Lignocellulose composite products
AssigneeGeorgia-Pacific Chemicals LLC
InventorsJeffrey Balogh, Kim K. Tutin, Anne M Cothran
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Abstract
Lignocellulose composite products that include a hydrophobizing agent. The lignocellulose composite product can include a plurality of lignocellulose substrates, an at least partially cured binder composition, and a hydrophobizing agent. In one example, the hydrophobizing agent can include about 30 wt % to about 98 wt % of a fatty acid compound, about 0.1 wt % to about 15 wt % of a rosin acid compound, and about 1 wt % to about 40 wt % of an unsaponifiable compound. In another example, the hydrophobizing agent can include a tall oil pitch and a fatty acid composition.
Claims20
A lignocellulose composite product, comprising:
- a plurality of lignocellulose substrates;
- an at least partially cured binder composition;
- and
- a first hydrophobizing agent comprising a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, wherein the first hydrophobizing agent has an acid value of about 20 to about 85, as measured according to ASTM D465-05(2010).
A lignocellulose composite product comprising:
- a plurality of lignocellulose substrates;
- about 1 wt % to about 10 wt % of an at least partially cured binder composition, based on a dried weight of the plurality of lignocellulose substrates;
- about 0.1 wt % to about 5 wt % of a first hydrophobizing agent comprising a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, based on the dried weight of the plurality of lignocellulose substrates, and
- about 0.1 wt % to about 5 wt % of a second hydrophobizing agent comprising a wax, based on the dried weight of the plurality of lignocellulose substrates, wherein:
- the binder composition, prior to curing, comprises a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-urea-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol formaldehyde resin, or a mixture thereof,
- the first hydrophobizing agent has an acid value of about 20 to less than 85, as measured according to ASTM D465-05(2010),
- the first hydrophobizing agent comprises:
- up to about 30 wt % of the fatty acid compounds, based on a total weight of the first hydrophobizing agent,
- up to about 25 wt % of the rosin acid compounds, based on the total weight of the first hydrophobizing agent, and
- at least 46 wt % of the unsaponifiable compounds, based on the total weight of the first hydrophobizing agent, and
- the wax comprises slack wax, paraffin wax, or a mixture thereof.
A process for making a lignocellulose composite product, comprising:
- contacting a plurality of lignocellulose substrates with a binder composition and a first hydrophobizing agent to produce a mixture, wherein the first hydrophobizing agent comprises a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, and wherein the first hydrophobizing agent has an acid value of about 20 to about 85, as measured according to ASTM D465-05(2010);
- and
- at least partially curing the binder composition in the mixture to produce the lignocellulose composite product.
Dependencies are inferred from the claim text.