Modified phenol-formaldehyde resin and the production thereof

In method of manufacturing a sheet material formed from a plurality of discrete members adhered together, including contacting a plurality of discrete sheet material members with a binding resin;

• disposing each of said sheet material members in contact with at least one other of said sheet material members and pressing said sheet material members together with sufficient heat and pressure to form a sheet material, the improvement comprising said binding resin, wherein said resin is formed by reacting phenol and formaldehyde with a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the mole ratio of phenolic compounds to formaldehyde being in the range from 1:2 to 1:3, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A method of manufacturing a cohesive article of a desired configuration comprising contacting a plurality of fibers with a modified phenol-formaldehyde resin and hot pressing said resin contacted fibers together to cause said fibers to adhere to each other wherein said resin is formed by reacting phenol and formaldehyde with a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A method of molding an object having a predetermined configuration from a plurality of smaller objects comprising disposing an object-resin composition in a mold cavity, closing said mold cavity and pressing said composition to adhere said composition together into said predetermined configuration, wherein said object-resin composition comprises a plurality of said smaller objects and a lignosulfonate-phenol-formaldehyde resin formed by reacting phenol and formaldehyde with a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the mole ratio of phenolic compounds to formaldehyde being in the range from 1:2 to 1:3, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A method of manufacturing a plywood article including applying a binder comprising a polymer between two layers of wood and pressing said wood layers together under conditions sufficient to adhere said layers together, the improvement comprising said polymer wherein said polymer is formed by reacting phenol and formaldehyde with a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the mole ratio of phenolic compounds to formaldehyde being in the range from 1:2 to 1:3, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A plywood article manufactured by applying a binder comprising a polymer between two layers of wood and pressing said wood layers together under conditions sufficient to adhere said layers together, the improvement comprising said polymer wherein said polymer is formed by reacting phenol and formaldehyde with a concentrate wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A method of manufacturing an oriented strand board including at least partially coating a plurality of wood fiber strand members with a polymeric binder;

• disposing said coated strand members in contact with at least one other of said strand members;
• and pressing said wood fiber strand members to adhere said strand members together;
• the improvement comprising said polymeric binder wherein said polymer is formed by reacting phenol and formaldehyde with a concentrate wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

An oriented strand board manufactured by at least partially coating a plurality of wood fiber strand members with a polymeric binder;

• disposing said coated strand members in contact with at least one other of said strand members;
• and pressing said wood fiber strand members to adhere said strand members together;
• the improvement comprising said polymeric binder wherein said polymer is formed by reacting phenol, formaldehyde, and a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A method of manufacturing a waferboard including binding together a plurality of discrete, relatively thin wood pieces with a polymer binder under pressure sufficient to adhere said wood pieces together into sheet form, the improvement comprising the polymer binder wherein said polymer is formed by reacting phenol, formaldehyde, and a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.

A waferboard manufactured by binding together a plurality of discrete, relatively thin wood pieces with a polymer binder under pressure sufficient to adhere said wood pieces together into sheet form, the improvement comprising the polymer binder wherein said polymer is formed by reacting phenol, formaldehyde, and a concentrated wood extract obtained by steam digesting wood chips under alkaline conditions, the weight of concentrated wood extract being from 5% to 50% of the weight of the phenol, calculated on the dry weight basis of each material.