Converting crystalline thermosetting urea–formaldehyde resins to amorphous polymer using modified nanoclay

Optimization of areca leaf sheath nanolignin synthesis by a mechanical method for in situ modification of ultra-low molar ratio urea-formaldehyde adhesives

This study addresses the optimization of the nanolignin preparation method from the areca leaf sheath (ALS) by a mechanical process using a high shear homogenizer at 13,000-16,000 rpm for 1-4 h and its application in enhancing the performance of ultralow molar ratio urea-formaldehyde (UF) adhesive. Response surface methodology (RSM) with a central composite design (CCD) model was used to determine the optimum nanolignin preparation method. The mathematical model obtained was quadratic for the particle size response and linear for the zeta potential response. Under the optimum conditions, a speed of 16,000 rpm for 4 h resulted in a particle size of 227.7 nm and a zeta potential of -18.57 mV with a high desirability value of 0.970. FE-SEM revealed that the characteristic changes of lignin to nanolignin occur from an irregular or nonuniform shape to an oval shape with uniform particles. Nanolignin was introduced during the addition reaction of UF resin synthesis. UF modified with nanolignin (UF-NL) was analyzed for its adhesive characteristics, functional groups, crystallinity, and thermomechanical properties. The UF-NL adhesive had a slightly greater solid content (73.23 %) than the UF adhesive, a gelation time of 4.10 min, and a viscosity of 1066 mPa.s. The UF-NL adhesive had similar functional groups as the UF adhesive, with a lower crystallinity of 59.73 %. Compared with the control plywood which has a tensile shear strength value of 0.79 MPa, the plywood bonded with UF-NL had a greater tensile shear strength of 1.07 MPa, with a lower formaldehyde emission of 0.065 mg/L.

Chitosan-tannin adhesive: Fully biomass, synthesis-free and high performance for bamboo-based composite bonding

Inspired by phenol-amine chemistry of mussels, a synthesis-free and fully biomass adhesive composed of chitosan and tannin (CST) was successfully developed by a facile method. The performance of CST adhesive for bonding bamboo, wood and bamboo-wood substrates were tested. When 160 °C hot-press temperature was used, dry lap shear strength above 5.00 MPa was obtained. The CST adhesive has remarkable water resistance and low cure temperature as high wet shear strength of 2.37 MPa for plybamboo specimens was achieved after 3 h boiling in water even though low hot-press temperature of 100 °C was applied. Further, high strength of 1.78 MPa remained after 72 h boiling. With higher hot-press temperatures used, wet shear strength above 3.60 MPa was achieved. The adhesion performance for wood substrate was also superior to other phenol-amine adhesives reported in literatures. The bamboo-wood composites assembled with CST adhesive show excellent mechanical performance, specifically modulus of rupture (MOR) of 100-133 MPa and modulus of elasticity (MOE) of 10-13 GPa were achieved with different hot-press temperatures used. Given the advantages including outstanding water resistance, facile preparation, fully biomass, and low cure temperature, CST adhesive exhibited great potential to be an ideal alternative to formaldehyde-based resin for wood and bamboo bonding.

The role of acetone-fractionated Kraft lignin molecular structure on surface adhesion to formaldehyde-based resins

One of the key strategies for valorizing kraft lignin (KL) into value-added products such as bio-based adhesives is to perform solvent fractionation of KL to produce lignin with improved homogeneity. Understanding the structure and properties of fractionated KL will aid in the selection of the best samples for certain applications. In this study, acetone-fractionated KL from softwood and hardwood was characterized to understand its chemical structure, elemental composition, molecular weight, and thermal properties. The results revealed that acetone-insoluble KL (AIKL) fractions from softwood and hardwood have greater molecular weight, polydispersity, glass temperature, carbohydrate content, aliphatic hydroxyl groups, and a variety of native wood lignin side chains. In contrast, acetone-soluble KL (ASKL) fractions have a significantly lower molecular weight and polydispersity, a lower glass-transition temperature, a more condensed structure, more aromatic hydroxyl groups, and fewer native wood lignin side chains. In addition, the ASKL samples demonstrated stronger adhesive force and work of adhesion toward phenol-formaldehyde (PF) and urea-formaldehyde (UF) resins than the AIKL samples, regardless of the lignin source. These findings suggest that ASKL has great potential as a substitute for phenol in PF resins and as a green additive to reinforce UF resins.

Application of Nano-SiO2 Reinforced Urea-Formaldehyde Resin and Molecular Dynamics Simulation Study

Nano-SiO₂ is a typical modifier used for urea-formaldehyde (UF) resins to balance the reduced formaldehyde content and maintain bond strength. However, the microstructure of UF resin and the interaction between UF resin and nano-SiO₂ are microscopic phenomena; it is difficult to observe and study its intrinsic mechanism in traditional experimental tests. In this work, the enhancement mechanism was explored by molecular dynamics simulations combined with an experiment of the effect of nano-SiO₂ additions on UF resin. The results showed that the best performance enhancement of UF resin was achieved when the addition of nano-SiO₂ was 3 wt%. The effects caused by different additions of nano-SiO₂ were compared and analyzed by molecular dynamics simulations in terms of free volume fraction, the radius of gyration, and mechanical properties, and the results were in agreement with the experimental values. Meanwhile, the changes in hydrogen bonding and radial distribution functions in these systems were counted to explore the interaction between nano-SiO₂ and UF resin. The properties of the UF resin were enhanced mainly through the large number of different forms of hydrogen bonds with nano-SiO₂, with the strongest hydrogen bond occurring between H_(SiO2)… O = _(PHMU).

Use of Thymus Plants as an Ecological Filler in Urea-Formaldehyde Adhesives Intended for Bonding Plywood

Innovative adhesive formulations have been developed in the laboratory based on urea-formaldehyde resin by adding medicinal plants to an industrial adhesive formulation containing raw materials: urea-formaldehyde resin, urea, ammonium sulphate and starch. Specifically, Thymus species (Thymus bleicherianus, Thymus capitates, Thymus satureioides, Thymus vulgaris and Thymus zygis) replaced part of the starch and were considered as the second filler in the formulations. The physico-chemical properties of the resulting adhesive formulations, such as: pH, viscosity, gel time, solids content, density, concentration of free formaldehyde and color were measured, and characterized using Scanning Electron Microscope (SEM), X-ray Diffraction (XRD), Differential Thermal Analysis (DTA), Thermogravimetric Analysis (TGA) and Fourier Transform Infrared spectroscopy (FTIR). In order to evaluate the mechanical performances of adhesive formulations based on plants, plywood panels were produced and their mechanical properties were studied. These mechanical properties included the shear strength, bending strength and the modulus of elasticity. The performance of these panels is comparable to that of plywood panels made using the standard adhesive formulation. From the results obtained, and following the statistical studies, the new adhesive formulations based on plants have the same physico-chemical properties, the same morphologies, and the same mechanical properties. Moreover, the novel adhesives are more viscous, and they have less free formaldehyde content than the commercial formulation.

Degradation of urea-formaldehyde resin residues by a hydrothermal oxidation method into recyclable small molecular organics

Urea-formaldehyde (UF) resin residues and the related product wastes as organic hazardous wastes are difficult to be biodegraded or recycled. In this research, a hydrothermal oxidation method using hydrogen peroxide (H₂O₂) solution has been developed for the degradation and recycling of UF resin residues. The effects of solution concentration, temperature, and time on the degradation efficiency and products of UF resin residues were studied. Under optimal conditions, i.e., 140 °C and 5 wt% H₂O₂ solution, over 75% of UF resin residues was degraded after 3 h. The degradation efficiency is much higher than that of the traditional hydrothermal treatment or acid hydrolysis method. In addition, results from Fourier transform infrared spectroscopy (FTIR), gas chromatography-mass spectroscopy (GC-MS), nuclear magnetic resonance spectroscopy (NMR), and X-ray diffraction (XRD) confirmed that H₂O₂ solution degrades UF resin residues to low molecular compounds, such as alcohols, methylal, and amides. This research provides a novel and high-efficient hydrothermal oxidization process for the degradation of UF resin residues, which might be a promising environmentally friendly and low-cost method for the disposal and recycling of industrial UF resin residues.

Recent Advances on the Development of Protein-Based Adhesives for Wood Composite Materials-A Review

The industrial market depends intensely on wood-based composites for buildings, furniture, and construction, involving significant developments in wood glues since 80% of wood-based products use adhesives. Although biobased glues have been used for many years, notably proteins, they were replaced by synthetic ones at the beginning of the 20th century, mainly due to their better moisture resistance. Currently, most wood adhesives are based on petroleum-derived products, especially formaldehyde resins commonly used in the particleboard industry due to their high adhesive performance. However, formaldehyde has been subjected to strong regulation, and projections aim for further restrictions within wood-based panels from the European market, due to its harmful emissions. From this perspective, concerns about environmental footprint and the toxicity of these formulations have prompted researchers to re-investigate the utilization of biobased materials to formulate safer alternatives. In this regard, proteins have sparked a new and growing interest in the potential development of industrial adhesives for wood due to their advantages, such as lower toxicity, renewable sourcing, and reduced environmental footprint. This work presents the recent developments in the use of proteins to formulate new wood adhesives. Herein, it includes the historical development of wood adhesives, adhesion mechanism, and the current hotspots and recent progress of potential proteinaceous feedstock resources for adhesive preparation.

Properties of High-Density Fiberboard Bonded with Urea-Formaldehyde Resin and Ammonium Lignosulfonate as a Bio-Based Additive

The potential of ammonium lignosulfonate (ALS) as an eco-friendly additive to urea–formaldehyde (UF) resin for manufacturing high-density fiberboard (HDF) panels with acceptable properties and low free formaldehyde emission was investigated in this work. The HDF panels were manufactured in the laboratory with very low UF resin content (4%) and ALS addition levels varying from 4% to 8% based on the mass of the dry wood fibers. The press factor applied was 15 s·mm⁻¹. The physical properties (water absorption and thickness swelling), mechanical properties (bending strength, modulus of elasticity, and internal bond strength), and free formaldehyde emission were evaluated in accordance with the European standards. In general, the developed HDF panels exhibited acceptable physical and mechanical properties, fulfilling the standard requirements for HDF panels for use in load-bearing applications. Markedly, the laboratory-produced panels had low free formaldehyde emission ranging from 2.0 to 1.4 mg/100 g, thus fulfilling the requirements of the E0 and super E0 emission grades and confirming the positive effect of ALS as a formaldehyde scavenger. The thermal analyses performed, i.e., differential scanning calorimetry (DSC), thermal gravimetric analysis (TGA), and derivative thermogravimetry (DTG), also confirmed the main findings of the research. It was concluded that ALS as a bio-based, formaldehyde-free adhesive can be efficiently utilized as an eco-friendly additive to UF adhesive formulations for manufacturing wood-based panels under industrial conditions.

Calcium carbonate modified urea-formaldehyde resin adhesive for strength enhanced medium density fiberboard production

This study investigated the improved properties of calcium carbonate (CaCO₃) modified urea–formaldehyde (UF) resin adhesive for medium density fiberboard (MDF) production. The CaCO₃ modified UF resins were prepared by adding different proportions of CaCO₃ to a low molar ratio UF resin at the initial stage of a typical synthetic process of the resin. The physicochemical properties of the resins were measured. The mechanical and environmental performances of the resin-bonded MDF panels were tested. The results show that the viscosity and free formaldehyde content of UF resins with or without CaCO₃ modification were not significantly different. The solid content of the CaCO₃ modified UF resin was significantly lower than that of the control group. In addition, the measured gel time of the CaCO₃ modified UF resin was 111–149 s, which was longer than that of the control resin (82 s). The gel time was further extended with the increase of the CaCO₃ content in the UF resin. The chemical group and crystal structure of UF resins with or without the modification of CaCO₃ were not significantly different. The internal bonding (IB) strength of the MDF panels significantly increased from 0.75 MPa to 0.97 MPa when the UF resin was modified with 2% of CaCO₃. This study provides scientific support for the preparation of inorganic mineral modified UF resins for strength enhanced wood-based panel manufacturing.

Reactions between CaCO₃ and CH₂O₂ during polycondensation of UF resin produce Ca²⁺. Ionic bond complexation binds Ca²⁺ with UF resin. The UF resin crystalline percentage decreases from 26.86% to 22.71%. IB strength of resin bonded fiberboard increases from 0.75 to 0.94 MPa.

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.

Eco-Friendly Fiberboard Panels from Recycled Fibers Bonded with Calcium Lignosulfonate

The potential of using residual softwood fibers from the pulp and paper industry for producing eco-friendly, zero-formaldehyde fiberboard panels, bonded with calcium lignosulfonate (CLS) as a lignin-based, formaldehyde free adhesive, was investigated in this work. Fiberboard panels were manufactured in the laboratory by applying CLS addition content ranging from 8% to 14% (on the dry fibers). The physical and mechanical properties of the developed composites, i.e., water absorption (WA), thickness swelling (TS), modulus of elasticity (MOE), bending strength (MOR), as well as the free formaldehyde emission, were evaluated according to the European norms. In general, only the composites, developed with 14% CLS content, exhibited MOE and MOR values, comparable with the standard requirements for medium-density fiberboards (MDF) for use in dry conditions. All laboratory-produced composites demonstrated significantly deteriorated moisture-related properties, i.e., WA (24 h) and TS (24 h), which is a major drawback. Noticeably, the fiberboards produced had a close-to-zero formaldehyde content, reaching the super E0 class (≤1.5 mg/100 g), with values, ranging from 0.8 mg/100 g to 1.1 mg/100 g, i.e., equivalent to formaldehyde emission of natural wood. The amount of CLS adhesive had no significant effect on formaldehyde content.

Utilization of Birch Bark as an Eco-Friendly Filler in Urea-Formaldehyde Adhesives for Plywood Manufacturing

The potential of using ground birch (Betula verrucosa Ehrh.) bark as an eco-friendly additive in urea-formaldehyde (UF) adhesives for plywood manufacturing was investigated in this work. Five-ply plywood panels were fabricated in the laboratory from beech (Fagus sylvatica L.) veneers bonded with UF adhesive formulations comprising three addition levels of birch bark (BB) as a filler (10%, 15%, and 20%). Two UF resin formulations filled with 10% and 20% wheat flour (WF) were used as reference samples. The mechanical properties (bending strength, modulus of elasticity and shear strength) of the laboratory-fabricated plywood panels, bonded with the addition of BB in the adhesive mixture, were evaluated and compared with the European standard requirements (EN 310 and EN 314-2). The mechanical strength of the plywood with the addition of BB in the adhesive mixture is acceptable and met the European standard requirements. Markedly, the positive effect of BB in the UF adhesive mixture on the reduction of formaldehyde emission from plywood panels was also confirmed. Initially, the most significant decrease in formaldehyde release (up to 14%) was measured for the plywood sample, produced with 15% BB. After four weeks, the decrease in formaldehyde was estimated up to 51% for the sample manufactured with 20% BB. The performed differential scanning calorimetry (DSC), thermal gravimetric analysis (TGA), and derivative thermogravimetry (DTG), also confirmed the findings of the study. As this research demonstrated, BB as a waste or by-product of wood processing industry, can be efficiently utilized as an environmentally friendly, inexpensive alternative to WF as a filler in UF adhesive formulations for plywood manufacturing.

Eco-Friendly, High-Density Fiberboards Bonded with Urea-Formaldehyde and Ammonium Lignosulfonate

The potential of producing eco-friendly, formaldehyde-free, high-density fiberboard (HDF) panels from hardwood fibers bonded with urea-formaldehyde (UF) resin and a novel ammonium lignosulfonate (ALS) is investigated in this paper. HDF panels were fabricated in the laboratory by applying a very low UF gluing factor (3%) and ALS content varying from 6% to 10% (based on the dry fibers). The physical and mechanical properties of the fiberboards, such as water absorption (WA), thickness swelling (TS), modulus of elasticity (MOE), bending strength (MOR), internal bond strength (IB), as well as formaldehyde content, were determined in accordance with the corresponding European standards. Overall, the HDF panels exhibited very satisfactory physical and mechanical properties, fully complying with the standard requirements of HDF for use in load-bearing applications in humid conditions. Markedly, the formaldehyde content of the laboratory fabricated panels was extremely low, ranging between 0.7-1.0 mg/100 g, which is, in fact, equivalent to the formaldehyde release of natural wood.

Application of Nanotechnology in Wood-Based Products Industry: A Review

Wood-based industry is one of the main drivers of economic growth in Malaysia. Forest being the source of various lignocellulosic materials has many untapped potentials that could be exploited to produce sustainable and biodegradable nanosized material that possesses very interesting features for use in wood-based industry itself or across many different application fields. Wood-based products sector could also utilise various readily available nanomaterials to enhance the performance of existing products or to create new value added products from the forest. This review highlights recent developments in nanotechnology application in the wood-based products industry.

Preparation of Shellac Resin Microcapsules Coated with Urea Formaldehyde Resin and Properties of Waterborne Paint Films for Tilia amurensis Rupr

A two-step in situ polymerization method was utilized to fabricate urea formaldehyde (UF) resin-coated shellac resin microcapsules. The morphology and composition of microcapsules with different core-wall ratios were analyzed by scanning electron microscope (SEM) and infrared (IR) spectrum. The effects of different concentrations of microcapsules on gloss, color difference, hardness, adhesion, and impact resistance of waterborne paint films were studied. At the same time, the self-healing effect of the prepared microcapsules applied to waterborne paint film was discussed. The results revealed that the shellac resin microcapsules coated with UF resin were successfully prepared. At the 0.67:1 and 0.75:1 core-wall ratios, the color differences of the paint film with 0–20.0% (weight percent) microcapsules were small and the color was uniform. Under the condition of 60° incident angle and the same microcapsule concentration, a good gloss was obtained. When the concentration was 20.0%, the hardness of paint film reached the maximum value. The adhesion of paint film was better, which was not affected by microcapsule concentration. When the concentration was 5.0% and 10.0%, the microstructure of paint film was good. The paint film with a 10.0% concentration of the shellac resin microcapsules coated with UF resin had better self-healing performance and the comprehensive performance was better. This paper provides the basis for the industrial application of self-healing waterborne wood paint films.