Adhesives, reaction systems, and processes for production of lignocellulosic composites

A process for the production of lignocellulosic composites consisting of the following steps:

• (a) providing a lignocellulosic substrate comprising a plurality of lignocellulosic adherends wherein the lignocellulosic substrate moisture content is greater than 6% by weight;
• (b) spraying a first stream of an adhesive onto the lignocellulosic substrate wherein the first stream comprises a polyfunctional isocyanate and a transition metal catalyst;
• wherein the first stream is free of a prepolymer;
• (c) spraying a second stream of the adhesive onto the lignocellulosic substrate wherein the second stream, which is different from the first stream, comprises a hydrophilic polyahl having oxyethylene segments that make up greater than 50% of the weight of the polyahl and a non-isocyanate reactive additive;
• wherein the second stream is free of a prepolymer;
• then
• (d) blending the lignocellulosic substrate and the two separate streams of the adhesive to produce an adhesive treated lignocellulosic substrate;
• (e) forming and pressing the lignocellulosic substrate under conditions suitable for curing the adhesive to produce a bonded lignocellulosic composite article having a total adhesive loading between about 1 and about 6% by weight of the bonded lignocellulosic article;
• (f) recovering the bonded lignocellulosic composite article;
• and
• wherein the conditions suitable for curing include heating the lignocellulosic substrate to a temperature of from 300° F.-400° F.