Storage stable melamine-urea-formaldehyde resins and applications thereof
AssigneeMomentive Specialty Chemicals Inc.
InventorsByung Young No, William K. Motter, David M. Harmon
Life of this patent
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Abstract
Melamine-urea-formaldehyde resins may be prepared using processes including a first cook stage, a second cook stage, and a final addition wherein: the molar ratio of formaldehyde to urea and melamine (F:U+M) in the first cook stage is from about 2.0 to about 5.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the second cook stage is from about 1.5 to 3.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the final addition from about 0.4 to 0.70.
Claims26
A method for preparing a melamine-urea-formaldehyde resin comprising a first cook stage, a second cook stage, and a final addition wherein:
- the first cook stage comprises adding at least formaldehyde and melamine to form a first cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 2.0 to about 5.0;
- the second cook stage comprises adding at least urea to form a second cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 1.5 to 3.0;
- and
- the final addition comprises adding at least urea to form a final addition molar ratio of formaldehyde to urea and melamine (F:U+M) from about 0.4 to 0.7.
A method for preparing a melamine-urea-formaldehyde resin comprising:
- charging formaldehyde and melamine to form a mixture at a first molar ratio of formaldehyde to urea and melamine (F:U+M) from about 2.0 to about 5.0 and then heating the mixture;
- charging a first amount of urea to the mixture to form a second molar ratio of formaldehyde to urea and melamine (F:U+M) from about 1.5 to 3.0 and heating the mixture;
- and
- charging a second amount of urea to the mixture to form a third molar ratio of formaldehyde to urea and melamine (F:U+M) from about 0.25 to 1.1.
A melamine-urea-formaldehyde resin prepared using a method comprising a first cook stage, a second cook stage, and a final addition wherein:
- the first cook stage comprises adding at least formaldehyde and melamine to form a first cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 2.0 to about 5.0;
- the second cook stage comprises adding at least urea to form a second cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 1.5 to 3.0;
- and
- final addition comprises adding at least urea to form a final addition molar ratio of formaldehyde to urea and melamine (F:U+M) from about 0.4 to 0.7.
An article of manufacture comprising a substrate and a melamine-urea-formaldehyde resin wherein:
- the substrate is selected from the group consisting of cellulosic-particles, -strands, -fibers, -veneers, and mixtures thereof;
- the melamine-urea-formaldehyde resin functions to adhere the substrate together into the article of manufacture;
- and
- the melamine-urea-formaldehyde resin is prepared using a method comprising a first cook stage, a second cook stage, and a final addition wherein:
- the first cook stage comprises adding at least formaldehyde and melamine to form a first cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 2.0 to about 5.0;
- the second cook stage comprises adding at least urea to foam a second cook stage molar ratio of formaldehyde to urea and melamine (F:U+M) from about 1.5 to 3.0;
- and
- the final addition comprises adding at least urea to form a final addition molar ratio of formaldehyde to urea and melamine (F:U+M) from about 0.4 to 0.7.
Dependencies are inferred from the claim text.