Unexpected role of amphiphilic lignosulfonate to improve the storage stability of urea formaldehyde resin and its application as adhesives

Preparation of a Highly Flame-Retardant Urea-Formaldehyde Resin and Flame Retardance Mechanism

Urea-formaldehyde (UF) resin is the most widely used adhesive resin. However, it is necessary to improve its flame-retardant performance to expand its applications. In this study, exploiting electrostatic interactions, anionic phytic acid and cationic chitosan were combined to form a bio-based intumescent flame-retardant, denoted phytic acid-chitosan polyelectrolyte (PCS). The molecular structure of the urea-formaldehyde resin was optimized by crosslinking with melamine and plasticizing with polyvinyl alcohol-124. Thus, by combining PCS with the urea-formaldehyde resin and with ammonium polyphosphate and ammonium chloride as composite curing agents, flame-retardant urea-formaldehyde resins (FRUFs) were prepared. Compared to traditional UF resin, FRUF showed excellent flame retardancy and not only reached the UL-94 V-0 level, but the limit of oxygen index was also as high as 36%. Compared to those of UF, the total heat release and peak heat release rate of FRUF decreased by 86.44% and 81.13%, respectively. The high flame retardancy of FRUF originates from the combination of oxygen and heat isolation by the dense carbon layer, quenching of phosphorus free radicals, and dilution of oxygen by a non-flammable gas. In addition, the mechanical properties of the FRUF remained good, even after modification. The findings of this study provide a reference for the flame-retardant application of FRUF for applications in multiple fields.

Preparation of a Flame-Retardant Curing Agent Based on Phytic Acid-Melamine Ion Crosslinking and Its Application in Wood Coatings

To broaden the applications of wood, it is necessary to prepare flame-retardant coatings that can protect wood substrates during combustion. In this study, a bio-based, intumescent, flame-retardant phytic acid-melamine polyelectrolyte (PM) was prepared using phosphorus-rich biomass phytic acid and nitrogen-rich melamine as raw materials through an ion crosslinking reaction. Subsequently, a series of bio-based, flame-retardant wood coatings were prepared by optimizing the structure of urea-formaldehyde resin with the addition of melamine, sodium lignosulfonate, and PM as a flame-retardant curing agent. Woods coated with PM-containing coatings displayed significantly improved flame-retardant performances in comparison to uncoated woods. For PM-cured woods, the measured values of total heat release and total smoke production were 91.51% and 57.80% lower, respectively, compared with those of uncoated wood. Furthermore, the fire growth index decreased by 97.32%, indicating a lower fire hazard. This increase in flame retardancy and smoke suppression performance is due to the dense expanded carbon layer formed during the combustion of the coating, which isolates oxygen and heat. In addition, the mechanical properties of the flame-retardant coatings cured with PM are similar to those cured with a commercial curing agent, NH4Cl. In addition, the prepared flame-retardant coating can also stain the wood. This study proves the excellent flame-retarding and curing effect of ammonium phytate in urea-formaldehyde resin coatings and provides a new approach for the application of bio-based flame retardants in wood coatings.

Preparation of nano disperse dyes using sulfomethylated lignin: Effects of sulfonic group contents

The molecular simulation software was firstly applied to analyze the adsorption of sulfomethylated lignin (SAL) on dye surfaces. Then, SALs with different sulfonic group contents were prepared and characterized by FTIR, NMR, EA and GPC measurements using alkali lignin (AL) as raw materials and sodium sulfite as sulfonating agents. Next, SAL_1.53 was determined to the optimum dispersant by TSI, particle size and thermal storage stability measurements, which had the smallest particle size of 173 nm and highest stability, comparable to the commercial Reax 85A lignin dispersant and basically satisfying the requirement of nano disperse dyes used in the digital printing technology. QCM, AFM and zeta potential results indicated that as the sulfonic group content of SAL increased, the adsorption mass, rigidity of the adsorbed layer, adsorption force and absolute zeta potential value all showed a gradually increasing tendency due to an enhanced hydrophilicity, and thus a decreased intermolecular agglomeration and an increased molecular chain stretching degree. A maximum was observed for SAL_1.53. This research not only provided a novel approach to the preparation of high-performance lignin dispersants for nano disperse dyes, but also would broaden the high value-added industrial applications of biomass lignin into the digital printing and dyeing field.

Preparation of uniform lignosulfonate-based colloidal spheres for UV-absorbing thermoplastics

Lignosulfonate-based colloidal spheres were prepared from sodium lignosulfonate and cetyltrimethylammonium bromide (NaLS/CTAB) complex through electrostatic and hydrophobic self-assembly. Due to the stronger hydrophobicity and UV-blocking performance, NaLS/CTAB colloids were easier to be blended with HDPE than lignosulfonate, and therefore applied to UV-absorbing thermoplastics. Results showed NaLS/CTAB colloidal spheres had a particle size of 160 nm with a polydispersity index of 0.081. NaLS/CTAB molecules started to form spheres at critical water content of 64 vol% when the initial concentration of NaLS/CTAB in EtOH was 0.5 mg/cm³ and the obtaining of colloids was completed at a water content of 90 vol%. The size and polydispersity of spheres were well controlled by adjusting initial concentrations of NaLS/CTAB in EtOH. Since NaLS/CTAB colloidal spheres retained phenylpropane units and phenolic hydroxyl groups of NaLS, NaLS/CTAB/HDPE composites displayed excellent UV-absorbing properties. Meanwhile, the mechanical property of NaLS/CTAB/HDPE composites was also superior to that of frequently-used CaCO₃/HDPE materials in industry, reaching the requirement of industrial uses. However, too high additions would result in the increased agglomeration of NaLS/CTAB spheres in HDPE, and thus the deteriorated mechanical property. Additionally, the added spheres played a role of "ball", which caused the decreased viscosity, improved flowability and processability of composites.

Effect of Copper (II) Sulfate on the Properties of Urea Formaldehyde Adhesive

The purpose of this work is to investigate the effects of copper (II) sulfate on the formaldehyde release and the mechanical properties of urea formaldehyde (UF) adhesive. Copper (II) sulfate has been used as a formaldehyde scavenger in UF resin, and its effects on the physical and chemical properties of UF adhesive have been studied. Moreover, the mechanical properties and formaldehyde release of plywood prepared with modified UF resin have been determined. The UF resin has been characterized by Fourier-transform infrared (FTIR) spectroscopy and thermogravimetric analysis (TGA). FTIR spectra showed that the addition of copper (II) sulfate to the UF resin does not affect the IR absorptions of its functional groups, implying that the structure of UF is not modified. Further results showed that the free formaldehyde content of the UF resin incorporating 3% copper (II) sulfate was 0.13 wt.%, around 71% lower than that of the untreated control UF adhesive. With a copper (II) sulfate content of 3%, the formaldehyde release from treated plywood was 0.74 mg·L-1, around 50% lower than that from the control UF adhesive, and the bonding strength reached 1.73 MPa, around 43% higher than that of the control.

Xylo-oligosaccharides and lignin production from Camellia oleifera shell by malic acid hydrolysis at mild conditions

Camellia oleifera shell (COS), a by-product of processing woody vegetable oil, is rich in hemicellulose and lignin. In this study, we investigated the effects of acid concentration, pretreatment temperature and reaction time on the concentration and yield of xylo-oligosaccharides (XOS) and the degree of polymerization (DP) distribution of XOS when pretreating COS with malic acid (MA). Under moderate condition (2 M MA, 120 ℃, 30 min), the maximum yield of XOS with DP 2-4 was 48.78% (based on the initial xylan) with low xylose, 5-hydroxymethylfurfural (HMF) and furfural, in which xylobiose (X₂), xylotriose (X₃) and xylotraose (X₄) concentrations were 5.22 g/L, 2.75 g/L and 2.91 g/L, respectively. In addition, acid-insoluble lignin (AIL) in the residue after MA pretreatment and milling wood lignin (MWL) were mainly composed of guaiacyl and syringyl. AIL has higher thermal stability than MWL, which can be the stabilizer for producing flame-resistant materials.

Lignosulphonates as an Alternative to Non-Renewable Binders in Wood-Based Materials

Lignin is a widely abundant renewable source of phenolic compounds. Despite the growing interest on using it as a substitute for its petroleum-based counterparts, only 1 to 2% of the global lignin production is used for obtaining value-added products. Lignosulphonates (LS), derived from the sulphite pulping process, account for 90% of the total market of commercial lignin. The most successful industrial attempts to use lignin for wood adhesives are based on using this polymer as a partial substitute in phenol-formaldehyde or urea-formaldehyde resins. Alternatively, formaldehyde-free adhesives with lignin and lignosulphonates have also been developed with promising results. However, the low number of reactive sites available in lignin's aromatic ring and high polydispersity have hindered its application in resin synthesis. Currently, finding suitable crosslinkers for LS and decreasing the long pressing time associated with lignin adhesives remains a challenge. Thus, several methods have been proposed to improve the reactivity of lignin molecules. In this paper, techniques to extract, characterize, as well as improve the reactivity of LS are addressed. The most recent advances in the application of LS in wood adhesives, with and without combination with formaldehyde, are also reviewed.

Surfactant-Induced Reconfiguration of Urea-Formaldehyde Resins Enables Improved Surface Properties and Gluability of Bamboo

The high-efficiency development and utilization of bamboo resources can greatly alleviate the current shortage of wood and promote the neutralization of CO₂. However, the wide application of bamboo-derived products is largely limited by their unideal surface properties with adhesive as well as poor gluability. Herein, a facile strategy using the surfactant-induced reconfiguration of urea-formaldehyde (UF) resins was proposed to enhance the interface with bamboo and significantly improve its gluability. Specifically, through the coupling of a variety of surfactants, the viscosity and surface tension of the UF resins were properly regulated. Therefore, the resultant surfactant reconfigured UF resin showed much-improved wettability and spreading performance to the surface of both bamboo green and bamboo yellow. Specifically, the contact angle (CA) values of the bamboo green and bamboo yellow decreased from 79.6° to 30.5° and from 57.5° to 28.2°, respectively, with the corresponding resin spreading area increasing from 0.2 mm² to 7.6 mm² and from 0.1 mm² to 5.6 mm². Moreover, our reconfigured UF resin can reduce the amount of glue spread applied to bond the laminated commercial bamboo veneer products to 60 g m⁻², while the products prepared by the initial UF resin are unable to meet the requirements of the test standard, suggesting that this facile method is an effective way to decrease the application of petroleum-based resins and production costs. More broadly, this surfactant reconfigured strategy can also be performed to regulate the wettability between UF resin and other materials (such as polypropylene board and tinplate), expanding the application fields of UF resin.

Preparation and Properties of the Urea-Formaldehyde Res-In/Reactive Halloysite Nanocomposites Adhesive with Low-Formaldehyde Emission and Good Water Resistance

Low-cost urea formaldehyde resin (UF)/reactive halloysite nanotubes (HNTs) nanocomposite adhesive was prepared successfully via in situ polymerization. The HNTs were modified to improve its compatibility with polymer. The XRD and FTIR results showed that physical and chemical interaction between the HNTs and polymer resin influenced the structure of UF owing to the functional groups on the HNTs. It is found from SEM images that the modified HNTs could be dispersed uniformly in the resin and the nanocomposite particles were spherical. The performance experiment confirmed that thermal stability of nanocomposite increased largely, formaldehyde emission of UF wood adhesive reduced 62%, and water resistance of UF wood adhesive improved by 84%. Meanwhile, the content of HNTs on the nanocomposites could be up to 60 wt %. The mechanism of the nanocomposites based on the reactive HNTs was proposed. The approach of the preparation could supply an idea to prepare other polymer/clay nanocomposites.

Lignin and Lignin-Derived Compounds for Wood Applications-A Review

Improving the environmental performance of resins in wood treatment by using renewable chemicals has been a topic of interest for a long time. At the same time, lignin, the second most abundant biomass on earth, is produced in large scale as a side product and mainly used energetically. The use of lignin in wood adhesives or for wood modification has received a lot of scientific attention. Despite this, there are only few lignin-derived wood products commercially available. This review provides a summary of the research on lignin application in wood adhesives, as well as for wood modification. The research on the use of uncleaved lignin and of cleavage products of lignin is reviewed. Finally, the current state of the art of commercialization of lignin-derived wood products is presented.