Binder composition with low formaldehyde emission and process for its preparation

Claim 2

A binder for use in production of particle board and plywood with low formaldehyde emission which consists essentially of a polymer formed by the reaction of an acidified starch hydrolyzate, urea and formaldehyde, wherein the starch hydrolyzate comprises from about 3% to about 40% by weight of the polymer on a dry solids basis and wherein the molar ratio of urea to formaldehyde in the polymer is from about 1:1 to about 1:1.5.

Claim 3

The binder of claim 1, wherein the starch hydrolyzate comprises between about 4% and about 25% by weight of the polymer.

Claim 4

A process for the preparation of a binder of claim 1 which comprises adjusting the pH of an aqueous solution of starch hydrolyzate and formaldehyde to from about 0.5 to about 3.0, said aqueous solution containing from about 40% to about 80% by weight of water and having a weight ratio of starch hydrolyzate to formaldehyde of from about 1:1 to about 1:10; slowly adding urea to said solution of starch hydrolyzate and formaldehyde while maintaining the temperature below about 95° C. until the molar ratio of urea to formaldehyde is from about 1:4 to about 1:2.5; then adjusting the pH of the mixture to from about 6.0 to about 8.5; and slowly adding more urea to the mixture while maintaining the temperature of the mixture in the range of from about 50° C. to about 70° C. until the molar ratio of urea to formaldehyde added to the mixture is from about 1:1 to about 1:1.5.

Claim 5

The process of claim 3, wherein the aqueous solution of starch hydrolyzate is prepared by adding a mixture of alpha-amylase and amyloglucosidase enzymes to a stirred slurry of starch at a pH from about 4 to about 8; slowly raising the temperature of the slurry to from about 80° C. to about 90° C.; and holding the temperature of the slurry at this temperature until the starch is solubilized and the mixture gives a negative starch-iodide test.

Claim 6

The process of claim 4, wherein the starch is selected from the group consisting of wheat flour, maize flour, rice starch, corn starch, potato starch, manioc starch, tapioca, and oxidized starch.

Claim 7

The process of claim 3, wherein the solution of starch hydrolyzate is prepared by treating a stirred slurry of starch at a pH from about 4 to about 8 first with an alpha-amylase enzyme at a temperature of from about 30° C. to about 60° C. and then with an amyloglucosidase enzyme at a temperature from about 60° C. to about 90° C. until the starch is solubilized and the mixture gives a negative starch-iodide test.

Claim 8

A process for preparation of a binder of claim 1 which comprises refluxing an aqueous solution of the starch hydrolyzate containing from about 40% to about 80% by weight of water and from about 2% to about 5% of the total amount of urea at a pH of from about 3 to about 5 for from about 20 to about 60 minutes; adding to the solution from about 50% to about 60% of the total amount of formaldehyde; adjusting the pH to from about 6.0 to about 8.5; adding from about 20% to about 40% of the urea, and again refluxing the mixture; adjusting the pH of the mixture to from between about 4.0 and about 5.5, and refluxing until the Gardner viscosity of the solution is E to F; adjusting the pH to from about 6.0 to about 8.5, adding the final portions of formaldehyde and urea, and maintaining the temperature of the mixture at from about 60° C. to about 80° C. for from 30 to 90 minutes.

Claim 9

A process for bonding lignocellulosic material under heat and pressure, where the bonded lignocellulosic material is characterized by a low emission of formaldehyde, which comprises applying the binder of claim 1 and from about 1% to about 20% by weight of the binder of a curing agent to said lignocellulosic material, and consolidating said lignocellulosic material at a temperature from about 100° C. to about 200° C. and a pressure from about 1 to about 30 kg/cm 2 .

Claim 10

The process of claim 8 wherein the curing agent is selected from the group consisting of: ammonium chloride, ammonium sulfate, ammonium thiocyanate, ammonium nitrate and aluminum nitrate.

Claim 11

The process of claim 9 wherein the curing agent further comprises urea.

Claim 12

Particle board prepared by the process of claim 8 wherein the binder comprises from about 5% to about 15% by weight of the lignocellulosic material.

Claim 13

Plywood prepared by the process of claim 8 wherein the binder is applied at a rate of from about 200 to about 400 grams of binder per square meter of contact surface area.