Depolymerized lignosulfonate and lignin as extender for phenolic resin
A resin composition for impregnating paper products used in manufacture of high-pressure decorative laminates includes a resin and lignin derivatives.
1 . A high-pressure decorative laminate, comprising:
a decorative layer; and
a core layer composed of at least one resin impregnated sheet of core paper, which is impregnated with a resin composition, the resin composition comprising a resin and lignin derivatives;
wherein the resin composition is prepared according to a method comprising:
mixing and cooking ammonium lignosulfonate, acetic acid, and methanol;
adding KOH or MgO and epicholorohydrin;
cooking the mixture;
mixing and cooking, with the mixture produced above, water, dioctyl sulfosuccinate sodium salt, resin, KOH, glyoxal, and methanol; and
adjusting to desired pH and viscosity.
2 . The high-pressure decorative laminate according to claim 1 , wherein the lignin derivatives are lignosulfonate and kraft lignin.
3 . The high-pressure decorative laminate according to claim 2 , wherein the lignosulfonate is ammonium lignosulfonates.
4 . The high-pressure decorative laminate according to claim 1 , wherein the decorative layer and the resin impregnated core sheet are layered to form a laminate lay-up and the laminate lay-up is heated and pressed to consolidate and cure the high-pressure laminate.
5 . The high-pressure decorative laminate according to claim 4 , further including an overlay paper layer.
6 . The high-pressure decorative laminate according to claim 1 , wherein the core layer includes two sheets of 160 to 550 grams/meter 2 resin impregnated Kraft paper.
7 . The high-pressure decorative laminate according to claim 6 , wherein the Kraft paper is impregnated with the resin composition and is partially cured.
8 . The high-pressure decorative laminate according to claim 7 , wherein the Kraft paper is impregnated with a resin content of approximately 28% to 37%.
9 . The high-pressure decorative laminate according to claim 1 , wherein the core layer includes an impregnation enhancing surfactant composition including an anionic surfactant and a non-ionic surfactant.
10 . The high-pressure decorative laminate according to claim 1 , wherein the core paper includes no more than 50% recycled materials.
11 . The high-pressure decorative laminate according to claim 10 , wherein the core paper includes an impregnation enhancing surfactant composition including an anionic surfactant and a non-ionic surfactant.