Phenol-formaldehyde polymer with carbon nanotubes, a method of producing same, and products derived therefrom
AssigneesFPInnovations, National Research Council of Canada
InventorsYaolin Zhang, Xiang-Ming Wang, Martin Feng, Gilles Brunette, Fuyong Cheng, Benoit Simard
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Abstract
The present invention provides methods to functionalize and solubilize WCNT with a phenolic polymer such as a lignin or a PF resin followed by in-situ integration of this functionalized CNT in the presence of formaldehyde and phenol and/or lignin to generate either CNT-reinforced phenol-formaldehyde polymer or CNT-reinforced lignin-phenol-formaldehyde polymer in either liquid or powder form suitable as an adhesive in the manufacture of a lignocellulosic composite material such as OSB and plywood.
Claims19
A method of producing a composite adhesive of phenol-formaldehyde polymer and carbon nanotubes (CNTs), comprising:
- functionalising CNTs with phenolic moieties, and wherein the functionalised CNTs are formed through a supramolecular interaction or a combined supramolecular/covalent interaction between the CNTs and a source of phenolic moieties by mixing in aqueous solution,
- combining the functionalised CNTs with a phenolic compound, formaldehyde or a formaldehyde equivalent, a hydroxide base and optionally at least one lignin to form a mixture, and
- polymerising the mixture at a phenol-formaldehyde polymerization temperature to produce a matrix of a phenol-formaldehyde polymer with the functionalised CNTs therein, wherein the functionalised CNTs are covalently linked to the polymer through said phenolic moieties, and the mixture comprising a molar ratio of formaldehyde or a formaldehyde equivalent, to phenolic compound of 1.8:1 to 3.0:1.
A method of producing a phenol-formaldehyde polymer adhesive comprising carbon nanotubes (CNTs) wherein the polymer is a Resol type, the method comprising:
- providing the CNTs,
- dispersing the CNTs in an alkaline aqueous solution comprising at least one phenolic polymer adhesive to produce a CNT-phenolic complex, wherein the CNT-phenolic complex is formed through a supramolecular interaction or a combined supramolecular/covalent interaction between the CNT and the phenolic polymer by mixing in aqueous solution,
- providing a polymerization mixture comprising a phenolic compound, formaldehyde or a formaldehyde equivalent, a hydroxide base and optionally at least one lignin,
- combining the CNT-phenolic polymer complex with the polymerization mixture to produce a polymerization medium, and
- raising the temperature of the medium to or above a phenol-formaldehyde polymerization temperature,
- wherein the medium is covalently bonded to produce the phenol-formaldehyde polymer, and the mixture comprising a molar ratio of formaldehyde or a formaldehyde equivalent, to phenolic compound of 1.8:1 to 3.0:1.
A phenol-formaldehyde polymer Resol type adhesive composition comprising:
- a phenolic polymer,
- a phenolic compound,
- formaldehyde or a formaldehyde equivalent,
- a hydroxide,
- carbon nanotubes (CNTs), wherein the CNTs and the phenolic polymer are in a supramolecular CNT-phenolic complex, and
- optionally at least one lignin
- wherein the composition is in aqueous form, and comprising a molar ratio of formaldehyde or a formaldehyde equivalent, to phenolic compound of 1.8:1 to 3.0:1.
Dependencies are inferred from the claim text.