Binder compositions and methods for making and using same

A process for making a binder composition, comprising:

• reacting a polyol and an acid anhydride to produce an unsaturated polyester prepolymer, wherein:
• the polyol comprises ethylene glycol, diethylene glycol, triethylene glycol, glycerol, polyglycerol, pentaerythritol, trimethylolpropane, diethanolamine, triethanolamine, ethyl diethanolamine, methyl diethanolamine, sorbitol, glucose, fructose, sucrose, starch, dextrin, maltodextrin, polyvinyl alcohol, hydroxyethylcellulose, 1,4-cyclohexanediol, 2-butene-1,4-diol, hydroxyl-terminated polybutadiene, or a mixture thereof, and
• the acid anhydride comprises phthalic anhydride, mellitic anhydride, pyromellitic anhydride, maleic anhydride, or a mixture thereof;
• reacting the unsaturated polyester prepolymer and an unsaturated epoxide to produce an unsaturated compound, wherein the unsaturated epoxide comprises allyl glycidyl ether, 3,4-epoxy-1-butene, 1,2-epoxy-5-hexene, or a mixture thereof;
• and
• mixing the unsaturated compound with a free radical precursor comprising an oxidant and a catalyst to produce the binder composition.

A process for making a composite product, comprising:

• combining a plurality of lignocellulose substrates, an unsaturated compound, and a free radical precursor to produce a resinated furnish, wherein:
• the unsaturated compound comprises a reaction product of an unsaturated epoxide and an unsaturated polyester prepolymer, wherein the unsaturated polyester prepolymer comprises a reaction product of a polyol and an acid anhydride, wherein:
• the unsaturated epoxide comprises allyl glycidyl ether, 3,4-epoxy-1-butene, 1,2-epoxy-5-hexene, or a mixture thereof,
• the polyol comprises ethylene glycol, diethylene glycol, triethylene glycol, glycerol, polyglycerol, pentaerythritol, trimethylolpropane, diethanolamine, triethanolamine, ethyl diethanolamine, methyl diethanolamine, sorbitol, glucose, fructose, sucrose, starch, dextrin, maltodextrin, polyvinyl alcohol, hydroxyethylcellulose, 1,4-cyclohexanediol, 2-butene-1,4-diol, hydroxyl-terminated polybutadiene, or a mixture thereof, and
• the acid anhydride comprises phthalic anhydride, mellitic anhydride, pyromellitic anhydride, maleic anhydride, or a mixture thereof;
• and
• the free radical precursor comprises an oxidant and a catalyst;
• and
• heating the resinated furnish to a temperature of about 60° C. to about 300° C. to produce the composite product.