An adhesive composition comprising isocyanate, phenol-formaldehyde and tannin, useful for manufacturing plywoods for exterior application

Abstract: The present invention relates to an adhesive composition comprising isocyanate, phenol-formaldehide and tannin, useful for manufacturing plywoods for exterior application.

Description: The object of the presente invention is to develop an adhesive composition for obtaining a product of best quality which can compete in the international market. More speciafically, the invention relates to an adhesive composition comprising isocyanate-phenolformaldehyde-tannin useful for manufacturing plywoods for exterior applications, not only with wood small tulips but with Pinus radiata as well. Plywood is a product which has been produced for many centuries. Originally it was produced by artisans preparing furniture from veneers of very expensive timbers to save on the amount of wood which was used. They only used adhesives of animal or vegetal origin as these were the only available ones. Since the beginning of this century plywood has been produced industrially due to its exceptional strength to weight ratio. At first casein, an animal derived protein, was used as the only adhesive, but from the 1930's the introduction of synthetic resins, namely urea-formaldehyde (UF) adhesives for interior applications and phenol-formaldehyde (PF) adhesives for exterior and marine-grade applications, revolutionized plywood manufacture. The use of synthetic resins allowed the manufacture of plywood always of consistant quality at affordable prices, and as a consequence of this a great expansion of its worldwide production capacity ensued, expansion which continued well after the end of the second world war. At present PF resins dominate the worldwide market for the production of exterior and marine grade plywood. One of the problems presented however by PF resins is that a variety of formulations are employed due to the very different types of wood used for veneers. PF resins furthermore have some serious limitations. They are not able for instance (i) to bond consistently well veneers of higher moisture content (8% to 12%), (ii) to bond equally well with the same formulation medium density veneers and high density veneers (0.6 to 0.8 Kg/ m³ into structural plywood and to accomplish all the above with lower adhesive spread levels. A resin of any nature or composition which is capable of overcoming all the defects of PF resins listed above, while still maintaining their excellent performance, would indeed be a great step forward in adhesives for exterior and marine grade plywood. Diisocyanates, in particular polymeric MDI, have been introduced in the wood industry for almost 15 years. These materials can produce excellent results when used as adhesives for particulate products but have been widely recognized as totally unusable for plywood. This is due to their low viscosity which makes these resins migrate from the glue-line into the veneers before and particularly during plywood hot-pressing operations, completely starving the glue-line of adhesive and leading to joints of very poor strength. A composite resin containing MDI which would be capable of utilizing the great strength capabilities of MDI, but capable to also bonding plywood would become as succesfull in the field of plywood manufacture as MDI is succesfull today in bonding wood particle products. Tannin-formaldehyde resins have been another set of adhesives which has been used commercially, in certain countries, during the last 20 years. Their exterior durability and their performance is similar and often superior to that of PF resins, to which they resemble due to the phenolic nature of polyflavonoid condensed tannins obtained from the bark and wood of certain trees. Up to now however, only mimosa (wattle), quebracho and chestnut tannins have been used commercially for plywood adhesives application. While they perform well on softwoods, they perform poorly on the higher densities hardwood veneers. Furthermore their limited worldwide production, not more than 150,000 Tons per year has severely limited their ability to make serious quantitative inroads in the worldwide PF wood adhesives market which is reputed to be of up to 5 million Tons yearly. The only tannin which could be produced in such large scale is that obtainable from the bark of pine trees. Pine trees are the most common forestry crop worldwide and thus great amounts of waste pine bark are available. This could be the source of considerable amounts of pine tannin. Unfortunately pine tannins are reputed to be not easily amenable to the formulation of wood adhesives as some of the other tannins mentioned above and no present successfull industrial use is at present recorded. The preparation thus of a composite adhesive system using in bulk the characteristics of MDI, of pine tannins and of PF resins to overcome at the industrial level most of the problems listed for the three materials when used singly is then a great step forward in the formulation of industrial plywood adhesives. The composition according to the invention comprises, for each 121 parts by weigth of phenolic resin and : either 30 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 27.5 parts by weight of isocyanate (MDI), 7.5 parts by weight of pine tannin, 6.75 part by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 15 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 20 parts by weight of wood flour and 34 parts by weight of water. The phenolic resin preferably may be prepared from 44.98% phenol, 26.30% paraformaldehyde, 19.19% water/methanol and 9.57% soda, but any phenolic resin can be used. Taking into account the main components of the adhesive composition of the invention, the way in which it operates can be explained as follows: the isocyanate reacts with the phenolic resin each one of these two components fortifying and partly hardening the other; the isocyanate groups react with the phenolic hydroxyl groups as well as with the methylol hydroxy groups of the phenol-formaldehyde resin. The tannin functions as an accelerator of the reaction and must be used in lesser amount in order to maintain this role in the compositions; it works as an accelerator because it reacts with the reactive methylol groups of the phenol-formaldehyde resin and, therefore, it is also a hardener and cross-linker of the phenol-formaldehyde resin; it acts as an accelerator because it is also a phenolic material, but containing natural phenols of a type ten times more reactive than the phenol-formaldehyde resin. The overall balance or hardener would be deficient for obtaining a hard gel and, therefore, an extra amount of paraformaldehyde is added. This compound is mainly a hardener and hardening aid for the tannin accelerator, as the other two polymers can be polymerized and hardened with themselves (in the case of the phenol-formaldehyde resin) or slowly with the water of the system (in the case of isocyanate). Summarizing: the isocyanate reacts with the phenol-formaldehyde resin, with the tannin, with the water and, probably, with the paraformaldehyde; the phenol-formaldhyde resin reacts with the isocyanate, with the tannin and with the paraformaldehyde; and the tanning reacts with the isocyanate, with the phenol-formaldehyde resin and with the paraformaldehyde. The compositions of the invention can be used in the manufacture of plywood and show excellent results with different timber species operating in the same manner with all types of wood (hardwood and softwood), something which is not achieved with the phenol-formaldehyde resins. Furthermore, the composition is highly resistant to small tulips (wood) penetration and has a good flow with viscosities upto 5000 cps, something which is not possible with known compositions. The following examples are presented in order to illustrate the invention. EXAMPLE 1 Adhesive compositions 1, 2 and 3 were prepared comprising the compounds shown in Table 1: ITEM 1 (2) 2 3 PHENOLIC RESIN 121 P.P. 121 121 ISOCYANATE (MDI) 30 27.5 15 PINE TANNIN 10 7.5 10 PARAFORMALDEHYDE 1 6.75 1 WOOD FLOUR 10 (1) 10 20 WATER 17 17 34 Plywoods were prepared using compositions 1, 2 and 3, with the following working conditions: woods: Tulips of Tepa, coigüe, ulmo and pine Small tulip moisture: 8 - 10% Small tulip thickness: 2.1 and 3.6 mm. Adhesive charge: 200 g/m² (for glue-line) Previous Press Time: 6′30″ Press Time: 14′ Press Temperature: 120°C Press pressure: 11 Kg/cm² COMPARATIVE EXAMPLE Assays were performed in order to obtain the average values of the adhesion percentages (APA standard) and shear (DIN Standard) with the plywoods obtained with adhesive compositions 1, 2 and 3 of the Example according to the invention and with plywoods manufactured with other adhesives according to the following table: PLYWOOD ADHESIVE A COMPOSITION 1 B NESTE-OY PHENOLIC, FINLAND C OXIQUIM PHENOLIC, CHILE D CIBA-GEIGY PHENOLIC, ENGLAND E COMPOSITION 2 F COMPOSITION 3 The DIN standard demands a shear which is 1 N/mm² or higher and the APA standard demands an adhesive average of 80% or more. All the plywoods have shear values which are higher than 1 N/mm², as can be seen from Figure 1 and only plywoods A and E, manufactured with compositions 1 and 2 of the invention, respectively, achieved the APA standard, as can be seen from Figure 2. PILOT PLANT ASSAY Assays were performed in order to measure the shear and adhesive values in plywoods manufactured in the pilot plant using compositions 2 and 3 of the Example according to the invention. results are shown in tabla 3 and are graphically presented in Figures 3 and 4. PLYWOOD SHEAR (N/mm²) ADHESION (%) 1 (a) 4.34 94.50 1' (b) 4.34 97.00 1 II (c) 3.89 96.00 1 III (d) 3.70 100.00 1,5 (e) 3.53 77.50 1,5 (f) 4.34 96.00 1.5 II (g) 4.31 88.00 1.5 III(h) 3.67 92.00 2 (i) 3.42 60.00 2' (j) 3.46 98.50 2 II (k) 3.95 95.00 2 III (l) 3.14 89.00 It can be noted that the shear resistance results are all higher than 3N/mm², thus largely exceeding the DIN standard. The adhesive values are high and with the exception of the boards, they exceed the 85% of adhesiveness and therefore the average of the boards may be accepted according to the APA standard. INDUSTRIAL ASSAY 1 For this industrial assay compositions 1 and 2 of the Example according to the invention were applied to pine, tepa, coigüe and "olivillo" small tulips under the conditions specified in Table 4. PROCESS CONDITIONS ASSAY COMPOSITION PRESS. TEMP. (°C) PRESS. TIME (MIN) PRESS PRESSURE (Kg/cm²) CHARGE (Kg/cm²) PRESS. TIME (MIN) OPEN TIME (MIN) 01 1 125 16 11 480 7 100 02 1 125 16 11 480 7 30 03 1 125 12 11 400 7 30 04 1 125 16 11 400 7 70 06 2 125 16 11 400 7 35 07 2 125 16 11 360 7 35 08 2 125 16 11 360 7 35 The shear resistance values and adhesive values for the plywoods are summarized in Table 5 and are plotted in Figures 5 and 6. SUMMARY OF PROPERTIES PLYWOOD SHEAR (N/mm²) ADHESION (%) 1,1 (m) 1.90 92.54 1,11 (n) 1.97 91.51 1,70 (o) 1.36 87.72 1,100 (p) 1.65 72.33 2,1 (q) 1.42 88.42 2,11 (r) 1.35 91.00 3,1 (s) 1.33 91.94 3,11 (t) 1.29 93.25 4,1 (u) 1.46 90.33 4,11 (v) 1.53 91.67 4,70 (w) 1.54 89.67 6,1 (x) 1.59 83.17 6,11 (y) 1.65 90.76 7,1 (z) 1.48 84.04 7,11 (A) 1.97 88.00 8,1 (B) 1.87 84,92 8,11 (C) 1.55 90.33 8,70 (d) 1.52 73.56 SIDE S 1.53 85.75 SIDE I 1.63 86.52 It can be seen from the graphs that the shear values for all the plywoods are higher than 1 N/mm² thus fulfilling the DIN standard and that the adhesive values are high with 84% of the boards assayed showing over 80% adhesion, thus achieving the APA standard. No unplyed probes or having 0% adhesion were found. INDUSTRIAL ASSAY 2 For this industrial assay, composition 1 of the example according to the invention was applied to tepa, coigüe, ulmo, olivillo and pine small tulips with thicknesses of 1.5, 2.2 and 4.0 mm. The operating conditions are specified in Tabla 6. PROCESS CONDITIONS ITEM VALUE Small tulip moisture (%) 8 - 10 Adhesive charge (g/m²) 200 Previous Press Time (Min) 6 Press Time (Min) 18 Press Temperature (°C) 125 Press Pressure (Kg/cm²) 11 Previous Press Pressure (Kg/cm²) 10 Open Time (Min) 30 - 45 The shear strength and wood failure values are summarized in Tables 7, 8, 9 and 10 and are plotted in figures 7, 8, 9 and 10. As can be seen from the tables and graphs, the moisture of the boards as well as the adherence with vacuum-pressure as well as with boiling water and heat resistance, fulfill the corresponding standard. PLYWOOD MOISTURE PLYWOOD N° MOISTURE % 01 9.1 02 9.7 03 9.5 04 9.1 08 9.7 The plywood moisture corresponds to average of five probes per plywood. TRACTION SHEAR ASSAY - VACUUM-PRESSURE PLYWOOD N° PROBE N° TENSILE STRENGTH KGF CM² WOOD FAILURE % 1 1 P 24.7 100 2 P 18.8 90 3 P 25.1 90 1 T 30.9 90 2 T 30.6 100 2 1 P 11.2 95 2 P 12.3 80 3 P 15.2 85 1 T 18.9 90 2 T 17.0 95 3 1 P 18.0 25 2 P 17.5 90 3 P 10.8 95 1 T 16.0 95 2 T 34.7 100 4 1 P 25.2 90 2 P 14.6 90 3 P 10.8 60 1 T 26.7 95 2 T 16.0 90 8 1 P 16.0 95 2 P 15.0 70 3 P 14.0 90 1 T 32.3 100 2 T 29.7 100 P means stress of the sheet parallel to the direction of the load and T, the transverse one. TRACTION SHEAR ASSAY, BOILING WATER IMMERSION PLYWOOD N° PROBE N° TENSILE STRENGTH KGF/CM² WOOD FAILURE % 1 1 P 12.2 100 2 P 13.7 100 3 P 13.7 100 1 T 15.8 100 2 T 19.9 95 2 1 P 9.5 100 2 P 17.9 100 3 P 14.0 100 1 T 26.0 95 2 T 15.6 90 3 1 P 16.4 90 2 P 16.0 90 3 P 20.0 80 1 T 26.4 100 2 T 26.9 100 4 1 P 12.6 100 2 P 9.3 100 3 P 22.4 85 1 T 32.0 100 2 T 27.5 100 8 1 P 16.9 70 2 P 7.3 100 3 P 27.5 100 1 T 15.4 90 2 T 25.7 100 P means, tress of the sheet paralel to the direction fo the load and T, the transverse one. HEAT RESISTANCE ASSAY PLYWOOD N° AFTER FLAME EXPOSURE 01 N.F. 02 N.F. 03 N.F. 04 N.F. 08 N.F. N.F.: Without failure.

Claims: Claim for the following Contracting States : AT, BE, CH, DE, DK, FR, GB, GR, IT, LI, LU, NL, SE Adhesive composition for manufacturing plywood for exterior application characterized in that it comprises: 121 parts by weight of phenolic resin, and further either 30 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 27.5 parts by weight of isocyanate (MDI), 7.5 parts by weight of pine tannin, 6.75 part by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 15 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 20 parts by weight of wood flour and 34 parts by weight of water. Claim for the following Contracting State : ES A process for preparing an adhesive composition for manufacturing plywood for exterior application characterized in that the process comprises: preparing said adhesive composition from 121 parts by weight of phenolic resin, and further either 30 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 27.5 parts by weight of isocyanate (MDI), 7.5 parts by weight of pine tannin, 6.75 parts by weight of paraformaldehyde, 10 parts by weight of wood flour and 17 parts by weight of water, or 15 parts by weight of isocyanate (MDI), 10 parts by weight of pine tannin, 1 part by weight of paraformaldehyde, 20 parts by weight of wood flour and 34 parts by weight of water.

Inventors: LEYSER ERNST VON, PIZZI ANTONIO, WESTERMEYER CRISTIAN, LEYSER, ERNST VON, PIZZI, ANTONIO, WESTERMEYER, CRISTIAN
Applicants: DITECO LTDA, QUIMICOS CORONEL SA, DITECO LTDA., QUIMICOS CORONEL S.A.
Application year: 1991
Main classification: C09J161
IPC codes: C09J175, C08G18, C08L97, C08L61, B27D1, C09J161