Storage stable amino-formaldehyde resins and applications thereof
View Patent ↗Amino-formaldehyde resins may be prepared using formulations including formaldehyde, glycerin and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof; under reaction conditions sufficient to prepare a resin, wherein; the amino-formaldehyde resin is prepared in a substantial absence of a sulfonating agent, ethylene glycol, and polyalkylene glycols. If the amino compound is urea, then the urea is present in a molar ratio of formaldehyde to urea ranging from 0.70 to 1.30; if the amino compound is melamine, then the melamine is present in a molar ratio of formaldehyde to melamine ranging from 1.3 to 2.2; and if the amino compound is a mixture of urea and melamine, then the mixture of urea and melamine is present in a molar ratio of formaldehyde to urea and melamine ranging from 0.35 to 1.3.
1. An amino-formaldehyde resin prepared using a formulation comprising, under condensation reaction conditions, formaldehyde, glycerin and at least one compound selected from the group consisting of urea, melamine, and mixtures thereof; wherein;
the amino-formaldehyde resin is prepared in a substantial absence of a sulfonating agent, ethylene glycol, and polyalkylene glycols;
if the at least one compound is urea, then the urea is present in a final molar ratio of formaldehyde to urea ranging from about 0.70 to about 1.30;
if the at least one compound is melamine, then the melamine is present in a final molar ratio of formaldehyde to melamine ranging from about 1.3 to about 2.2; and
if the at least one compound is a mixture of urea and melamine, then the mixture of urea and melamine is present in a final molar ratio of formaldehyde to urea and melamine ranging from about 0.35 to about 1.3; and wherein;
the amino-formaldehyde resin has improved storage stability, as compared to a conventional resin which has the same final ratio of formaldehyde to amino compounds as the amino-formaldehyde resin but which does not use glycerin in the formulation; and
the amino-formaldehyde resin comprises a glycerin modified amino-formaldehyde resin prepared by introducing the glycerin using a front end addition process.
2. The amino-formaldehyde resin of claim 1 wherein the resin is a UF resin and the urea is present in a final molar ratio of formaldehyde to urea ranging from about 0.70 to about 1.30.
3. The amino-formaldehyde resin of claim 2 wherein the resin is a UF resin and the urea is present in a final molar ratio of formaldehyde to urea of about 1.15.
4. The amino-formaldehyde resin of claim 2 wherein the resin is a UF resin and the glycerin is present at a concentration of about 6 weight percent of the formulation.
5. The amino-formaldehyde resin of claim 1 wherein the resin is a MF resin and the melamine is present in a final molar ratio of formaldehyde to melamine ranging from about 1.3 to about 2.2.
6. The amino-formaldehyde resin of claim 5 wherein the resin is a MF resin and the melamine is present in a final molar ratio of formaldehyde to melamine of about 1.7.
7. The amino-formaldehyde resin of claim 5 wherein the resin is a MF resin and the glycerin is present at a concentration of about 15 weight percent of the formulation.
8. The amino-formaldehyde resin of claim 1 wherein the resin is a MUF resin and the mixture of urea and melamine is present in a final molar ratio of formaldehyde to urea and melamine ranging from about 0.35 to about 1.3.
9. The amino-formaldehyde resin of claim 8 wherein the resin is a MUF resin and the mixture of urea and melamine is present in a final molar ratio of formaldehyde to urea and melamine of about 0.65.
10. The amino-formaldehyde resin of claim 8 wherein the resin is a MUF resin and the glycerin is present at a concentration of about 15 weight percent of the formulation.
11. The amino-formaldehyde resin of claim 1 wherein the amino-formaldehyde resin is a UF or a MUF resin and the UF or MUF resin is prepared using a formaldehyde urea concentrate.
12. The amino-formaldehyde resin of claim 1 wherein the amino-formaldehyde resin is a MF or a MUF resin and the MF or MUF resin is prepared using melamine having a particle size of from about 50 to 400 microns.
13. The amino-formaldehyde resin of claim 1 wherein the resin is a UF or a MUF resin and the UF or MUF resin is prepared using an urea having a purity of about 98 percent.
14. A process for preparing an amino-formaldehyde resin comprising combining under condensation reaction conditions formaldehyde, glycerin, and at least one compound selected from the group consisting of urea, melamine, and mixtures thereof; wherein;
the amino-formaldehyde resin is prepared in a substantial absence of a sulfonating agent, ethylene glycol, and polyalkylene glycols;
if the at least one compound is urea, then the urea is present in a final molar ratio of formaldehyde to urea ranging from about 0.70 to about 1.30;
if the at least one compound is melamine, then the melamine is present in a final molar ratio of formaldehyde to melamine ranging from about 1.3 to about 2.2; and
if the at least one compound is a mixture of urea and melamine, then the mixture of urea and melamine is present in a final molar ratio of formaldehyde to urea and melamine ranging from about 0.35 to about 1.3; and wherein;
the amino-formaldehyde resin has improved storage stability, as compared to a conventional resin which has the same final ratio of formaldehyde to amino compounds as the amino-formaldehyde resin but which does not use glycerin in the formulation; and
the amino-formaldehyde resin comprises a glycerin modified amino-formaldehyde resin prepared by introducing the glycerin using a front end addition process.
15. An article of manufacture comprising a substrate and an amino-formaldehyde resin wherein:
the substrate is in a form selected from the group consisting of cellulosic:
-particles, -strands, -fibers, -veneers, and mixtures thereof;
the amino-formaldehyde resin functions to adhere the substrate together into or within the article of manufacture; and
the amino-formaldehyde resin is prepared using the formulation of claim 1 .
16. The article of manufacture of claim 15 wherein the article of manufacture is particle board.