Multi-part lignin-based resin system for decorative laminates

1. A method for making a multi-part resin system used in the manufacture of decorative laminates, comprising:

forming a lignin-formaldehyde resin consisting essentially of water, lignin, alkali, and formaldehyde;

forming a phenol-formaldehyde resin;

mixing the lignin-formaldehyde resin and the phenol-formaldehyde resin to form the multi-part resin system;

diluting the multi-part resin system with methanol and/or water such that it has a viscosity from approximately 20 cps to approximately 70 cps and adjusting the pH to between 8.5 and 9.5.

2. The method according to claim 1 , wherein the phenol-formaldehyde resin is a resol type phenol-formaldehyde.

3. The method according to claim 1 , wherein forming the lignin-formaldehyde resin comprises introducing water and heating the water to between 70° C.and 95° C.;

introducing lignin and mixing with the water for at least 15 minutes at 80° C. to 95° C.; introducing the alkali; introducing the formaldehyde; and mixing the water, lignin, alkali, and formaldehyde and maintaining the water, lignin, alkali, and formaldehyde mixture between 70° C. and 95° C.

4. The method according to claim 3 , wherein the water, lignin, alkali, and formaldehyde mixture is maintained at a temperature between 70° C. and 95° C. for a time between 20 minutes and 180 minutes.

5. The method according to claim 4 , wherein the lignin is either in powder form with a solid content of 85% to 95% or in the form of a paste whose solid content is around 50% to 65%.

6. The method according to claim 1 , wherein mixing includes mixing the phenol-formaldehyde resin and a lignin-formaldehyde resin at around 40° C. to 70° C.

7. The method according to claim 1 , further including adjusting a pH in the multi-part resin system.

8. The method according to claim 1 , further including the step of impregnating a core paper with the multi-part resin system and forming a decorative laminate with the impregnated core paper.

9. A multi-part resin system, comprising:

a lignin-formaldehyde resin consisting essentially of water, lignin, alkali, and formaldehyde; and

a phenolic resin.

10. The multi-part resin system according to claim 9 , wherein the lignin-formaldehyde resin is formed under alkali conditions.

11. A method for making a decorative laminate, comprising:

preparing a decorative sheet impregnated;

preparing at least one core layer sheet impregnated, wherein preparing the at least one core layer sheet includes making a multi-part resin system and impregnating the at least one core layer sheet with the multi-part resin system, wherein making the multi-part resin system includes forming a lignin-formaldehyde resin consisting essentially of water, lignin, alkali, and formaldehyde; forming a phenol-formaldehyde; mixing the lignin-formaldehyde resin and the phenol-formaldehyde to form the multi-part resin system, and diluting the multi-part resin system with methanol and/or water such that it has a viscosity from approximately 20 cps to approximately 70 cps and adjusting the pH to between 8.5 and 9.5;

pressing and heating the decorative sheet and the at least one core layer sheet to form a decorative laminate.

12. The method according to claim 11 , wherein the phenol-formaldehyde resin is a resol type phenol-formaldehyde resin.

13. The method according to claim 11 , wherein forming the lignin- formaldehyde resin comprises introducing water and heating the water to between 70° C. and 95° C.;

introducing lignin and mixing with the water for at least 15 minutes at 80° C. to 95° C.; introducing the alkali; introducing the formaldehyde; and mixing the water, lignin, alkali, and formaldehyde and maintaining the water, lignin, alkali, and formaldehyde mixture between 70° C. and 95° C.

14. The method according to claim 13 , wherein the water, lignin, alkali, and formaldehyde mixture is maintained at a temperature between 70° C. and 95° C. for a time between 20 minutes and 180 minutes.

15. The method according to claim 14 , wherein the lignin is either in powder form with a solid of 85-95% or in the form of a paste whose solid is around 50% to 65%.

16. The method according to claim 11 , wherein mixing includes mixing the phenol-formaldehyde resin and a lignin-formaldehyde resin at around 40° C. to 70° C.

17. The method according to claim 11 , further including adjusting a pH in the multi-part resin system.

18. The method according to claim 11 , further including the step of impregnating a core paper with the multi-part resin system and forming a decorative laminate with the impregnated core paper.