the rapid thickening action of the soy protein component, thus allowing the adhesive time to penetrate into the wood&#39;s structure. Water would react with the prepolymer for cure of the prepolymer in addition to the reaction between the prepolymer and the soy protein hydrolyzate component. Such a balanced cure results in strong bonds by virtue of the wood penetration of the adhesive coupled with the necessary speed of cure required in commercial settings. The examples will amply demonstrate the performance of the inventive adhesive in engineered wood applications. 
     Information on soy protein can be found in, for example, Kirk-Othmer,  Encyclopedia of Chemical Technology,  Third Edition, Volume 21, pp. 418-422 (1983). Soy protein hydrolyzates generally are prepared by hydrolyzing soy protein powder with an aqueous caustic solution. Treatment of soy protein with soluble caustic is necessary because the caustic breaks the internal hydrogen bonds of the coiled protein molecules and makes most of their complex polar structure available for adhesion to wood. See, for example, Bian, et al., “Adhesive Performance of Modified Soy Protein Polymers”,  Polym. Prep., Am. Chem. Soc. Div., Polym. Chem.,  Volume 39 (1988), pp. 72-73. The major mechanism of protein gluing involves the dispersing and unfolding of the protein molecules in solution so that the unfolded molecules&#39; increased surface area can contact an increased area of the wood. Additionally, the unfolded protein molecules become entangled with each other during the curing process for improving bond strength. The resulting protein hydrolyzate generally has a pH of greater than about 9 and often between about 9.5 and 12. Consequently, the hydrolyzed soy protein molecules are high in polarity, an added benefit for RF curing. 
     Appropriate caustics for use in hydrolyzing soy protein include, for example, the oxides, hydroxides, and the like, of alkali metals and alkaline earth metals, caustic alcohols, and the like. Representative suitable caustics include, for example, NaOH, CaO, CH 3 ONa, C 2 H 5 ONa, C 3 H 7 ONa, and the like, and mixtures thereof. Non-caustic bases also can be used including, for example, NH 4 OH, various amine bases, and the like. Reaction temperatures typically range from about 25° to about 120° C. with corresponding reaction times of about 1 to about 7 hours. Again, this operation is conventional and is known in the art. 
     Isocyanate-functional prepolymers are made from polyisocyanates reacted with a compound containing active hydrogen functionality with hydroxyl groups being typical, although mercaptan groups, amine groups, and carboxyl groups also can be used. Polyisocyanates are conventional in nature and include, for example, hexamethylene diisocyanate, toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), m- and p-phenylene diisocyanates, bitolylene diisocyanate, cyclohexane diisocyanate (CHDI), bis-(isocyanatomethyl)cyclohexane (H6XDI), dicyclohexylmethane diisocyanate (H 12 MDI), dimer acid diisocyanate (DDI), trimethyl hexamethylene diisocyanate, lysine diisocyanate and its methyl ester, isophorone diisocyanate, methyl cyclohexane diisocyanate, 1,5-napthalene diisocyanate, xylylene and xylene diisocyanate and methyl derivatives thereof, polymethylene polyphenyl isocyanates, chlorophenylene-2,4-diisocyanate, polyphenylene diisocyanates available commercially as, for example, Mondur MR or Mondur MRS, isophorone diisocyanate (IPDI), hydrogenated methylene diphenyl isocyanate (HMDI), tetramethyl xylene diisocyanate (TMXDI), hexamethylene diisocyanate (HDI), or oligomer materials of these materials such as a trimer of IPDI, HDI or a biuret of HDI, and the like and mixtures thereof. Triisocyanates and high-functional isocyanates also are well known and can be used to advantage. Aromatic and aliphatic diisocyanates, for example, (including biuret and isocyanurate derivatives) often are available as pre-formed commercial packages and can be used to advantage in the present invention. 
     Preferred polyols for reacting with the polyisocyanates include, for example, polyether polyols (e.g., block polyethylene and polypropylene oxide homo- and copolymers ranging in molecular weight from about 300 to about 3,000) optionally alkylated (e.g., polytetramethylene ether glycols), caprolactone-based polyols, and the like. However, the component also may be formulated with mixtures of aliphatic and aromatic polyols, or a multi-functional, active hydrogen-bearing polymer. Thus, in addition to polyether polyols, the hydroxyl-functional component may include derivatives of acrylates, esters, vinyls, castor oils, as well as polymers and mixtures thereof. 
     Isocyanate equivalents should predominate over active hydrogen equivalents in the polyisocyanate/polyol reaction mixture in order for the resulting prepolymer to contain residual isocyanate groups. Reaction conditions for this reaction are well known in the art, such as described by Heiss, et al., “Influence of Acids and Bases on Preparation of Urethane Polymers”,  Industrial and Engineering Chemistry,  Vol. 51, No. 8, August 1959, pp. 929-934. Depending upon the reaction conditions used (such as, for example, temperature and the presence of strong acids or bases, and catalysts), the reaction may lead to the formation of ureas, allophanates, biurets, or isocyanates. 
     The isocyanate prepolymer must be separated from the aqueous hydrolyzed soy protein in order to preclude premature gellation and crosslinking. This is because the isocyanate group from the prepolymer can react with either water in the soy protein hydrolyzate solution or with any amine or any carboxyl group in the hydrolyzed soy protein molecules at a relatively fast rate of reaction, particularly under the influence of catalysis using dibutyl tin dilaurate catalyst (T-12 brand, see Examples) and base (in the soy protein hydrolyzate). Thus, the inventive wood glue is a two-pack or two-part composition whose packs or parts are mixed together just prior to application to the wood. 
     Application of the inventive glue is conventional for this art. Cure of the glue can be by simple heating as taught in this art and practiced commercially at, say, from about room temperature to about 175° C. for times ranging from as short as say, 30 seconds, on up to about 2 minutes, with cure times dependent upon reaction temperature and catalyst concentration. 
     Alternatively, radio frequency or dielectric heating can cure the inventive wood glue. The principal of dielectric heating is defined as the rapid movement of the radio waves through a material that causes molecular friction to take place and subsequently produce heat. Instead of current flow, the forces used in dielectric heating are caused by charges on the plates placed on opposite sides of the material to be heated—one plate being positive and one plate being negative. These oppositely charged plates set up forces of attraction between themselves. The forces in the electric field can influence the movement of the adhesive molecules, because these molecules are not electrically symmetrical, but have dipole moment, i.e., the measure of electrical asymmetry of a molecule. Since oppositely charged particles are attracted to each other, the molecules in the adhesive line up with the negative poles towards the positive plate (or electrode) and the positive poles towards the negative plate. As the charges on the plates reverse, the dipole molecules in the adhesive rotate to keep the same alignment just described. This rotation of the molecules produces friction that generates heat that is required for cure of the adhesive composition. The amount of heat actually developed by the adhesive composition in the RF field depends upon factors including, for example, the amount of moisture in the composition, the strength (voltage) of the electric field, the frequency of the radio waves, and the length of time that the composition spends in the field. 
     Two important properties determine how much heat the adhesive material will develop in an alternating electric field: the dielectric constant and the power factor. The dielectric constant of a material is a measure of the ability of the dipole molecules in such material to rotate when subjected to an electric field. The power factor of a material is a measure of the ability of such material to convert the energy in the electric field into heat energy. The dielectric constant is determined by the strength of the permanent charge on the dipole molecules. Strong permanent dipole charges increase the molecular movement. The linkage that exists between the molecules of the material determines the power factor. These linkages hold the molecules closely together and their resistance to movement results in friction when the molecules move and, thus, heat is generated. 
     Another factor that may contribute to heat in dielectric heating is the ionic conductivity, given that some adhesives also contain ions. Some ions in the adhesive composition are positively charged, while others are negatively charged. When an adhesive composition is placed in an alternating electric field set up between two positively charged plates, the negatively charged ions try to move toward the positive pole while the positively charged ions try to move toward the negative plate. Since the charge on the plates is rapidly reversing in dielectric heating, there is considerable back and forth movement of the ions which rapid change in direction and movement results in frictional heating also. 
     Thus, for RF curability of the inventive adhesive or glue, it is important that the adhesive have sufficient polarity to respond to the dielectric or RF heating when it is placed in a dielectric heating unit. Since the immediate handling strength in the RF cured finger joint is an important consideration, it is necessary that the adhesive should provide a fast curing rate as well as a sufficiently high T g  that the adhesive will solidify rapidly in a short amount of time. While proper selection of a catalyst may achieve the purpose of providing the necessary rate of reaction for providing proof-loading (immediate handling strength), they also contribute negative attributes to the adhesive, such as decreased open times, shelf stability, and the like. On the other hand, it is also important that the adhesive should possess a good water resistance, such as the requirements specified in the ASTM D-5751 non-structural laminate performance test and most specifically, the ASTM D-2559 structural laminate wet performance test. In this sense, the role of the soy protein hydrolyzate (the minor component) is to contribute to the RF curability, and the role of the prepolymer (the major component) is to provide the adhesive with integrity for structural applications. 
     On the other hand, the soy protein hydrolyzate generally is prepared by hydrolyzing soy protein powder with aqueous caustic, as described above. Thus, the hydrolyzate typically has pH of above 9. Consequently, such hydrolyzate is high in polar molecules which positively aids in RF curing and may even contain a small amount of electrically conductive material. This makes the soy protein hydrolyzate an ideal component for inclusion in the adhesive composition of the present invention. 
     An important part of this invention is centered on the preparation of a soy protein hydrolyzate that will provide a glue mix (with the prepolymer) having an acceptable consistency and pot-life, because the prepolymer and soy protein hydrolyzate are incompatible and difficult to mix together due to the large difference of polarity between them. If a sufficiently high shear rate is applied to force these two components together, the resulting mix viscosity is too high to be acceptable for practical (and commercial) application of the glue mix. Furthermore, the presence of caustic in the soy protein hydrolyzate also catalyzes the crosslinking reaction of the prepolymer and the soy protein hydrolyzate mix almost immediately, resulting in a mixed adhesive having an unacceptably short pot-life. Again, such an adhesive composition is not acceptable for commercial purposes. 
     Consequently, an appropriate inhibitor (such as, for example, benzoyl chloride or monophenyldichlorophosphate) is added to the prepolymer to retard the crosslinking reaction of the mixed adhesive system. The glue mix consistency also is improved and the pot-life is increased to an acceptable range (e.g., say, 12-20 minutes) by incorporating a nonionic wetting agent (e.g., Dynol™ 604 surfactant) in the soy protein hydrolyzate. On the other hand, there is a fine balancing point between the glue mix pot-life and the immediate handling strength (proof-loading) after RF cure. Too long of a glue mix pot-life (say, greater than 20 minutes) usually results in undesirable proof-loading following RF cure because the rate of reaction has been decreased too much. Addition of these adjuvant components and others to adhesive compositions, however, is well known and well practiced commercially, and such adjuvant components may be used in the inventive adhesive in conventional and unconventional fashion as those skilled in this art will appreciate. 
     Finally, it should be noted that RF curing is self-limiting in terms of heat generation. As the molecules in the composition cross-link or react, the amount of free polar molecules decreases. With less polar molecules to rapidly “vibrate” under the influence of RF, less heat is generated. Thus, over-heating generally is not a problem. 
     Equipment for RF curing is commercially available and well known in the art. Reference is made to the undated booklet entitled  Radio Frequency Heating,  by Franklin International (Columbus, Ohio) for a good review of the fundamentals of RF heating and equipment used therein. 
    
    
     The following examples show how the present invention has been practiced but should not be construed as limiting the invention. In this application, all units are in the metric system unless otherwise noted. Also, all citations are expressly incorporated herein by reference. 
     EXAMPLES 
     Example I 
     A 22-liter, three-neck round bottom reaction flask was charged with 6,987 g of a polyether diol (MW of 2,000, average OH number of 56, viscosity @ 25° C. of 215 cps, density of 8.33 lbs/gal, Ashland Chemical Co. code 033-192), 11,744 g of polymeric methylene diisocyanate or MDI (Mondur MRS poly(methylenephenylene) polyisocyanate, average functionality of 2.8, average equivalent weight of 133, NCO content of 31.6%, viscosity @ 25° C. of 250 cps, Miles Chemical) and 18.7 g of D-1400 defoamer (polydimethylsiloxane and treated amorphous silica foam control agent, Dow Coming Corporation, Midland, Mich.). These ingredients were mechanically agitated at room temperature (viz., 24.8° C.) under a nitrogen blanket to form a mixture. 19.86 g of dibutyl tin dilaurate catalyst (DABCO® T-12 catalyst, 18.0% total tin, Air Products and Chemicals, Inc., Allentown, Pa.) was added to the mixture and a mild exotherm was observed to push the temperature to about 42° C. in 30 minutes. A second portion of T-12 catalyst, 17.64 g, was added to the reaction flask and the reaction was continued for another 30 minutes. Finally, 140.6 g of benzoyl chloride was added to the reaction flask and mechanical agitation was continued to an additional 15 minutes to produce an isocyanate prepolymer. This product was labeled as EP 5815-106-3 or 5815-140. 
     Example II 
     The isocyanate prepolymer made in Example I was mixed with a soy protein hydrolyzate (HTI ProBond 3050, 36-38% solids, pH of 9.5-11.0, viscosity of 400-2000 cps, Hopton Technologies, Inc., Albany, Oreg.) at varying ratios. Generally, the speed of the resulting reaction was based on such ratio (isocyanate prepolymer:soy protein hydrolyzate). When the ratio of isocyanate prepolymer to soy protein hydrolyzate was e.g., 9:1), an open time (time to cure) of greater than 10 minutes was observed. If this same ratio was much lower (e.g., 3:2) the mixture cured to a granular solid within 2 minutes. At a ratio of 4:1, an open time of 3-6 minutes was observed to give an excellent finger joint performance. 
     Example III 
     The two-part adhesive composition disclosed in Example II (EP 5815-106-3) was compounded at a 4:1 ratio, cured at either 330° F. or 350° F., and used to bond parallel laminated veneer (PLV) finger joints. The following force and percent wood failure (WF) results were recorded: 
     
       
         
               
               
               
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
             
             
               
                   
                   
               
               
                   
                 PRF 
                 EP 5815-106-3 
                 EP 5815-106-3 
               
               
                   
                 (350° F.) 
                 (350° F.) 
                 (330° F.) 
               
             
          
           
               
                   
                 6 HOURS 
                 30 MINUTES 
                 24 HOURS 
                 1 HOUR 
                 24 HOURS 
               
             
          
           
               
                   
                 Force 
                 % 
                 Force 
                 % 
                 Force 
                 % 
                 Force 
                 % 
                 Force 
                 % 
               
               
                 Run 
                 (lbs) 
                 WF 
                 (lbs) 
                 WF 
                 (lbs) 
                 WF 
                 (lbs) 
                 WF 
                 (lbs) 
                 WF 
               
               
                   
               
               
                 1 
                 9090 
                 95 
                 9310 
                 95 
                 12160 
                 100 
                 10110 
                 100 
                 11860 
                 100 
               
               
                 2 
                 9900 
                 90 
                 11310 
                 95 
                 12270 
                 100 
                 8370 
                 100 
                 8470 
                 100 
               
               
                 3 
                 8280 
                 90 
                 10230 
                 100 
                 11330 
                 100 
                 9590 
                 100 
                 0790 
                 99 
               
               
                 4 
                 8280 
                 90 
                 12380 
                 100 
                 11050 
                 100 
                 8850 
                 100 
                 10710 
                 100 
               
               
                 5 
                 7560 
                 85 
                 10960 
                 100 
                 12240 
                 100 
                 9240 
                 100 
                 9830 
                 100 
               
               
                 6 
                 9310 
                 90 
                 11110 
                 100 
                 11780 
                 100 
                 9130 
                 95 
                 8980 
                 100 
               
               
                 7 
                 7449 
                 95 
                 10210 
                 95 
                 13090 
                 100 
                 8650 
                 100 
                 9500 
                 99 
               
               
                 8 
                 7610 
                 95 
                 11610 
                 100 
                 14190 
                 100 
                 9340 
                 100 
                 9570 
                 100 
               
               
                 9 
                 6240 
                 95 
                 11000 
                 95 
                 10740 
                 100 
                 9070 
                 100 
                 11070 
                 100 
               
               
                 10 
                 8990 
                 90 
                 9010 
                 95 
                 10930 
                 100 
                 10200 
                 100 
                 10760 
                 100 
               
               
                 11 
                 10990 
                 100 
                 9970 
                 95 
                 11610 
                 100 
                 10520 
                 100 
                 9780 
                 100 
               
               
                 12 
                 9170 
                 95 
                 11770 
                 95 
                 10020 
                 100 
                 9250 
                 100 
                 10330 
                 100 
               
               
                 13 
                 10790 
                 85 
                 11840 
                 95 
                 12640 
                 100 
                 11750 
                 100 
                 9880 
                 99 
               
               
                 14 
                 11320 
                 95 
                 9980 
                 95 
                 11280 
                 100 
                 10440 
                 100 
                 12710 
                 100 
               
               
                 15 
                 9940 
                 100 
                 10850 
                 95 
                 12140 
                 100 
                 11350 
                 100 
                 9840 
                 100 
               
               
                 16 
                 9710 
                 85 
                 10850 
                 95 
                 11230 
                 100 
                 10520 
                 100 
                 10050 
                 100 
               
               
                 17 
                 9720 
                 90 
                 9350 
                 100 
                 9400 
                 100 
                 8720 
                 100 
                 9960 
                 100 
               
               
                 18 
                 8350 
                 85 
                 11240 
                 95 
                 9540 
                 99 
                 8760 
                 100 
                 7980 
                 100 
               
               
                 19 
                 10230 
                 90 
                 8540 
                 100 
                 12290 
                 100 
                 9620 
                 100 
                 10670 
                 100 
               
               
                 20 
                 10190 
                 85 
                 11990 
                 100 
                 11420 
                 99 
                 9510 
                 100 
                 12090 
                 100 
               
               
                 21 
                 9330 
                 95 
                 10020 
                 95 
                 10720 
                 100 
                 10620 
                 100 
                 11870 
                 99 
               
               
                 22 
                 8220 
                 95 
                 9350 
                 95 
                 11200 
                 100 
                 11190 
                 100 
                 12880 
                 100 
               
               
                 23 
                 7090 
                 90 
                 10070 
                 100 
                 10160 
                 99 
                 9080 
                 100 
                 10820 
                 100 
               
               
                 24 
                 8530 
                 95 
                 9980 
                 100 
                 11000 
                 100 
                 10490 
                 100 
                 10610 
                 100 
               
               
                 25 
                 10620 
                 95 
                 11350 
                 100 
                 11750 
                 100 
                 8010 
                 100 
                 11430 
                 100 
               
               
                 26 
                 9940 
                 90 
                 11540 
                 100 
                 11010 
                 100 
                 9580 
                 100 
                 10620 
                 100 
               
               
                 27 
                 10030 
                 90 
                 10500 
                 100 
                 11440 
                 100 
                 8050 
                 100 
                 10170 
                 100 
               
               
                 28 
                 10000 
                 95 
                 12170 
                 100 
                 11220 
                 100 
                 11000 
                 100 
                 12620 
                 100 
               
               
                 29 
                 10400 
                 90 
                 10550 
                 95 
                 10360 
                 100 
                 11230 
                 95 
                 10950 
                 100 
               
               
                 30 
                 11850 
                 90 
                 10660 
                 95 
                 10360 
                 100 
                 11230 
                 95 
                 10950 
                 100 
               
               
                 31 
                   
                   
                 10150 
                 100 
                 11070 
                 100 
                 1078- 
                 100 
                 12780 
                 99 
               
               
                 32 
                   
                   
                 9250 
                 100 
                 11760 
                 100 
                 11820 
                 95 
               
               
                 AVG 
                 9311 
                 92 
                 10597 
                 98 
                 11350 
                 100 
                 9952 
                 100 
                 10587 
                 100 
               
               
                 Std. 
                 (1325) 
                 (4) 
                 (987) 
                 (3) 
                 (1004) 
                 (1) 
                 (1252) 
                 (1) 
                 (1264 
                 (1) 
               
               
                 Dev. 
               
               
                 # of 
                 2 
                 17 
                 28 
                 29 
                 25 
               
               
                 100% 
               
               
                 WF 
               
               
                   
               
             
          
         
       
     
     These results demonstrate that the inventive adhesive not only provides excellent finger joint application for PLV boards, but also outperformed the industrial standard PRF composition. 
     Example IV 
     The two-part adhesive composition disclosed in Example II (5815-140) was cured at 330° F. for 30 seconds in a strength development study to join Douglas fir finger joints with high moisture content (16%-22%). PRF adhesive was used as a comparison adhesive. The results recorded are set forth below. 
     
       
         
               
               
               
             
           
               
                 TABLE 2* 
               
               
                   
               
               
                 TIME 
                 EP 5815 140/HTI 3050 
                 PRF 
               
               
                 (min) 
                 (psi) 
                 (psi) 
               
               
                   
               
             
             
               
                  5 
                 4531 ± 675  
                 3006 ± 957  
               
               
                 10 
                 5458 ± 1152 
                 1782 ± 80  
               
               
                 30 
                 6018 ± 2969 
                 4564 ± 1458 
               
               
                 60 
                 7408 ± 1790 
                 3152 ± 1890 
               
               
                   
               
               
                 *Each data point is the average of 4 specimens.  
               
             
          
         
       
     
     These results demonstrate that the inventive adhesive provided faster and stronger finger joint strength on high moisture content Douglas fir wood than the industrial standard PRF. 
     Example V 
     Several formulations based on the commercial soy protein hydrolyzate, HTI 3050, and prepolymers containing different levels of the T-12 brand tin catalyst concentrations were compared in an engineered wood application using Douglas fir (specific gravity of 0.47-0.50) test procedure followed was ASTM D-5751. The following results (PSI is pounds per square inch; WF is wood failure) were recorded. 
     
       
         
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
               
                 T-12 Catalyst Concentration 
                 0* 
                 0.05* 
                 0.2** 
               
               
                 Closed Assembly Time (min) 
                 8 
                 6 
                 4 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Dry 
               
             
          
           
               
                 PSI 
                 1963 
                   
                 1320 
                   
                 1505 
                   
               
               
                 WF (%) 
                 95 
                   
                 85 
                   
                 95 
               
             
          
           
               
                 Vacuum-Pressure 
               
             
          
           
               
                 PSI (Standard Deviation) 
                 949 
                 (101) 
                 975 
                 (94) 
                 793 
                 (127) 
               
               
                 WF (%) (Standard Deviation) 
                 52 
                 (17) 
                 56 
                 (13) 
                 46 
                 (24) 
               
             
          
           
               
                 Two-Cycle Boil 
               
             
          
           
               
                 PSI (Standard Deviation) 
                 802 
                 (113) 
                 705 
                 (87) 
                 765 
                 (56) 
               
               
                 WF (%) (Standard Deviation) 
                 79 
                 (13) 
                 85 
                 (12) 
                 69 
                 (21) 
               
               
                   
               
               
                 *Same formulation as in Example I, except in the T-12 concentration and the high reaction temperature (75 ± 5° C. for 3 hours).  
               
               
                 **Same as in Example I.  
               
             
          
         
       
     
     These results demonstrate that the inventive adhesive formulations based on soy protein hydrolyzates are suitable for non-structural applications. 
     Example VI 
     Two additional isocyanate prepolymers were made according to the procedure set forth in Example I, except that an inhibitor was added after the NCO determination (ACC method Ac-21a-79) revealed that the desired extent of reaction had been achieved. 
     
       
         
               
               
               
             
               
               
               
             
           
               
                 TABLE 4 
               
               
                   
               
               
                 INGREDIENT* (g) 
                 6204-144 
                 6298-46A** 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Polyetherdiol (MW of 2,000, see Example I) 
                 332.1 
                 0 
               
               
                 Polyether diol (MW of 1,000) 
                 0 
                 448 
               
               
                 Mondur MRS polyisocyanate (see Example I) 
                 1116.9 
                 1104 
               
               
                 Rubinate 9310 polyisocyanate 
                 0 
                 260.2 
               
               
                 D-1400 antifoam agent (see Example I) 
                 1.62 
                 2.24 
               
               
                 Dibutyl tin dilaurate (T-12 brand, see 
                 3.42 
                 3.63 
               
               
                 Example I) 
               
               
                 Monophenyldichlorophosphate (inhibitor) 
                 4.05 
                 4.54 
               
               
                   
               
               
                 *Polyether diol (MW of 1000, OH number of 112, viscosity @ 25° C. of 322 cps, density of 8.34 lbs/gal, Ashland Chemical Code 033-191).  
               
               
                 Rubinate 9310 polyisocyanate (% NCO = 29.3%, viscosity @ 25° C. = 35 cps, average functionality = 2.1, ICI Polyurethanes).  
               
               
                 **Same prepolymeras 6298-84B, 100A, 121C, 145C, and 167.  
               
             
          
         
       
     
     It should be noted that the flexibility of the prepolymers can be ranked in the order of 5815-140&gt;6204-144&gt;6204-46A. It will subsequently be detailed that, while the increased rigidity of the prepolymer structure might help the immediate strength after RF curing, such prepolymer will not have the necessary acceptable accelerated aging resistance to water (wet cycles under vacuum, pressure, or steam) to meet the standards for structural (exterior) engineered wood applications. 
     Example VII 
     Several soy protein hydrolyzates were prepared at ambient temperature according to the formulations set forth below. 
     
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 5 
               
               
                   
               
               
                 INGREDIENT 
                   
                   
                   
                   
               
               
                 (g) 
                 6289-009A 
                 6289-009B 
                 6289-010B 
                 6298-19B 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Deionized water 
                 87.5 
                 87.5 
                 87.5 
                 87.5 
               
               
                 Pro-Cote 200 
                 48.5 
                 48.5 
                 48.5 
                 48.5 
               
               
                 polymer* 
               
               
                 Soybean oil 
                 1.5 
                 1.5 
                 1.5 
                 1.5 
               
               
                 Deionized water 
                 72.5 
                 72.5 
                 72.5 
                 72.5 
               
               
                 Hydrated lime 
                 6.0 
                 6.0 
                 6.0 
                 6.0 
               
               
                 (fresh)** 
               
               
                 Deionized water 
                 12.0 
                 12.0 
                 12.0 
                 12.0 
               
               
                 50 wt-% sodium 
                 6.0 
                 6.0 
                 6.0 
                 6.0 
               
               
                 hydroxide 
               
               
                 2-Phenyl phenol 
                 2.5 
                 2.5 
                 2.5 
                 2.5 
               
               
                 Sodium silicate 
                 4.0 
                 5.0 
                 4.5 
                 5.0 
               
               
                 solution*** 
               
               
                   
               
               
                 *Pro-Cote 200 natural polymer extract from soybeans (light tan granular powder, pH of 4.6 in a water slurry, less than 2% retained on 30 mesh screen, Protein Technologies International, St. Louis, MO).  
               
               
                 **prepared by mixing 6.6 g of anhydrous calcium oxide with 10 g of deionized water.  
               
               
                 ***SiO 2 /Na 2 O weight ratio of 2.4 (Occidental Chemical Corp.)  
               
             
          
         
       
     
     A typical procedure can be found is Pizzi,  Wood Adhesive-Chemistry and Technology,  Vol. 2, pp. 1-29 (1989) and involves mixing and dispersing soy protein powder (Pro-Cote®200) and soybean oil in water at ambient temperature for about 3 minutes. After the soy protein powder was thoroughly dispersed, more water was added and mixing continued for another 2 minutes. Hydrated lime then was added and mixing continued for another 5 minutes, followed by the addition of NaOH (50 wt-%). This reaction was permitted to continue for about 30 minutes. The addition of 2-phenyl phenol and sodium silicate solution was made to provide mold resistance in high humidity environments and to gain better viscosity stability control. 
     Example VIII 
     Another technique was developed to prepare soy protein hydrolyzates at 60° C. using the formulations set forth below. 
     
       
         
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 6 
               
             
             
               
                   
               
               
                 FORMULATIONS 6204- 
               
               
                 (g) 
               
             
          
           
               
                 INGREDIENT 
                 112A 
                 112B 
                 112C 
                 121 
                 122A 
                 122B 
               
               
                   
               
             
          
           
               
                 Water 
                 688 
                 658 
                 688 
                 592 
                 685 
                 688 
               
               
                 Soy Protein Powder (Pro-Cote 
                 194 
                 194 
                 194 
                 174.6 
                 0 
                 0 
               
               
                 200) 
               
               
                 Soy Protein Powder (Pro-Cote 
                 0 
                 0 
                 0 
                 0 
                 194 
                 194 
               
               
                 PX-270)* 
               
               
                 2-Phenyl phenol 
                 10 
                 10 
                 10 
                 9 
                 10 
                 10 
               
               
                 Antifoam (Dow Corning 1400 
                 0.4 
                 0.4 
                 0.4 
                 0.4 
                 0.4 
                 0.4 
               
               
                 agent) 
               
               
                 NH 4 OH (37 wt-%) 
                 24.1 
                 24.1 
                 24.1 
                 0 
                 0 
                 0 
               
               
                 NaOH (50 wt-%) 
                 0 
                 12.1 
                 30.1 
                 19.2 
                 15.5 
                 15.5 
               
               
                 CaO (98% purity) 
                 0 
                 0 
                 0 
                 7.1 
                 12.5 
                 18.8 
               
               
                 Water (to adjust viscosity) 
                 124 
                 124 
                 124 
                 27 
                 62.5 
                 62.5 
               
               
                 Sodium silicate solution 
                 0 
                 0 
                 0 
                 37 
                 0 
                 0 
               
               
                 (SiO 2 /Na 2 O ratio of 2.4) 
               
               
                   
               
               
                 *Pro-Cote PX-270 is a modified polymer derived from soybeans (fine light tan powder less than 2% retained on 30 mesh screen, pH of 4.7 in water slurry, Protein Technologies International, St. Louis, MO).  
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 7 
               
             
             
               
                   
               
               
                 FORMULATIONS 6298- 
               
               
                 (g) 
               
             
          
           
               
                 INGREDIENT 
                 139B 
                 139C 
                 142B 
                 156B 
                 162B 
               
               
                   
               
             
          
           
               
                 Water 
                 324 
                 324 
                 482 
                 500 
                 366 
               
               
                 Soy Protein Powder 
                 97 
                 97 
                 97 
                 97 
                 97 
               
               
                 (Pro-Cote 200) 
               
               
                 2-Phenyl phenol 
                 5 
                 5 
                 5 
                 5 
                 5 
               
               
                 NaOH (50 wt-%) 
                 10.67 
                 10.67 
                 3.2 
                 3.2 
                 10.67 
               
               
                 CaO (98% purity) 
                 3.95 
                 3.95 
                 0.79 
                 0.79 
                 3.95 
               
               
                 HCl (4.63 wt-%) 
                 94.46 
                 122 
                 0 
                 0 
                 94.46 
               
               
                 NaCl 
                 0 
                 0 
                 6.66 
                 6.22 
                 0 
               
               
                 Dynol ™ 604 surfactant 
                 0 
                 0 
                 0 
                 1.02 
                 1.59 
               
               
                 Sodium silicate solution 
                 20.4 
                 19.55 
                 19.55 
                 19.55 
                 20.4 
               
               
                 (SiO 2 /Na 2 O ratio of 2.4) 
               
               
                   
               
             
          
         
       
     
     Water and 2-phenyl phenol were charged into a round-bottomed reactor and heated to 60°±2° C. with mechanical agitation. When the temperature reached 60°±2° C., soy protein powder was added to the reaction with stirring continued for 2-5 minutes until a homogeneous dispersion was achieved. A 50 wt-% aqueous NaOH solution and/or NH 4 OH and/or CaO and/or sodium silicate and/or HCl and/or NaCl and/or water and/or Dynol™ 604 solution then was/were slowly added into the reaction to adjust the final pH and viscosity. 
     Example IX 
     Two-part polyurethane adhesives were made from the isocyanate prepolymers of Example I and the soybean hydrolyzates of Examples VII (Tables 5) at a ratio weight of 4:1 in order to obtain a homogeneous glue mixture. The glue mixture along with a commercial melamine formaldehyde adhesive was applied to Douglas fir finger joint specimens (1.5″×1.5″×6″). The joints then were crowded together by a hammer until a “tip gap” of 1-40 mils was achieved prior to curing by RF. Following RF curing, the surface temperature of the joints was measured and the adhesives were ranked visually within 20 seconds of RF treatment as: wet, tacky, or dry. Following RF curing, the bondline temperature of the joints also was measured and the finger joint strength was determined by clamping the finger joints into a vise and hitting them with a hammer within 30 seconds. A subjective ranking was assigned depending on the relative resistance of the finger joint to breaking under the impact of the hammer swing as: poor, fair, good, or excellent. 
     Curing of the finger joints was accomplished using low, 5 MHz RF (4,200 v, 30 seconds) curing. The results recorded are set forth below. 
     
       
         
               
               
               
             
           
               
                 TABLE 8 
               
               
                   
               
               
                   
                 Bondline Temp. 
                 Hammer 
               
               
                 L Adhesive 
                 (° F.) 
                 Strength 
               
               
                   
               
             
             
               
                 Prepolymer of Example I/6298-19B 
                 140 
                 Excellent 
               
               
                 hydrolyzate of Example VII, Table 5 
               
               
                 (4/1 weight ratio) 
               
               
                 Cascomel ® MF 216S melamine 
                 177 
                 Excellent 
               
               
                 formaldehyde adhesive (Borden 
               
               
                 Chemicals, Columbus OH) 
               
               
                   
               
             
          
         
       
     
     These results demonstrate that at the correct bondline temperature, the inventive adhesive formulation provided excellent adhesive performance. Such performance matched that of a conventional commercial melamine formaldehyde adhesive. 
     Example X 
     Adhesive formulations like those described in Example IX were prepared using different soy protein hydrolyzates (see Example VIII, Table 6) having varying pH levels and the isocyanate prepolymer 6298-84B (see Example VI, Table 4). The finger joints were cured at 30 MHz (3,500 v, 10 seconds). Following RF curing, the surface temperature of the joints was measured and the adhesives ranked visually within 20 seconds of RF treatment as: wet, tacky, or dry. Bond strength was determined by clamping the finger joints into a vise and hitting them with a hammer at 30 seconds. A subjective ranking was assigned depending on the resistance of the finger joint to breaking under the impact of the hammer swing as: poor, fair, good, or excellent. The results recorded are set forth below. 
     
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 9 
               
               
                   
               
               
                 Soy Protein 
                   
                 Surface Temp 
                 Appearance 
                 Bond 
               
               
                 Hydrolyzate* 
                 pH 
                 After RF (° F.) 
                 After RF 
                 After RF 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 6204-112A 
                 9.5 
                 128 
                 Tacky 
                 Good 
               
               
                 6204-112B 
                 10.2 
                 130 
                 Tacky 
                 Fair 
               
               
                 6204-112C 
                 11.9 
                 135 
                 Dry 
                 Good 
               
               
                   
               
               
                 *See Example VIII, Table 6.  
               
             
          
         
       
     
     These results demonstrate that as the pH of the soy protein hydrolyzates increase, the degree of RF curing increases based on measured surface temperature, ranked appearance, and bond performance. This data also would suggest that as pH increases, the polarity of the mixed adhesive increases, which leads to a better RF cure. 
     Example XI 
     Tests like those described in Example X were conducted on prepolymer 6298-121C (Example VI, Table 4) and the soy protein hydrolyzate of Example VIII, Table 7. The results recorded are set forth below. 
     
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 10 
               
               
                   
               
               
                 Soy Protein 
                   
                 Time of Test 
                   
                 Surface Temp. 
                 Hammer 
                   
               
               
                 Hydrolyzate 
                 pH 
                 Post RF (sec) 
                 Appearance 
                 (° F.) 
                 Strength 
                 Amp. Draw* 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 6204-133B 
                 10.8 
                 15 
                 Dry 
                 133 
                 Good 
                 0.65 
               
               
                   
                   
                 20 
                 Dry 
                 126 
                 Excellent 
                 0.75 
               
               
                   
                   
                 20 
                 Dry 
                 147 
                 Excellent 
                 0.65 
               
               
                   
                   
                 30 
                 Dry 
                 145 
                 Excellent 
                 0.70 
               
               
                   
                   
                 30 
                 Dry 
                 144 
                 Good 
                 0.60 
               
               
                   
                   
                 40 
                 Dry 
                 145 
                 Excellent 
                 0.75 
               
               
                   
                   
                 40 
                 Dry 
                 144 
                 Excellent 
                 0.60 
               
               
                 6204-135 
                 9.5 
                 20 
                 Tacky 
                 130 
                 Good 
                 0.70 
               
               
                   
                   
                 20 
                 Tacky 
                 150 
                 Poor 
                 0.65 
               
               
                   
                   
                 30 
                 Tacky 
                 162 
                 Fair 
                 0.70 
               
               
                   
                   
                 30 
                 Tacky 
                 142 
                 Fair 
                 0.60 
               
               
                   
                   
                 40 
                 Dry 
                 140 
                 Excellent 
                 0.75 
               
               
                   
                   
                 40 
                 Dry 
                 145 
                 Excellent 
                 0.70 
               
               
                 6204-137 
                 10.7 
                 15 
                 Dry 
                 153 
                 Good 
                 0.70 
               
               
                   
                   
                 20 
                 Dry 
                 145 
                 Excellent 
                 0.75 
               
               
                   
                   
                 20 
                 Dry 
                 145 
                 Excellent 
                 0.75 
               
               
                   
                   
                 30 
                 Dry 
                 160 
                 Excellent 
                 0.85 
               
               
                   
                   
                 30 
                 Dry 
                 145 
                 Excellent 
                 0.70 
               
               
                   
                   
                 40 
                 Dry 
                 172 
                 Excellent 
                 0.70 
               
               
                   
                   
                 40 
                 Dry 
                 150 
                 Excellent 
                 0.70 
               
               
                 6204-139 
                 10.2 
                 20 
                 Tacky 
                 156 
                 Poor 
                 0.65 
               
               
                   
                   
                 20 
                 Tacky 
                 145 
                 Fair 
                 0.65 
               
               
                   
                   
                 30 
                 Dry 
                 148 
                 Good 
                 0.75 
               
               
                   
                   
                 30 
                 Dry 
                 150 
                 Excellent 
                 0.70 
               
               
                   
                   
                 40 
                 Dry 
                 149 
                 Excellent 
                 0.70 
               
               
                   
                   
                 40 
                 Dry 
                 160 
                 Excellent 
                 0.68 
               
               
                   
               
               
                 *Amp Draw is the peak amperage draw during RF curing  
               
             
          
         
       
     
     These results demonstrate that all of the polyurethane-soy protein hydrolyzate adhesives cured well by RF, based on the draw of current during RF treatment, the measured surface temperatures, and the appearances after RF curing. Most importantly, these formulations provided excellent hammer strength when tested at 15, 20, 30, and 40 seconds after RF cure. Such results are indicative that the RF cured finger joints would have an acceptable immediate handling strength also. Among the formulations tested, soy protein hydrolyzate 6204-137 was judged the best. 
     Example XII 
     While RF curability is an important consideration in the development of two-part polyurethane-soy protein hydrolyzate adhesives, the ultimate strength of the finger joint is an equally important consideration. Thus, finger joint specimens were prepared by first cutting each paired specimen member into 1.5″×1.5″×6″ segments to be cured by RF (30 MHz, 3500 v, 10 seconds). After the curing of the mated finger joints, each specimen then was cut into 1″×⅜×11″ specimens to be tested at specific times post RF cure. The results displayed below are based on prepolymer 6298-100A (see Example VI, Table 4) mix with soy protein hydrolyzates at a 4:1 ratio. 
     
       
         
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
                 TABLE 11 
               
             
             
               
                   
                   
               
               
                   
                 One Day (Average 
                   
                 4 Days (Average 
               
               
                   
                 of 5 Specimens) 
                   
                 of 10 Specimens) 
               
             
          
           
               
                 Soy Protein 
                 Strength 
                   
                 Strength 
                   
               
               
                 Hydrolyzate* 
                 (psi) 
                 WF % 
                 (psi) 
                 WF % 
               
               
                   
               
               
                 6204-121 
                 5312 ±, 1816 
                 88 ± 12 
                 5744 ± 1137 
                 92 ± 6  
               
               
                 6204-122A 
                 6348 ± 2202 
                 84 ± 15 
                 7226 ± 2082 
                 81 ± 21 
               
               
                 6204-122B 
                 6755 ± 1429 
                 82 ± 19 
                 7284 ± 806  
                 81 ± 19 
               
               
                   
               
               
                 *For hydrolyzates, see Example VIII, Table 6.  
               
             
          
         
       
     
     
       
         
               
               
               
               
             
           
               
                   
                 TABLE 12* 
               
               
                   
                   
               
               
                   
                 Soy Protein Hydrolyzates* 
                 6298-139C 
                 6298-142B 
               
               
                   
                   
               
             
             
               
                   
                 Appearance 
                 Dry 
                 Dry 
               
               
                   
                 Peak Amperage Draw 
                 0.75 
                 0.73 
               
               
                   
                 Hammer Strength 
                 Excellent 
                 Excellent 
               
               
                   
                 Ultimate Strength (psi)** 
                 6959 ± 1387 
                 5321 ± 1288 
               
               
                   
                 % Wood Failure 
                 47 ± 25 
                 42 ± 34 
               
               
                   
                   
               
               
                   
                 *For Hydrolyzes, see Example VIII, Table 7; and for prepolymer, see 6298-145C in Example VI, Table 4. Prepolymer:Soy Protein Hydrolyzate of 4:1.  
               
               
                   
                 **Ultimate Strength is an average of 9 specimens RF cured, and then aged at ambient temperature for 6 days.  
               
             
          
         
       
     
     These results demonstrate that the two-part polyurethane-soy protein hydrolyzate adhesives possess good ultimate finger strength when cured by RF. 
     Example XIII 
     Additional RF curing was conducted using the three prepolymers described in Examples I and VI, and with the soy protein hydrolyzates described in Example VIII, Table 7. Bond strength (hammer strength) was tested 30 seconds after RF cure. 
     
       
         
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 13 
               
               
                   
               
               
                   
                   
                 Time of Test 
                   
                 Surface 
                   
                   
               
               
                 Prepolymer (mix ratio with soy 
                 Ranked Pot-Life 
                 Post RF Cure 
                   
                 Temp. 
                 Hammer 
                 Amp. Draw 
               
               
                 protein hydrolyzate) 
                 (min) 
                 (min) 
                 Appearance 
                 (° F.) 
                 Strength 
                 (Peak-End) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 6298-156B SOY PROTEIN HYDROLYZATE 
               
             
          
           
               
                 6298-167 (80/20) 
                 22 
                 30 
                 Dry 
                 138 
                 Good 
                 0.60-0.50 
               
               
                 6298-167 (75/25) 
                 13 
                 30 
                 Dry 
                 151 
                 Excellent 
                 0.75-0.55 
               
               
                 6204-144 (80/20) 
                 16.5 
                 30 
                 Dry 
                 140 
                 Excellent 
                 0.65-0.50 
               
               
                 8364A37174 (80/20)* 
                 9.5 
                 20 
                 Dry 
                 149 
                 Excellent 
                 0.70-0.55 
               
               
                 8364A37174 (80/20) 
                 9.5 
                 30 
                 Dry 
                 140 
                 Excellent 
                 0.65-0.50 
               
               
                 8364A37174 (75/25) 
                 8.5 
                 30 
                 Tacky 
                 151 
                 Poor 
                 0.80-0.60 
               
             
          
           
               
                 6298-162B SOY PROTEIN HYDROLYZATE 
               
             
          
           
               
                 6298-167 (80/20) 
                 9.5 
                 30 
                 Dry 
                 142 
                 Excellent 
                 0.60-0.50 
               
               
                 6204-144 (80/20) 
                 8 
                 30 
                 Dry 
                 156 
                 Excellent 
                 0.70-0.55 
               
               
                 8364A37174 (80/20) 
                 7.5 
                 30 
                 Dry 
                 150 
                 Excellent 
                 0.70-0.60 
               
               
                 8364A37174 (75125) 
                 3.5 
                 30 
                 Dry 
                 143 
                 Excellent 
                 1.05-0.55 
               
               
                   
               
               
                 *8364A37174 prepolymer is the same as 5815-140 of Example I.  
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
               
             
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 14 
               
               
                   
               
               
                 Prepolymer (mix 
                   
                   
                   
                   
                   
                   
               
               
                 ratio with soy 
                   
                 Time of Test 
                   
                 Surface 
                   
                   
               
               
                 Protein 
                 Ranked Pot-Life 
                 Post RF Cure 
                   
                 Temp. 
                 Hammer 
                 Amp. Draw 
               
               
                 hydrolyzate) 
                 (min) 
                 (min) 
                 Appearance 
                 (° F.) 
                 Strength 
                 (Peak-End) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 6298-162B SOY PROTEIN HYDROLYZATE 
               
             
          
           
               
                 6298-167M (80/20)* 
                 24 
                 30 
                 Tacky 
                 148 
                 Fair 
                 0.65-0.55 
               
               
                 6298-167M (80/20) 
                 24 
                 45 
                 Tacky 
                 150 
                 Fair 
                 0.75-0.60 
               
               
                 6298-167M (80/20) 
                 24 
                 60 
                 Tacky 
                 158 
                 Good 
                 0.70-0.55 
               
               
                 6204-167M (80/20) 
                 17 
                 30 
                 Tacky 
                 123 
                 Poor 
                 0.65-0.55 
               
               
                 6204-167M (80/20) 
                 17 
                 45 
                 Tacky 
                 138 
                 Poor 
                 0.65-0.55 
               
               
                 8364A37174M (80/20) 
                 18.5 
                 30 
                 Tacky 
                 148 
                 Excellent 
                 0.65-0.55 
               
               
                 8364A37174M (80/20) 
                 18.5 
                 45 
                 Tacky 
                 141 
                 Poor 
                 0.70-0.55 
               
               
                 6298-167M (75/25) 
                 4 
                 30 
                 Dry 
                 144 
                 Excellent 
                 1.15-0.55 
               
               
                 6204-144M (75125) 
                 5 
                 30 
                 Dry 
                 130 
                 Excellent 
                 1.20-0.60 
               
               
                   
               
               
                 *The “M” series of prepolymers contained an additional 0.25% of monophenyldichlorophosphate.  
               
             
          
         
       
     
     These results indicate that as the prepolymer and soy protein hydrolyzate mix ratio decreased from 4:1 to 3:1, the cured adhesive appeared dry, together with excellent hammer strength. However, the pot-life became short. On the other hand, if an additional 0.25% inhibitor (monophenyldichlorophosphate) is added to the prepolymer, the ranked pot-life increased. This substantially retarded the RF curing which led to a tacky appearance and decreased bond strength. 
     Example XIV 
     Finger joint ultimate strength also was obtained using the three prepolymers described in Example I and VI, and the soy protein hydrolyzates described in Example VIII, Table 7. The finger joint specimens were cured by RF (30 MHz, 3500 v, 10 seconds). After standing at ambient temperature for 7 days, these specimens were cut into 1″×⅜″×11″ specimens to be tested for tensile strength. The results recorded are displayed below: 
     
       
         
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 15 
               
             
             
               
                   
               
               
                 Wood Strength, psi (Wood Failure, %) 
               
             
          
           
               
                   
                 6298-167/ 
                 6298-167/ 
                 6204-144/ 
                 *8364A37174/ 
                 6204-144/ 
                 8364A37174/ 
               
               
                 Sample 
                 6298-156B 
                 6298-156B 
                 6298-156B 
                 6298-156B 
                 6298-162B 
                 6298-156B 
               
               
                 No. 
                 (4/1) 
                 (3/1) 
                 (4/1) 
                 (4/1) 
                 (4/1) 
                 (4/1) 
               
               
                   
               
             
          
           
               
                 1 
                 4651 
                 (20) 
                 7947 
                 (45) 
                 5616 
                 (99) 
                 5029 
                 (99) 
                 9973 
                 (98) 
                 6517 
                 (99) 
               
               
                 2 
                 5288 
                 (70) 
                 8779 
                 (30) 
                 6331 
                 (99) 
                 5571 
                 (99) 
                 8016 
                 (90) 
                 7821 
                 (99) 
               
               
                 3 
                 4192 
                 (20) 
                 5165 
                 (40) 
                 7707 
                 (99) 
                 6291 
                 (98) 
                 9328 
                 (95) 
                 5656 
                 (99) 
               
               
                 4 
                 5632 
                 (80) 
                 7253 
                 (90) 
                 7152 
                 (30) 
                 5398 
                 (100) 
                 8237 
                 (40) 
                 3584 
                 (100) 
               
               
                 5 
                 5072 
                 (900 
                 8987 
                 (90) 
                 7376 
                 (30) 
                 5656 
                 (100) 
                 8509 
                 (45) 
                 3680 
                 (100) 
               
               
                 6 
                 7555 
                 (85) 
                 8165 
                 (100) 
                 8445 
                 (40) 
                 6616 
                 (99) 
                 7971 
                 (100) 
                 2904 
                 (100) 
               
               
                 7 
                 6539 
                 (40) 
                 3915 
                 (100) 
                 4901 
                 (99) 
                 3381 
                 (99) 
                 7123 
                 (99) 
                 8053 
                 (90) 
               
               
                 8 
                 8187 
                 (25) 
                 4899 
                 (100) 
                 6085 
                 (95) 
                 4371 
                 (100) 
                 8173 
                 (90) 
                 5091 
                 (99) 
               
               
                 9 
                 6328 
                 (25) 
                 6963 
                 (70) 
                 6736 
                 (90) 
                 4936 
                 (99) 
                 8995 
                 998) 
                 7061 
                 (95) 
               
               
                 Average 
                 5938 
                 (51) 
                 6898 
                 (74) 
                 6705 
                 (76) 
                 5249 
                 (99) 
                 8481 
                 (84) 
                 5586 
                 (99) 
               
               
                 St. Dev. 
                 1330 
                 (30) 
                 1826 
                 (28) 
                 1098 
                 (32) 
                 978 
                 (1) 
                 843 
                 (24) 
                 1911 
                 (3) 
               
               
                   
               
               
                 *8364A37174 is the same as 5815-140 prepolymer.  
               
             
          
         
       
     
     These results demonstrate that adhesives derived from prepolymers 6204-144 and 8364A37174 exhibited better overall ultimate finger joint strength than the adhesive derived from the 6298-167 prepolymer, taking both strength and wood failure into consideration. 
     Example XV 
     In order to determine whether the two-part polyurethane-soy protein hydrolyzate adhesives exhibit good accelerated aging (wet stress) resistance, ASTM D-5751 non-structural laminate and ASTM D-2559 structural laminate wet performance tests were performed. Prepolymers described in Examples I and VII were mixed with different soy protein hydrolyzates at a weight ratio of 4:1. The results recorded are set forth below. 
     
       
         
               
             
               
               
               
               
               
             
           
               
                 TABLE 16 
               
             
             
               
                   
               
               
                 ASTM D-5751 
               
               
                 Douglas Fir (MC of 6.5-7.2%, Sp. Gr. Of 0.41-0.51) 
               
             
          
           
               
                 Prepolymer 
                 8364A37174* 
                 6298-145C** 
                 8364A37174 
                 6298-145C 
               
               
                 Hydrolzate 
                 6298-156B** 
                 6298-156B 
                 6298-156B 
                 6298-156B 
               
               
                   
               
               
                 CAT (min) 
                  13 
                  12 
                   7 
                   6 
               
               
                 Dry (psi) 
                 1656 
                 1327 
                 1456 
                 1336 
               
               
                 Dry (WF %) 
                  85 
                  50 
                  90 
                  75 
               
               
                 Vac-Pressure (psi) 
                 881 ± 34  
                 422 ± 251 
                 886 ± 54  
                 358 ± 317 
               
               
                 Vac Pressure (WF %) 
                 81 ± 16 
                 9 ± 9 
                 81 ± 12 
                 358 ± 317 
               
               
                 2-Boil Cycles (psi) 
                 712 ± 80  
                 451 ± 321 
                 791 ± 66  
                 510 ± 254 
               
               
                 2-Boil Cycles (WF %) 
                 65 ± 17 
                 44 ± 20 
                 80 ± 13 
                 54 ± 28 
               
               
                   
               
               
                 *8364A37174 is the same as 5815-140 of Example I.  
               
               
                 **For 6298-145C, see Example VI, Table 4.  
               
               
                 ***For 6298-156B, see Example VIII, Table 7.  
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
           
               
                 TABLE 17 
               
             
             
               
                   
               
               
                 ASTM D-2559 
               
               
                 Douglas Fir (MC of 6.9-8.2%, Sp. Gr. OF 0.46-0.48 
               
             
          
           
               
                   
                 6298-145C* 
                 6298-145C 
                 8364A37174** 
                 8364A37174 
               
               
                 Adhesive 
                 6298-156B*** 
                 6298-162B*** 
                 6298-156B 
                 6298-162B 
               
               
                   
               
             
          
           
               
                 SPECIFIC GRAVITY OF BOARD 
               
             
          
           
               
                 Board 1 
                 0.445 
                 0.445 
                 0.444 
                 0.444 
               
               
                 Board 2 
                 0.464 
                 0.460 
                 0.459 
                 0.457 
               
               
                 Board 3 
                 0.538 
                 0.533 
                 0.478 
                 0.472 
               
               
                 Board 4 
                 0.465 
                 0.465 
                 0.470 
                 0.472 
               
               
                 Board 5 
                 0.445 
                 0.448 
                 0.454 
                 0.454 
               
               
                 Board 6 
                 0.439 
                 0.441 
                 0.441 
                 0.441 
               
             
          
           
               
                 DELAMINATION % PER GLUELINE 
               
             
          
           
               
                 GL1 
                 10.81 
                 5.22 
                 0.56 
                 0.31 
               
               
                 GL2 
                 20.00 
                 6.46 
                 0.15 
                 0.27 
               
               
                 GL3 
                 5.97 
                 8.02 
                 0.43 
                 0.35 
               
               
                 GL4 
                 16.38 
                 8.52 
                 0.79 
                 0.14 
               
               
                 GL5 
                 4.66 
                 7.05 
                 0 
                 2.41 
               
               
                 TOTAL 
                 57.82 
                 35.27 
                 1.93 
                 3.48 
               
               
                 DELAMINATION (%) 
               
               
                   
               
               
                 *For 6298-145C, see Example VI, Table 4.  
               
               
                 **8364A37174 is the same as 5815-140 of Example I.  
               
               
                 ***For 6298-156B or 162B, see Example VIII, Table 7.  
               
             
          
         
       
     
     The foregoing tabulated results clearly indicate that the adhesive derived from the flexible prepolymer, 8364A37174, outperformed the adhesive derived from the rigid polymer system, 6298-145C, in the wet stress performance tests using soy protein hydrolyzates 6298-156B and 6298-162B using different closed assembly times. 
     Example XVI 
     Additional testing according to ASTM D-2559 delamination specifications of the 4:1 weight ratio prepolymer:soy protein was undertaken with the following results being recorded. 
     
       
         
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
             
               
               
               
               
             
           
               
                 TABLE 18 
               
               
                   
               
               
                 Douglas Fir (MC of 8-10%, Sp. Gr. Of 0.45-0.53) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Adhesive 
                 5815-140* 
                 5815-140** 
                 5815-140** 
               
               
                   
                 6289-009A*** 
                 6289-009B*** 
                 6389-010B*** 
               
               
                 Closed Assembly 
                 6 
                 6 
                 4 
               
               
                 Time (min) 
               
             
          
           
               
                 SPECIFIC GRAVITY OF BOARDS 
               
             
          
           
               
                 Board 1 
                 0.493 
                 0.476 
                 0.477 
               
               
                 Board 2 
                 0.446 
                 0.481 
                 0.481 
               
               
                 Board 3 
                 0.491 
                 0.550 
                 0.558 
               
               
                 Board 4 
                 0.447 
                 0.519 
                 0.519 
               
               
                 Board 5 
                 0.485 
                 0.486 
                 0.487 
               
               
                 Board 6 
                 0.447 
                 0.464 
                 0.462 
               
             
          
           
               
                 DELAMINATION % PER GLUELINE 
               
             
          
           
               
                 GL 1 
                 2.36 
                 0 
                 0.38 
               
               
                 GL 2 
                 1.60 
                 0.36 
                 1.03 
               
               
                 GL 3 
                 1.30 
                 1.30 
                 4.29 
               
               
                 GL 4 
                 0.55 
                 1.53 
                 3.59 
               
               
                 GL 6 
                 3.48 
                 0.48 
                 1.27 
               
               
                 Total Delamination % 
                 9.29 
                 3.67 
                 10.56  
               
               
                   
               
               
                 *Same as EP 5815-106-3, see Example I.  
               
               
                 **Same as EP 5815-106-3 except without tin catalyst from Example I.  
               
               
                 ***6289 series, see Example VI, Table 5.  
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
               
             
               
               
               
               
               
             
           
               
                 TABLE 19 
               
               
                   
               
               
                 Soy Protein Hydrolyzate: 6298-174 (same as 6298-156B) 
               
               
                 Douglas Fir (MC of 7-10%, Sp. Gr. Of 0.050-0.60) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Prepolymer Used 
                 6204-144* 
                 8364A37174** 
                 6204-144 
                 8364A37174 
               
               
                 Closed Assembly 
                 10 
                 9 
                 5 
                 4 
               
               
                 Time (min) 
               
             
          
           
               
                 SPECIFIC GRAVITY OF BOARD 
               
             
          
           
               
                 Board 1 
                 0.507 
                 0.508 
                 0.514 
                 0.536 
               
               
                 Board 2 
                 0.522 
                 0.517 
                 0.511 
                 0.529 
               
               
                 Board 3 
                 0.552 
                 0.574 
                 0.582 
                 0.596 
               
               
                 Board 4 
                 0.536 
                 0.534 
                 0.530 
                 0.529 
               
               
                 Board 5 
                 0.522 
                 0.523 
                 0.525 
                 0.509 
               
               
                 Board 6 
                 0.507 
                 0.504 
                 0.501 
                 0.500 
               
             
          
           
               
                 DELAMINATION % PER GLUELINE 
               
             
          
           
               
                 Glueline 1 
                 0 
                 0 
                 0.56 
                 0.94 
               
               
                 Glueline 2 
                 0.07 
                 0 
                 0.13 
                 0 
               
               
                 Glueline 3 
                 0 
                 0.09 
                 0.07 
                 0.08 
               
               
                 Glueline 4 
                 0 
                 0 
                 0 
                 0 
               
               
                 Glueline 5 
                 0 
                 2.22 
                 0 
                 0 
               
               
                 Total 
                 0.07 
                 2.3 
                 0.76 
                 1.01 
               
               
                 Delamination % 
               
               
                   
               
               
                 *For 6204-144, see Example VI, Table 4.  
               
               
                 **8364A37174 is the same as 5815-140 of Example I.  
               
             
          
         
       
     
     These results indicate that low degrees of delamination were obtained with the novel adhesive, which in turn indicates its suitability for exterior structural engineered wood applications, particularly with the more flexible prepolymers 8364A37174 and 6204-144.