POLYISOCYANATE COMPOSITIONS

Abstract: A polyisocyanate composition comprising an iron and/or aluminum composition, which is a complex of at least one metal selected from the group consisting of iron or aluminum and a beta -dicarbonyl compound in which the molar ratio of Fe or Al to beta -dicarbonyl compound is in the range 1:3.5 to 1:10.

Description: POLYISOCYANATE COMPOSITIONS This invention relates to novel organometallic compositions and polyisocyanate compositions containing them and, in particular, to organometallic compositions based on iron or aluminum and which are useful in polyisocyanate compositions for binding lignocellulosic material. The use of organic polyisocyanates as binders for lignocellulosic material in the manufacture of sheets or moulded bodies such as waferboard, chipboard, fibreboard and plywood is well known. In a typical process the organic polyisocyanate, optionally in the form of a solution, dispersion or aqueous emulsion, is applied to the lignocellulosic material which is then subjected to heat and pressure. Suitable polyisocyanate compositions are disclosed in PCT Application WO 97/17388 and our co-pending UK Application GB 9815029.5. These compositions comprise a Group IVB metal compound, preferably a titanium chelate, optionally in combination with a compatibilising compound and/or conventional release agents. Although these compositions perform well as binders for lignocellulosic material and provide good release performance, it is desirable to develop alternative compositions which provide at least as good stability on storage before use, together with good curing properties and excellent bonding strength when applied to the lignocellulosic material whilst demonstrating an excellent release performance. It has now been surprisingly found that certain compositions prepared from β- dicarbonyl compounds can be used to prepare polyisocyanate compositions which are very stable on prolonged storage and economical when used for binding lignocellulosic material. According to one aspect of the invention an organometallic composition, suitable for use in curing polyisocyanate compositions, comprises a complex of at least one metal selected from iron and/or aluminum and at least one β-dicarbonyl compound wherein the molar ratio of metal to β-dicarbonyl compound is in the range 1 : 3.5 to 1 : 10. Also according to the invention, a polyisocyanate composition comprises an organometallic composition, said organometallic composition being a complex of at least one metal selected from the group consisting of iron and/or aluminum and a β-dicarbonyl compound in which the molar ratio of metal to β-dicarbonyl compound is in the range 1 : 3.5 to 1 :10 . The iron or aluminum composition used in the polyisocyanate composition of the invention is described herein as a "complex". It is believed that some of the β -dicarbonyl compound will be chemically bound to the metal (Fe or Al) but some can be described as "free" ester. The exact proportions which are bound and free will depend partly upon the exact molar ratios present in the complex and which metal is used, but it has been shown that the "free" ester does influence the properties, particularly the stability on storage, of the polyisocyanate composition as a binder for lignocellulosic materials. The use of the word "complex" does not imply that said complex is necessarily separately prepared before addition to a polyisocyanate to form the polyisocyanate compositions of the invention. The complex can be formed in the course of preparing the inventive polyisocyanate composition using alternative methods as described hereinafter. The β-dicarbonyl compound used to prepare the complexes of the invention can be any suitable β-dicarbonyl compound. Preferred β-dicarbonyl compounds include acetylacetone (2,4-pentanedione), benzoyl acetone, dibenzoylmethane, 2,2,6,6- tetramethylheptanedione and l,l ,l-trifluoro-2,4-pentanedione and esters of acetoacetic acid such as ethylacetoacetate, methylacetoacetate, isopropylacetoacetate and tertiarybutylacetoacetate. A complex may be based on one β-dicarbonyl compound but particularly useful complexes have been prepared from a mixture of β-dicarbonyl compounds, such as a mixture of acetylacetone and ethylacetoacetate. The molar ratio of metal to β-dicarbonyl compound in the complex is in the range 1 : 3.5 to 1 : 10. Preferably, the molar ratio is preferably in the range 1 : 4 to 1 : 8 and more preferably in the range 1 : 5 to 1 : 8. In agreement with conventional theories about the co-ordination chemistry of iron or aluminum, it is believed that three molecules of the b-dicarbonyl compound will be chemically bound to a metal atom and the remainder will be "free". Typically, the complexes of iron or aluminum are prepared from aluminum or iron alkoxides having the general formula M(OR)3 in which M is Al or Fe and R is a substituted or unsubstituted, cyclic or linear, alkyl, alkenyl, aryl or alkyl-aryl group or mixtures thereof. Preferably, R contains up to 8 carbon atoms and, more preferably, up to 6 carbon atoms. Generally, all three OR groups will be identical but alkoxides derived from a mixture of alcohols can be used and mixtures of alkoxides can be employed when more than one metal is present in the complex. Suitable alkoxides include trimethoxyaluminum. trimethoxyiron. triethoxyaluminum, triethoxyiron. tri- isopropoxyaluminum, tri-isopropoxyiron, tri-n-propoxyaluminum, tri-n-propoxyiron, tritertiarybutoxy- aluminum, tritertiarybutoxyiron, tri-sec-butoxyaluminum and tri-sec- butoxyiron. Alternatively, the complex can be prepared from compounds known as condensed alkoxides of aluminum. A condensed alkoxide is typically prepared by the controlled addition of water to an alkoxide, followed by removal of alcohol which is displaced. The condensed alkoxides which are produced consist of a mixture of polymeric compounds containing Al-O-Al linkages and A1OR groups in which R has the meaning given above. Complexes of condensed aluminum alkoxides can also be prepared by forming a complex of a β -dicarbonyl compound with an alkoxide, adding water to the complex and removing any by-product alcohol. Other aluminum or iron compounds, such as aluminum or iron trichloride or alkoxides which have been substituted with other moieties can be used as raw materials for the formation of the complex used in the invention. The complex can be readily prepared by mixing, for example, an alkoxide or condensed alkoxide with an appropriate amount of β -dicarbonyl compound. Alcohol from the alkoxide will be displaced by the β-dicarbonyl compound and, preferably, the displaced alcohol is removed by, for example, distillation. In a preferred method, 3 moles of β-dicarbonyl compound (e.g. acetylacetone) per atom of Al or Fe are added to an alkoxide or condensed alkoxide and the displaced alcohol is removed by distillation. Any additional acetoacetate ester required is then added to the stripped product. This method is advantageous because it provides a consistent product of known stoichiometry. In one method of preparing the polyisocyanate compositions of the invention, a product containing 2 or 3 moles of β -dicarbonyl compound per Fe or Al atom can be mixed with additional β -dicarbonyl compound to produce the complex of the invention and this complex can be added to a polyisocyanate composition. For aluminum complexes, a product containing 1 mole of β-dicarbonyl compound per Al atom is a suitable starting material for this method. Alternatively, the product containing 2 or 3 moles of β -dicarbonyl compound per Fe or Al atom can be prepared and any additional β -dicarbonyl compound required to produce the polyisocyanate composition of the invention can be added to the polyisocyanate before or after the iron or aluminum compound has been added. Other methods of preparing the composition of the invention will be apparent to a person skilled in this art. The amount of iron or aluminum complex present in the polyisocyanate composition of the invention is usual h in the range 0.01 to 10 % by weight, based on the polyisocyanate and, preferably, the amount is in the range 0.1 to 4%. More preferably, the amount of complex present is in the range 0.2 to 1 % by weight with respect to polyisocyanate. Polyisocyanates for use in the polyisocyanate composition of the present invention may be any organic polyisocyanate compound or mixture of organic polyisocyanate compounds, provided said compounds have at least 2 isocyanate groups. Organic polyisocyanates include diisocyanates, particularly aromatic diisocyanates. and isocyanates of higher functionality. Examples of organic polyisocyanates which may be used in the composition of the present invention include aliphatic isocyanates such as hexamethylene diisocyanate; and aromatic isocyanates such as m- and jP-phenylene diisocyanate, tolylene-2,4- and tolylene-2,6-diisocyanate, diphenyl- methane-4,4'-diisocyanate, chlorophenylene-2,4- diisocyanate, naphthylene-1,5- diisocyanate, diphenylene-4,4'-diisocyanate, 4,4'- diisocyanate 3, 3 '-dimethyl- diphenyl, 3-methyldiphenylmethane-4,4'-diisocyanate and diphenyl ether diisocyanate; and cycloaliphatic diisocyanates such as cyclohexane-2,4- and -2,3 -diisocyanate, 1 -methylcyclohexyl-2,4- and -2,6-diisocyanate and mixtures thereof and bis-(isocyanatocyclohexyl)methane and triisocyanates such as 2,4,6- triisocyanatotoluene and 2,4,4-triisocyanatodiphenylether. Modified polyisocyanates containing isocyanurate, carbodiimide or uretonimine groups may be employed as well. Further blocked polyisocyanates, like the reaction product of a phenol or an oxime and a polyisocyanate, may be used, having a deblocking temperature below the temperature applied when using the polyisocyanate composition. The organic polyisocyanate may also be an isocyanate-ended prepolymer made by reacting an excess of a diisocyanate or higher functionality polyisocyanate with a polyol. Water-emulsifiable organic polyisocyanates like those described in UK patent no. 1 444 933, in European patent publication no. 516 361 and in PCT patent publication no. 91/03082 can also be used. Mixtures of isocyanates may be used, for example a mixture of tolylene diisocyanate isomers such as the commercially available mixtures of 2.4- and 2.6-isomers and also the mixture of di- and higher poly-isocyanates. Polyisocyanate mixtures may optionally contain monofunctional isocyanates such as -ethyl phenylisocyanate. Such mixtures are well-known in the art and include the crude phosgenation products containing methylene bridged polyphenyl polyisocyanates. including diisocyanate, triisocyanate and higher polyisocyanates together with any phosgenation by-products. Preferred isocyanates to be used in the present invention are those wherein the isocyanate is an aromatic diisocyanate or polyisocyanate of higher functionality such as a pure diphenylmethane diisocyanate or a mixture of methylene bridged polyphenyl polyisocyanates containing diisocyanates, triisocyanates and higher functionality polyisocyanates. Methylene bridged polyphenyl polyisocyanates are well known in the art. They are prepared by phosgenation of corresponding mixtures of polyamines. For convenience, polymeric mixtures of methylene bridged polyphenyl polyisocyanates containing diisocyanate, triisocyanate and higher functionality polyisocyanates are referred to hereinafter as polymeric MDI. Suitable polyisocyanates include SUPRASEC™ DNR, SUPRASEC™ 2185, RUBI ATE ™ M and RUBLNATE™ 1840, all available from Huntsman Polyurethanes. Preferably the polyisocyanate is liquid at room temperature. Conventional release agents can be added to or used in combination with the polyisocyanate composition of the present invention containing an iron or aluminum complex of a β-dicarbonyl compound. The conventional release agent is present in an amount varying between 0.2 and 10 %, preferably between 0.5 and 6 % and most preferably between 1 and 3 % by weight based on the polyisocyanate whereas the iron or aluminum complex of a β-dicarbonyl compound is preferably present in an amount varying between 0.2 and 4 %, most preferably between 0.2 and 2 % by weight based on the polyisocyanate. Examples of conventional release agents include polysiloxanes, saturated or unsaturated fatty acids (such as oleic acid) or fatty acid amides or fatty acid esters or salts of unsaturated fatty acids (such as potassium oleate) and polyolefin waxes. Preferred conventional release agents to be used according to the present invention are polyolefm waxes or mixtures of polyolefm waxes, especially functionalised polyolefm waxes, which are dispersible in an aqueous medium to form an aqueous emulsion. More preferably, the polyolefm waxes are selected from oxidised polyethylene waxes and oxidised polypropylene waxes. A preferred method for using the release agent is to apply the emulsion to the surface of the polyisocyanate treated lignocellulosic material or to the press metal surface prior to hot pressing the combination. When used, the aqueous emulsion of the polyolefm wax should normally contain a sufficient amount of the polyolefm wax to provide a coverage of about 0.01 to about 1 , and preferably about 0.02 to about 0.5 mg of the polyolefm wax per cm^ of lignocellulosic material or press metal surface. Generally, lower levels of polyolefm wax are preferred as they are more cost effective. When taking the emulsifϊers into account, the aqueous emulsions will usually contain about 0.2 to about 10 %, preferably about 0.3 to about 5 % by weight of total solids. The emulsions are usually prepared at 30 to 40 % total solids, transported to the point of use and then diluted with water to the desired concentration. It has been found that the polyolefm wax emulsion, when used in combination with polyisocyanate compositions of the present invention, may be usefully applied to the lignocellulosic material or press metal surface in an amount equivalent to 8 to 14 mg per cm2. A particularly preferred polyethylene wax emulsion which can be used in a process in combination with a polyisocyanate composition of the present invention is RubilonTM g03 or Rubilon^M 605 , both available from Imperial Chemical Industries. A particularly preferred polypropylene wax emulsion which can be used in the present process is ME 42040 available from Michelman Inc. of Cincinnati, Ohio. The most preferred conventional release agents to be used according to the present invention are salts of unsaturated fatty acids (such as potassium oleate) and the most preferred method for using the release agent is to apply the solution to the surface of the polyisocyanate treated lignocellulosic material or to the press metal surface prior to hot pressing the combination. When used, the aqueous emulsion of the salt of the unsaturated acid should normal] contain a sufficient amount of fatty acid salt to provide a coverage of about 0.005 to about 1. and preferably about 0.01 to about 0.5 mg of fatty acid salt per cιτ)2 of lignocellulosic material or press metal surface. Generally, lower levels of fatty acid salt are preferred as they are more cost effective. In order to further improve the storage stability of the polyisocyanate composition of the present invention a diluent may be added to the composition. Suitable diluents include plasticizers of the type mentioned in "Taschenbuch der Kunststoff-Additive". Ed. by R. Gachter and H. Muller. Carl Hanser Verlag Mϋnchen. third edition, 1989. Preferred diluents are phthalates, aliphatic carboxylates, fatty acid esters, linseed oil and soybean oil. A particularly preferred diluent is Priolube 1403 available from Unichema being methyl oleate. These diluents are added in amounts of from 1 to 40 parts by weight per 100 parts by weight of polyisocyanate and preferably in amounts of from 1 to 15 parts by weight per 100 parts by weight of polyisocyanate. The composition further may comprise conventional additives like flame retardants, lignocellulosic preserving agents, fungicides, waxes, sizing agents, fillers. surfactants, thixotropic agents and other binders like formaldehyde condensate adhesive resins and lignin (optionally in combination with a lignin solvent such as described in PCT Patent Application No. EP96/00924). A particularly preferred additive to be used in the polyisocyanate composition of the present invention is a coupling agent such as an organofunctional silane (for example, Dynasylan AMEO, available from Huels). Adding such a coupling agent to the polyisocyanate composition leads to improved board properties. The organofunctional silane coupling agents are used in amounts ranging from 0.01 to 3 %, preferably from 0.1 to 2 % by weight based on the polyisocyanate. The polyisocyanate composition of the present invention can be made by simply mixing the ingredients at room temperature. The present invention is also concerned with a process for preparing lignocellulosic bodies by bringing lignocellulosic parts into contact with the present polyisocyanate composition and by pressing this combination. Therefore the present invention also provides a process for binding lignocellulosic material comprising the steps of a) bringing said lignocellulosic material in contact with the present polyisocyanate composition and b) subsequently allowing said material to bind. The lignocellulosic bodies are prepared by bringing the lignocellulosic parts into contact with the polyisocyanate composition by means such as mixing, spraying and/or spreading the composition with/onto the lignocellulosic parts and by pressing the combination of the polyisocyanate composition and the lignocellulosic parts, preferably by hot-pressing, normally at 150° C to 250°C and 2 to 6 MPa specific pressure. Such binding processes are commonly known in the art. In waferboard manufacture the lignocellulosic material and the polyisocyanate composition may be conveniently mixed by spraying the present polyisocyanate composition on the lignocellulosic material while it is being agitated. As described hereinbefore, in a preferred process according to the invention, a release agent, which is preferably an aqueous emulsion of a polyolefm wax, is applied to the surface of the polyisocyanate treated lignocellulosic material or to the press metal surface prior to hot pressing the combination. The lignocellulosic material after treatment with the polyisocyanate composition is placed on caul plates made of aluminum or steel which serve to carry the furnish into the press where it is compressed to the desired extent usually at a temperature between 150° C and 250° C. Alternatively, lignocellulosic material after treatment with the polyisocyanate composition is formed into a 'pre-mat' on a continuous production line where it is compressed to the desired extent usually at a temperature between 150° C and 250° C between continuous steel bands to yield the desired composite product. While the process is particularly suitable for the manufacture of waferboard known extensively as oriented strand board and will be largely used for such manufacture, the process may not be regarded as limited in this respect and can also be used in the manufacture of medium density fiberboard, particle board (also known as chipboard) and plywood. Thus the lignocellulosic material used can include wood strands, woodchips, wood fibres, shavings, veneers, wood wool, cork, bark, sawdust and like waste products of the wood working industry as well as other materials having a lignocellulosic basis such as paper, bagasse, straw , flax, sisal, hemp, rushes, reeds, rice hulls, husks, grass, nutshells and the like. Additionally, there may be mixed with the lignocellulosic materials other paniculate or fibrous materials such as ground foam waste (for example, ground polyurethane foam waste), mineral fillers, glass fibre, mica, rubber, textile waste such as plastic fibres and fabrics. When the polyisocyanate composition is applied to the lignocellulosic material, the weight ratio of polyisocyanate/lignocellulosic material will vary depending on the bulk density of the lignocellulosic material employed. Therefore, the polyisocyanate compositions may be applied in such amounts to give a weight ratio of polyisocyanate/lignocellulosic material in the range of 0.1 : 99.9 to 20 : 80 and preferably in the range of 0.5 : 99.5 to 10 : 90. If desired, other conventional binding agents, such as formaldehyde condensate adhesive resins, may be used in conjunction with the polyisocyanate composition. More detailed descriptions of methods of manufacturing waferboard and similar products based on lignocellulosic material are available in the prior art. The techniques and equipment conventionally used can be adapted for use with the polyisocyanate compositions of the present invention. The polyisocyanate compositions of the present invention are extremely effective in minimising unwanted adhesion to caul plates, press plates and other surfaces with which the treated lignocellulosic material may come into contact. Their storage stability and release performance is improved compared to polyisocyanate compositions of the prior art, as well as the obtained board properties. The sheets and moulded bodies produced from the polyisocyanate compositions of the present invention have excellent mechanical properties and they may be used in any of the situations where such articles are customarily used. The invention is illustrated but not limited by the following examples. EXAMPLE 1 A luminum tris(acetylacetonate) To a flask containing 50 g of a mixture of heptane isomers was added 30.8 g (0.125 mol) of Al(tri-sec-butoxide)3. To this was added with stirring 37.55g (0.375 mol) of acetylacetone. After stirring, a white precipitate of aluminum tris(acetylacetonate) was collected and washed on a filter paper. Yield = 36.6g (91 %). Iron tris(acetylacetonate) 20.3 g of anhydrous iron(III) chloride (0.124 mol) was dissolved in 30 g of demineralised water. To this was added 45 ml of ammonia solution (SG. 0.880). The mixture was then heated on a steam bath for 30 minutes. The precipitate of iron(III) hydroxide was filtered and washed free of chloride. The moist iron (III) hydroxide and 60 g of acetylacetone (0.6 mol) were mixed together and heated for 30 minutes. Crystals of Fe(acac)3 were deposited and were recrystallised from ethanol. The metal acetylacetonates prepared as above were mixed with ethyl acetoacetate (EAA) in various molar ratios, as shown in Table 1. Table 1: Preparation of complexes containing metal acetylaetonates * per mole metal tris(acetylacetonate) The samples were evaluated by preparing a number of compositions comprising 100 parts by weight of polyisocyanate (polymeric MDI, Suprasec DNR, available from Imperial Chemical Industries) and 0.3 parts of the samples designated 1A to IF or (for comparison) iron or aluminum tris(acetylacetonate). The compositions were then stored at 45° C and the viscosity tested by means of a Brookfield viscometer at various intervals. Results are given in Table 2 below [all viscosities are in Pa s]. Table 2: Measurement of Viscosity Profiles of Polyisocyanate compositions containing metal acetylacetonates Generally, the most relevant period for storage stability at room temperature is the period 14 to 46 days after production of the polyisocyanate composition. From Table 2 it can be seen that iron and aluminum complexes used in the polyisocyanate composition of the invention provide an economical means of stabilising the composition. EXAMPLE 2 Samples of aluminum tris(ethyl acetoacetate) was mixed with additional ethyl acetoacetate as indicated in Table 3 below. Table 3: Preparation of complexes containing aluminum tris (ethylacetoacetate) ^per mole of A1(EAA)3 The samples were evaluated by preparing compositions comprising 100 parts by weight of polyisocyanate (polymeric MDI, Suprasec DNR, available from Imperial Chemical Industries) and 0.3 parts of the samples designated 2A and 2B or (for comparison) aluminum tris(ethyl acetoacetate). The compositions were then stored at 45° C and the viscosity tested by means of a Brookfield viscometer at various intervals. Results are given in Table 4 below [all viscosities are in Pa s]. Table 4: Measurement of viscosity profiles of polyisocyanate compositions containing complexes of Aluminum tris (ethylacetoacetate) EXAMPLE 3 A sample of an organometallic composition was prepared by mixing 1 mole of iron tris(acetylacetonate), as prepared in Example 1 with a further 2.5 moles ethyl acetoacetate. The sample was evaluated by preparing a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, Rubinate 1840, available from Imperial Chemical Industries) and 0.3 parts of the sample. The composition was then stored at 45° C and the viscosity tested by means of a Brookfield viscometer at various intervals. Results are given in Table 5 below [all viscosities are in Pa s]. Table 4: Measurement of viscosity profiles of polyisocyanate compositions containing complexes of iron tris(acetylacetonate) EXAMPLE 4 A flask was charged with Fe (III) acetylacetonate (2.5g from Aldrich). Ethylacetoacetate (2.3g) was then added and mixed to give PRODUCT 4A. A polyisocyanate composition was then prepared comprising 0.48 parts weight of PRODUCT A described above and 100 parts by weight of standard polyisocyanate (SUPRASEC DNR, available from Imperial Chemical Industries) to yield a material PRODUCT 4B. Composition of the Invention Single layer boards of aspen were prepared of 12 x 450 x 450 mm at a density 650 kg/m^. PRODUCT B was used to bind the layers (2.5 and 6% resin loading based on dry wood). The layers also contained a sizing wax emulsion (SPG 60 available from Condea Chemie) at 1 % loading (solid wax) based on dry wood. The pre-pressing moisture content was 8 %. Standard Isocvanate (comparative) Single layer boards of aspen were prepared of 12 x 450 x 450 mm at a density 650 kg/ir SUPRASEC DNR was used to bind the layers (2.5 and 6% resin loading based on dry wood). The layers also contained a sizing wax emulsion (SPG 60 available from Condea Chemie) at 1 % loading (solid wax) based on dry wood. The pre-pressing moisture content was 8 %. Composites where then prepared using the following pressing conditions: Press Close (Contact position): 50s Cure Time: 10s / mm Degass Time: 15s Press Temperature: 200 deg C The composite produced under conditions described above were then tested using a range of industry standard tests to measure physical properties (Modulus of elasticity and rupture according to EN310 / Swelling after 24hrs of soaking in water according to EN317). Table 6: Modulus of elasticity (MOE) Table 7: Modulus of rupture (MOR) Table 8: Swell after 24hr (Swell) The measured properties showed no significant performance difference between composites prepared with SUPRASEC DNR and PRODUCT 4B. This therefore demonstrates the utility in using polyisocyanate compositions of the invention to produce composites whilst not affecting physical performance of the resulting composite panels. EXAMPLE 5 Release Performance using polyisocyanates containing iron acetylacetonate Boards were made using a polyisocyanate comprising different parts weight of PRODUCT 4A described above and 100 parts by weight of standard polyisocyanate (SUPRASEC DNR - see Table 9). In order to reproduce the failure mode all spray of release agent was stopped from the 7 th repeat onwards. It is considered that a release rating (see below) of 3 will cause a catastrophic failure under plant conditions. The release trials were run in parallel and for each composite the release from the top and bottom plattent were measured. The % wood failure (amount of the platten covered by residual wood) was also recorded. Results are summarised in Table 10 and 11 below. Composites where prepared using the following pressing conditions: Press Close (Contact position): 20s Cure Time: 9.3s / mm Degass Time: 20s Press Temperature: 170 deg C Table 9: Compositions tested for release performance Table 10: Release performance of Compositions 5 A and 5B Table 20: Release performance of Compositions 5C and 5D The release rating is given a value from 1 to 5 having the following significance: 1 complete sticking, board can not be removed without destruction of the board 2 sticking with wood failure higher than 50 % 3 sticking with wood failure less than 25 % but higher than 5 % 4 sticking with wood failure less than 5 %. Little force needed to remove board. 4.5 sticking without wood failure, hanging board. No effort needed to remove board. 5 perfect release, the board releases spontaneously. The results of Table 10 and 11 show that a composition of the invention improves the performance of a system using an external release agent and allows this performance to be maintained as the level of external release agent is significantly reduced. EXAMPLE 6 Release Performance using polyisocyanate containing aluminium acetylacetonate A flask was charged with Aluminium (III) acetylacetonate (0.69g from Aldrich). Ethylacetoacetate (0.27g) was then added and mixed to give PRODUCT 6A. A polyisocyanate composition was then prepared comprising 0.96 parts weight of PRODUCT 6A described above and 300 parts by weight of standard polyisocyanate (SUPRASEC DNR, available from Imperial Chemical Industries) to yield a material PRODUCT 6B. Boards were made using PRODUCT 6B and compared to boards prepared with standard polyisocyanate (see Table 12). In order to reproduce the failure mode all spray of release agent was stopped from the 7 l repeat onwards. It is considered that a release rating (see below) of 3 will cause a catastrophic failure under plant conditions. The release trials were run in parallel and for each composite the release from the top and bottom platen were measured. The % wood failure (amount of the platen covered by residual wood) was also recorded. Results are summarised in Table 13 below. Composites where prepared using the following pressing conditions: Press Close (Contact position): 20s Cure Time: 9.3s / mm Degass Time: 20s Press Temperature: 170 deg C Table 12 Compositions tested for release performance Table 13 Release performance of Compositions 6C and 6D * - not measured The release rating is given a value from 1 to 5 having the following significance: 1 complete sticking, board can not be removed without destruction of the board 2 sticking with wood failure higher than 50 % 3 sticking with wood failure less than 25 % but higher than 5 % 4 sticking with wood failure less than 5 %. Little force needed to remove board. 4.5 sticking without wood failure, hanging board. No effort needed to remove board. 6 perfect release, the board releases spontaneously. The results of Table 13 show that a composition of the invention improves the performance of a system using external release agent and allows this performance to be maintained as the level of external release agent is significantly reduced.

Claims: CLAIMS 1 A polyisocyanate composition comprising an iron and/or aluminum composition, which is a complex of at least one metal selected from the group consisting of iron or aluminum and an β-dicarbonyl compound in which the molar ratio of Fe or Al to β-dicarbonyl compound is in the range 1 : 3.5 to 1 : 10 . 2 An composition according to claim 1 characterised in that the β -dicarbonyl compound is acetylacetone, benzoyl acetone, dibenzoylmethane, 2,2,6,6- tetramethylheptanedione, 1 ,1 ,1 -trifluoro- 2,4-pentanedione, ethylacetoacetate, methylacetoacetate, isopropylaceto- acetate or tertiarybutylacetoacetate. 3 A polyisocyanate composition according to claim 1 in which the complex is a complex of iron having a molar ratio of Fe to β-dicarbonyl compound in the range 1 : 3.5 to 1 : 10. 4 A polyisocyanate composition according to claim 3 in which the molar ratio of Fe to β-dicarbonyl compound is in the range 1 : 4 to 1 : 8 5 A polyisocyanate composition according to claim 3 in which the molar ratio of Fe to β-dicarbonyl compound is in the range 1 : 5 to 1 : 8 6 A polyisocyanate composition according to claim 1 in which the complex is a complex of aluminum having a molar ratio of Al to β-dicarbonyl compound in the range 1 : 3.5 to 1 : 10. 7 A polyisocyanate composition according to claim 6 in which the molar ratio of Al to β-dicarbonyl compound is in the range 1 : 4 to 1 : 8. 8 A polyisocyanate composition according to claim 6 in which the molar ratio of Al to β-dicarbonyl compound is in the range 1 : 5 to 1 : 8. A polyisocyanate composition according to any one of the preceding claims in which the β-dicarbonyl compound is ethyl acetoacetate. A polyisocyanate composition according to any one of the preceding claims in which the complex has been prepared from a iron or aluminum alkoxide having the general formula M(OR)3 in which M is Fe or Al and R is a substituted or unsubstituted, cyclic or linear, alkyl, alkenyl, aryl or alkyl- aryl group. A polyisocyanate composition according to claim 10 in which R contains up to 6 carbon atoms. A polyisocyanate composition according to any one of claims 1 to 9 in which the complex has been prepared from a condensed iron or aluminum alkoxide . A polyisocyanate composition according to any one of the preceding claims in which the complex is prepared from an alkoxide or condensed alkoxide and displaced alcohol is removed. A polyisocyanate composition according to any one of the preceding claims in which the complex is present in an amount in the range 0.01 to 10 % by weight based on the polyisocyanate. A polyisocyanate composition according to claim 14 in which the amount of complex is in the range 0.1 to 4 % by weight based on the polyisocyanate. A polyisocyanate composition according to claim 14 in which the amount of complex is in the range 0.2 to 1 % by weight based on the polyisocyanate A polyisocyanate composition according to any one of the preceding claims in which the polyisocyanate is diphenylmethane diisocyanate or a mixture of methylene bridged polyphenyl polyisocyanates. A polyisocyanate composition according to any one of the preceding claims additionally comprising a release agent which is applied to lignocellulosic prior to hot pressing. A polyisocyanate composition according to claim 18 in which the complex is present in an amount in the range 0.2 to 4 % by weight based on the polyisocyanate and the release agent is present in an amount in the range 0.2 to 10% by weight based on the polyisocyanate. A polyisocyanate composition according to claim 18 or 19 in which the release agent is a polysiloxane, a saturated fatty acid, an unsaturated fatty acid, a fatty acid amide, a fatty acid ester, a polyolefine wax or a salt of an unsaturated fatty acid. A polyisocyanate composition according to any one of claims 18 to 19 in which the release agent is an oxidised polyethylene wax or an oxidised polypropylene wax. A polyisocyanate composition according to any one of claims 18 to 19 in which the release agent is an oleate based fatty acid A polyisocyanate composition according to any one of the claims 18 to 19 in which the release agent is a salt of an unsaturated fatty acid. A polyisocyanate composition according to any one of the preceeding claims additionally comprising a diluent. A polyisocyanate composition according to claim 24 in which the diluent is a phthalate, an aliphatic carboxylate, a fatty acid ester, linseed oil or soybean oil. A polyisocyanate composition according to claim 25 in which the diluent is present in an amount in the range 1 to 40 parts by weight per 100 parts by weight of polyisocyanate. A process for binding lignocellulosic material comprising the steps of (a) bringing lignocellulosic material into contact with a polyisocyanate composition according to any one of the preceding claims and (b) subsequently allowing said material to bind. A process according to claim 27 in which the polyisocyanate composition is brought into contact with the lignocellulosic material and the combination thereby formed is hot-pressed between metal plates at a temperature in the range 150° C to 250° C and a specific pressure in the range 2 to 6 MPa. A process according to claim 27 or 28 in which the polyisocyanate composition is applied in such an amount as to give a weight ratio of polyisocyanate to lignocellulosic material in the range 0.1 : 99.9 to 20 : 80. A process according to any one of claims 27 to 28 in which a release agent is applied to the surface of the polyisocyanate treated lignocellulosic material or to the press metal plate surface before hot pressing the combination. A process according to claim 30 in which the release agent is an aqueous emulsion of a polyolefme wax or a mixture of polyolefine waxes. A process according to claim 30 in which the polyolefine wax is an oxidised polyethylene wax or an oxidised polypropylene wax. A process according to claim 30 or 31 in which the emulsion of polyolefine wax has a total solids content of 0.2 to 10% by weight. A process according to any one of claims 30 to 33 in which the release agent is a polyolefine wax and is applied in an amount sufficient to provide coverage of 0.01 to 1 mg polyolefine wax per cm^ of lignocellulosic material or press metal surface. A process according to claim 30 in which the release agent is an unsaturated fatty acid and is applied in an amount sufficient to provide coverage of 0.01 to 1 mg saturated fatty acid per cm^ of lignocellulosic material or press metal surface. A process according to claim 30 in which the release agent is a salt of a unsaturated fatty acid and is applied in an amount sufficient to provide coverage of 0.01 to 1 mg saturated fatty acid salt per cm^ of lignocellulosic material or press metal surface.

Inventors: SKINNER CHRISTOPHER JOHN, SKINNER, CHRISTOPHER, JOHN
Applicants: HUNTSMAN ICI CHEM LLC, SKINNER CHRISTOPHER JOHN, HUNTSMAN ICI CHEMICALS, LLC, SKINNER, CHRISTOPHER, JOHN
Application year: 2000
Main classification: C08G18
IPC codes: B01J31, C07F15, C08G18, C08L97