Abstract: Amino-formaldehyde resins, articles of manufacture from the amino-formaldehyde resins, and processes for making the resins and articles are provided herein. In one embodiment, the amino-formaldehyde resins may be prepared using a reaction mixture including formaldehyde, a monohydroxy cyclic compound, and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof. In another embodiment, the amino-formaldehyde resins are produced by reacting formaldehyde, a monohydroxy cyclic compound, and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof, and the monohydroxy cyclic compound may be added as a front addition, an intermediate addition, a back addition, or a combination thereof, to the reaction mixture of formaldehyde and the at least one amino compound.

Abstract: Amino-formaldehyde resins, articles of manufacture from the amino-formaldehyde resins, and processes for making the resins and articles are provided herein. In one embodiment, the amino-formaldehyde resins may be prepared using a reaction mixture including formaldehyde, a monohydroxy cyclic compound, and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof. In another embodiment, the amino-formaldehyde resins are produced by reacting formaldehyde, a monohydroxy cyclic compound, and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof, and the monohydroxy cyclic compound may be added as a front addition, an intermediate addition, a back addition, or a combination thereof, to the reaction mixture of formaldehyde and the at least one amino compound.

Abstract: Amino-formaldehyde resins may be prepared using formulations including formaldehyde, glycerin and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof; under reaction conditions sufficient to prepare a resin, wherein; the amino-formaldehyde resin is prepared in a substantial absence of a sulfonating agent, ethylene glycol, and polyalkylene glycols. If the amino compound is urea, then the urea is present in a molar ratio of formaldehyde to urea ranging from 0.70 to 1.30; if the amino compound is melamine, then the melamine is present in a molar ratio of formaldehyde to melamine ranging from 1.3 to 2.2; and if the amino compound is a mixture of urea and melamine, then the mixture of urea and melamine is present in a molar ratio of formaldehyde to urea and melamine ranging from 0.35 to 1.3.

Abstract: An aqueous reaction product of a composition that may consist essentially of a source of an acid having a pKa in water of about 2 to about 8, a source of a base having a pKb in water of about 2 to about 6, and urea. A curable urea/formaldehyde resin composition may contain a curable urea/formaldehyde resin and the foregoing composition, and may be made by combining the resin with the composition. A reconstituted wood product may be made by combining particulate lignocellulosic material with the foregoing curable resin, and curing the resin. Optionally, a reconstituted wood panel may contain a particulate lignocellulosic material and a binder composition comprising the cured product of curable resin and the aforesaid aqueous reaction product. A concentrate for forming a polymerization enhancing composition is also disclosed.

Abstract: Melamine-urea-formaldehyde resins may be prepared using processes including a first cook stage, a second cook stage, and a final addition wherein: the molar ratio of formaldehyde to urea and melamine (F:U+M) in the first cook stage is from about 2.0 to about 5.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the second cook stage is from about 1.5 to 3.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the final addition from about 0.4 to 0.70.

Abstract: Melamine-urea-formaldehyde resins may be prepared using processes including a first cook stage, a second cook stage, and a final addition wherein: the molar ratio of formaldehyde to urea and melamine (F:U+M) in the first cook stage is from about 2.0 to about 5.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the second cook stage is from about 1.5 to 3.0; and the molar ratio of formaldehyde to urea and melamine (F:U+M) in the final addition from about 0.4 to 0.70.

Abstract: Amino-formaldehyde resins may be prepared using formulations including formaldehyde, glycerin and at least one amino compound selected from the group consisting of urea, melamine, and mixtures thereof; under reaction conditions sufficient to prepare a resin, wherein; the amino-formaldehyde resin is prepared in a substantial absence of a sulfonating agent, ethylene glycol, and polyalkylene glycols. If the amino compound is urea, then the urea is present in a molar ratio of formaldehyde to urea ranging from 0.70 to 1.30; if the amino compound is melamine, then the melamine is present in a molar ratio of formaldehyde to melamine ranging from 1.3 to 2.2; and if the amino compound is a mixture of urea and melamine, then the mixture of urea and melamine is present in a molar ratio of formaldehyde to urea and melamine ranging from 0.35 to 1.

Abstract: A method and apparatus for producing a synthetic board from cellulosic or lignocellulosic fibers is disclosed wherein a standard isocyanate binder is emulsified and immediately applied to the fibers before consolidation into a finished board product. The apparatus includes an emulsification and application nozzle comprising a diluent inlet, a binder inlet, a mixing section for emulsifying the diluent and the binder, and a spray nozzle for applying the binder/diluent emulsion to the fibers. The method includes supplying a binder stream, supplying a diluent stream, emulsifying the binder with the diluent and immediately applying the emulsion to the fibers. The method further includes flushing the binder/diluent emulsion using the diluent at the end of a binder application run to prevent curing of the emulsion and clogging of the apparatus. The binder/diluent emulsion can be applied to the fibers either in the blowline or downstream of the blowline, such as in the blender.

Abstract: A method and apparatus for producing a synthetic board from cellulosic or lignocellulosic fibers is disclosed wherein a standard isocyanate binder is emulsified and immediately applied to the fibers before consolidation into a finished board product. The apparatus includes an emulsification and application nozzle comprising a diluent inlet, a binder inlet, a mixing section for emulsifying the diluent and the binder, and a spray nozzle for applying the binder/diluent emulsion to the fibers. The method includes supplying a binder stream, supplying a diluent stream, emulsifying the binder with the diluent and immediately applying the emulsion to the fibers. The method further includes flushing the binder/diluent emulsion using the diluent at the end of a binder application run to prevent curing of the emulsion and clogging of the apparatus. The present invention can be used to apply the binder/diluent emulsion to the fibers either in the blowline or downstream of the blowline, such as in the blender.