Modified phenolic resins for making composite products
AssigneeGeorgia-Pacific Chemicals LLC
InventorsRamji Srinivasan, Benjamin D. Gapud, Kelly A. Shoemake
Life of this patent
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Abstract
Methods for making phenolic resins modified with one or more monosaccharides and methods for making composite products therewith are provided. In at least one specific embodiment, a method for making a composite product can include contacting a plurality of cellulosic sheets with a resin composition that includes a phenolic resin and a monosaccharide. The resin composition can include about 0.5 wt % to about 30 wt % of the monosaccharide, based on a combined weight of the phenolic resin and the monosaccharide. The method can also include at least partially curing the resin composition to produce a composite product.
Claims20
A method for making a composite product, comprising:
- contacting a plurality of cellulosic sheets with a resin composition comprising a phenolic resin and a monosaccharide, wherein the resin composition comprises about 0.5 wt % to about 30 wt % of the monosaccharide, based on a combined weight of the phenolic resin and the monosaccharide;
- partially curing the resin composition to produce a post-formable laminate;
- heating the post-formable laminate to a temperature of about 118° C. to about 220° C.;
- and
- bending the post-formable laminate at the temperature of about 118° C. to about 220° C. to produce a post-formed composite product.
A method for making a composite product, comprising:
- contacting a plurality of cellulosic sheets with a resin composition comprising a phenol-formaldehyde resin and glucose, wherein the phenol-formaldehyde resin has a molar ratio of formaldehyde to phenol of about 1.1:1 to about 4:1 and a viscosity of about 30 cP to about 500 cP at a temperature of 25° C.;
- partially curing the resin composition to produce a post-formable laminate;
- heating the post-formable laminate to a temperature of about 135° C. to about 220° C. for about 3 seconds to about 60 seconds;
- and
- bending the post-formable laminate at the temperature of about 135° C. to about 220° C. to produce a post-formed composite product.
A composite product, comprising:
- a plurality of cellulosic sheets, and
- a cured resin composition, wherein the cured resin composition, prior to curing, comprises one or more phenolic resins and about 0.5 wt % to about 30 wt % of one or more monosaccharides, based on a combined weight of the one or more phenolic resins and the one or more monosaccharides, wherein the composite product comprises a bend having a radius of 4 mm or less along a cross-direction or a machine direction of the composite product, based on the procedure of NEMA test 3.14 from Standard NEMA Publications Book LD3-2005.
Dependencies are inferred from the claim text.