# US 9,518,185 B2 · Bonding resin for wood-based composites providing light coloring, low platen sticking, and water resistance > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,518,185 B2 - Document ID: US9518185B2 - Status: Granted - Kind: B2 - Application number: 14/338,606 - Filed: 2014-07-23 - Published: 2016-01-28 - Granted: 2016-12-13 - Earliest claimed: 2014-07-23 - Assignees: Weyerhaeuser NR Company - Applicants: Weyerhaeuser Nr Company - Inventors: Jack G. Winterowd; Erik M. Parker - Web page: https://patentgrep.com/patent/US9518185B2 ## CPC - C09J 175/04: Polyurethanes - B27N 3/002: {characterised by the type of binder (compositions of macromolecular compounds C08L)} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard} - B32B 21/042: {of wood (B32B21/13 takes precedence)} - C08L 75/04: Polyurethanes - C08L 97/02: Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)} - B32B 2255/08: on wood layer - B32B 2255/26: Polymeric coating - B32B 2317/16: Wood, e.g. woodboard, fibreboard, woodchips - B32B 2375/00: Polyureas; Polyurethanes - B32B 2379/00: Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain - B32B 2419/04: Tiles for floors or walls - B32B 2419/06: Roofs, roof membranes - C08L 2205/16: Fibres; Fibrils - C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H) - B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) ## Abstract Disclosed herein are adhesives, wood-based composites incorporating the adhesives, and methods of forming wood-based composites using the adhesives. In some embodiments, an adhesive emulsion includes a continuous phase having an aqueous, alkaline solution that includes a melamine/urea/formaldehyde (“MUF”) resin, and a dispersed phase that includes a multifunctional aromatic isocyanate component. The solution including the MUF resin has a percent solids content of about 1.0% to about 90.0%, and the MUF resin and the multifunctional aromatic isocyanate component are present in a ratio of about 92:8 to about 40:60 on a solids mass basis. Wood-based composites formed using the adhesives demonstrate an optimal combination of characteristics desirable to the wood products industry. ## Claims ### Claim 1 An adhesive emulsion, comprising: (a) a continuous phase, comprising an aqueous, alkaline solution comprising a melamine/urea/formaldehyde resin; and (b) a dispersed phase, comprising a multifunctional aromatic isocyanate component; wherein the aqueous, alkaline solution comprising the melamine/urea/formaldehyde resin has a percent solids content of about 1.0% to about 90.0%; and wherein the melamine/urea/formaldehyde resin and the multifunctional aromatic isocyanate component are present in a ratio of about 92:8 to about 40:60 on a solids mass basis. ### Claim 2 (depends on 1) The adhesive emulsion of claim 1, wherein the aqueous, alkaline solution comprising the melamine/urea/formaldehyde resin has a percent solids content of about 40.0% to about 70.0%. ### Claim 3 (depends on 1) The adhesive emulsion of claim 1, wherein the aqueous, alkaline solution comprising the melamine/urea/formaldehyde resin is present in about 38.0-93.0 parts on a solids mass basis and the multifunctional aromatic isocyanate component is present in about 7.0-62.0 parts on a solids mass basis. ### Claim 4 (depends on 1) The adhesive emulsion of claim 1, wherein the multifunctional aromatic isocyanate component comprises polymeric methylene diphenyldiisocyanate. ### Claim 5 (depends on 1) The adhesive emulsion of claim 1, wherein the melamine/urea/formaldehyde resin comprises a melamine-based component that is about 5.0% or greater of the solids mass of the melamine/urea/formaldehyde resin. ### Claim 6 (depends on 1) The adhesive emulsion of claim 1, wherein the melamine/urea/formaldehyde resin comprises a urea-based component that is about 5.0% or greater of the solids mass of the melamine/urea/formaldehyde resin. ### Claim 7 (depends on 1) The adhesive emulsion of claim 1, wherein the melamine/urea/formaldehyde resin comprises a formaldehyde-based component that is about 30.0% or greater of the solids mass of the melamine/urea/formaldehyde resin. ### Claim 8 (depends on 1) The adhesive emulsion of claim 1, wherein the melamine/urea/formaldehyde resin is a condensation polymer derived from melamine, urea, and formaldehyde. ### Claim 9 (depends on 1) The adhesive emulsion of claim 1, wherein the aqueous, alkaline solution comprising a melamine/urea/formaldehyde resin has a pH of about 7.5-11. ### Claim 10 (depends on 1) The adhesive emulsion of claim 1, wherein the aqueous, alkaline solution comprising the melamine/urea/formaldehyde resin further comprises an alkaline component. ### Claim 11 (depends on 10) The adhesive emulsion of claim 10, wherein the alkaline component is sodium hydroxide. ### Claim 12 (depends on 1) The adhesive emulsion of claim 1, further comprising an additive selected from the group consisting of surfactants, diluents, viscosifying agents, colorants, preservatives, formaldehyde scavengers, and combinations thereof. ### Claim 13 (depends on 1) The adhesive emulsion of claim 1, wherein the adhesive emulsion contains no catalyst of a reaction between the melamine/urea/formaldehyde resin and the multifunctional aromatic isocyanate component. ### Claim 14 (depends on 1) The adhesive emulsion of claim 1, wherein the multifunctional aromatic isocyanate component comprises toluene 2,4-diisocyanate. ### Claim 15 (depends on 1) The adhesive emulsion of claim 1, wherein the multifunctional aromatic isocyanate component comprises toluene 2,6-diisocyanate. ### Claim 16 (depends on 1) The adhesive emulsion of claim 1, wherein the multifunctional aromatic isocyanate component comprises 2,4′-methylene bis(phenylisocyanate). ### Claim 17 (depends on 1) The adhesive emulsion of claim 1, wherein the multifunctional aromatic isocyanate component comprises 4,4′-methylene bis(phenylisocyanate). ### Claim 18 (depends on 1) The adhesive emulsion of claim 1, wherein the aqueous, alkaline solution comprising a melamine/urea/formaldehyde resin has a pH of about 8.0-10.0. ### Claim 19 (depends on 10) The adhesive emulsion of claim 10, wherein the alkaline component is potassium hydroxide. ### Claim 20 (depends on 10) The adhesive emulsion of claim 10, wherein the alkaline component is ammonium hydroxide. ### Claim 21 (depends on 10) The adhesive emulsion of claim 10, wherein the alkaline component is an organic amine.