Composite products containing a powdered binder and methods for making and using same
View Patent ↗Composite products, powdered binders, resinated furnishes, and methods for making and using same. In one example, a composite product can include a plurality of lignocellulose substrates and an at least partially cured, powdered binder. Prior to curing the powdered binder can include about 5 wt % to about 95 wt % of a powdered carbohydrate, and about 5 wt % to about 95 wt % of a powdered nitrogen-containing compound, where the weight percent values are based on a total weight of the powdered carbohydrate and the powdered nitrogen-containing compound. The powdered carbohydrate can include a monosaccharide, a disaccharide, or a mixture thereof. The powdered nitrogen-containing compound can include an ammonium compound, an alkylammonium compound, an amino acid, a hydrate thereof, a salt thereof, or any mixture thereof.
1. A composite product, comprising:
a plurality of lignocellulose substrates; and
an at least partially cured, powdered binder, wherein, prior to curing, the powdered binder comprises:
about 5 wt % to about 95 wt % of a powdered carbohydrate, and
about 5 wt % to about 95 wt % of a powdered nitrogen-containing compound,
wherein:
the weight percent values are based on a total weight of the powdered carbohydrate and the powdered nitrogen-containing compound,
the powdered carbohydrate comprises a monosaccharide, a disaccharide, or a mixture thereof, and
the powdered nitrogen-containing compound comprises an ammonium compound, an alkylammonium compound, an amino acid, a hydrate thereof, a salt thereof, or any mixture thereof, and
wherein the composite product comprises about 1 wt % to about 5 wt % of the at least partially cured, powdered binder, based on a dry weight of the plurality of lignocellulose substrates.
2. The composite product of claim 1 , wherein, prior to curing, the powdered binder comprises about 60 wt % to about 95 wt % of the powdered carbohydrate and about 5 wt % to about 40 wt % of the powdered nitrogen-containing compound, wherein the weight percent values are based on the total weight of the powdered carbohydrate and the powdered nitrogen-containing compound.
3. The composite product of claim 1 , wherein, prior to curing, the powdered binder comprises about 70 wt % to about 90 wt % of the powdered carbohydrate and about 10 wt % to about 30 wt % of the powdered nitrogen-containing compound, wherein the weight percent values are based on the total weight of the powdered carbohydrate and the powdered nitrogen-containing compound.
4. The composite product of claim 3 , wherein carbohydrate comprises glucose and the powdered nitrogen-containing compound comprises ammonium lignosulfonate, lysine, or a mixture thereof.
5. The composite product of claim 1 , wherein the composite product further comprises about 0.1 wt % to about 5 wt % of a wax, based on a dry weight of the lignocellulose substrates.
6. The composite product of claim 1 , wherein the powdered carbohydrate comprises glucose, fructose, galactose, sucrose, lactose, maltose, lactulose, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof.
7. The composite product of claim 1 , wherein the powdered nitrogen-containing compound comprises ammonium lignosulfonate, ammonium sulfamate, alkylammonium lignosulfonate, alkylammonium sulfamate, lysine, arginine, histidine, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof.
8. The composite product of claim 1 , wherein the composite product has an internal bond strength of about 207 kPa to about 552 kPa, as measured according to ASTM D1037-12.
9. The composite product of claim 1 , wherein, prior to curing, the powdered binder comprises about 70 wt % to about 90 wt % of the powdered carbohydrate and about 10 wt % to about 30 wt % of the powdered nitrogen-containing compound, wherein the weight percent values are based on the total weight of the powdered carbohydrate and the powdered nitrogen-containing compound, wherein the powdered carbohydrate comprises glucose, fructose, galactose, sucrose, lactose, maltose, lactulose, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof, and wherein the powdered nitrogen-containing compound comprises ammonium lignosulfonate, ammonium sulfamate, alkylammonium lignosulfonate, alkylammonium sulfamate, lysine, arginine, histidine, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof.
10. The composite product of claim 9 , wherein the composite product has an internal bond strength of about 207 kPa to about 552 kPa, as measured according to ASTM D1037-12.
11. The composite product of claim 1 , wherein the composite product is an oriented strand board comprising a core layer disposed between two face layers, wherein the core layer comprise a core composition and the two face layers each comprise a face composition, wherein the face composition comprises the at least partially cured binder composition, and wherein the composite product has a face to core ratio of about 40:60 to about 60:40.
12. The composite product of claim 11 , wherein the core composition comprises an at least partially cured aldehyde-based resin, and wherein the at least partially cured aldehyde-based resin comprises a phenol-formaldehyde resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol-formaldehyde resin, a phenol-urea-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-formaldehyde resin, or any mixture thereof.
13. A method for producing a composite product, comprising:
contacting a plurality of lignocellulose substrates with a powdered binder to produce a mixture, wherein the powdered binder comprises:
about 5 wt % to about 95 wt % of a powdered carbohydrate; and
about 5 wt % to about 95 wt % of a powdered nitrogen-containing compound,
wherein:
the weight percent values are based on a total weight of the powdered carbohydrate and the powdered nitrogen-containing compound,
the powdered carbohydrate comprises a monosaccharide, a disaccharide, or a mixture thereof, and
the powdered nitrogen-containing compound comprises an ammonium compound, an alkylammonium compound, an amino acid, a hydrate thereof, a salt thereof, or any mixture thereof; and
heating the mixture at a temperature of about 100° C. to about 300° C. for about 1 minute to less than 10 minutes to produce a composite product comprising the powdered binder at least partially cured.
14. The method of claim 13 , wherein the mixture is heated at a temperature of about 140° C. to about 280° C. for about 2 minutes to less than 8 minutes to produce the composite product, and wherein the composite product has an internal bond strength of about 207 kPa to about 552 kPa, as measured according to ASTM D1037-12.
15. The method of claim 13 , wherein the composite product is an oriented strand board comprising one or more core layers disposed between two face layers, wherein the core layers comprise a core composition and the face layers comprise a face composition, and wherein the face composition comprises the at least partially cured binder composition.
16. The method of claim 15 , wherein the core composition comprises an at least partially cured aldehyde-based resin, and wherein the at least partially cured aldehyde-based resin comprises a phenol-formaldehyde resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol-formaldehyde resin, a phenol-urea-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-formaldehyde resin, or any mixture thereof.
17. The method of claim 13 , wherein the powdered binder comprises about 60 wt % to about 95 wt % of the powdered carbohydrate and about 5 wt % to about 40 wt % of the powdered nitrogen-containing compound, and wherein the weight percent values are based on the total weight of the powdered carbohydrate and the powdered nitrogen-containing compound.
18. The method of claim 13 , wherein the powdered carbohydrate comprises glucose, fructose, galactose, sucrose, lactose, maltose, lactulose, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof, and wherein the powdered nitrogen-containing compound comprises ammonium lignosulfonate, ammonium sulfamate, alkylammonium lignosulfonate, alkylammonium sulfamate, lysine, arginine, histidine, an isomer thereof, a hydrate thereof, a salt thereof, or any mixture thereof.