The present invention is generally concerned with improved particleboard, plywood and hardboard products which can be economically produced. In accordance with the present process an extended phenol formaldehyde glue system is used which comprises a lignin sulfonate salt. The extended system in a preferred modification is secured by reacting lignin sulfonate with formaldehyde under influence of caustic and heat. The resulting product is then reacted with phenolic resin to secure a very reactive final glue system.

The manufacture of hardboard and particleboard products are well known in the art. Generally these boards are produced using random geometric configuration wood chips such as described in U.S. Pat. No. 2,642,371, issued June 16, 1953, entitled "Composite Wooden Board", inventor Fahrni, and U.S. Pat. No. 2,686,143, issued Aug. 10, 1954, entitled "Process for Manufacturing Composite Wooden Board", inventor Fahrni. The particleboards may be a single homogeneous ply or may be multiply, such as a core ply of relatively coarse chips and two face plies of relatively flat elongated chips. Generally these particleboards are manufactured using a glue system to adhere the particles one to the other and then subjecting the mat mass to heat and pressure for predetermined time periods.

The hot press conditions may vary widely depending upon operating factors such as type of panel, thickness of panel, etc. Temperatures may range from about 250°F to 600°F, such as about 330°F, pressure from about atmospheric to 1000 psi, such as about 50 psi to 200 psi, and the time periods from about 1 minute to about 10 minutes.

Many types of glue systems have been used. Two well known systems comprise a phenol formaldehyde system and a urea formaldehyde system. Since these glue systems constitute a large proportion of the manufacturing cost, many extenders have been tried and used commercially. However, those known extenders have not been successful due to the fact that, if used in the desired economical amounts, the resulting strengths of the board products are appreciably impaired.

It has now been discovered that a phenol formaldehyde glue system may be effectively extended by the incorporation therein of a lignin sulfonate salt, such as ammonium lignin sulfonate and an alkali metal lignin sulfonate such as sodium and/or potassium lignin sulfonate.

The preferred salt is sodium lignin sulfonate. The amount of lignin sulfonate salt used may vary appreciably as compared to the phenol formaldehyde resin, but is in the range by weight of about 25% to 60%, preferably 30% to 50%, such as about 40% based on resin solids. When using these amounts it is essential that the pH of the system be maintained above about 10.0, as in the range of about 10.4 to 11.5, such as about 11.0.

The mol ratio of phenol to formaldehyde in the system may vary widely. The preferred ratio of phenol to formaldehyde is from 1 to 1.25, to 1 to 2.5. A very desirable ratio is 1 to 1.85.

The lignin sulfonates used (lignosulfonates) are made from the lignin of sulfite pulp mill liquids. The lignin sulfonates are a light tan to dark brown powder and are stable in the dry form. They are nonhygroscopic with no definite melting point and decompose above about 200°C. The viscosity in an aqueous 50% solids solution ranges from about 120 to 600 cps and the specific gravity is about 1.0 to 2.0, such as about 1.5.

The present invention may be fully understood by the following examples illustrating embodiments of the same.

EXAMPLE I

Sodium lignin sulfonates as described were diluted to form an aqueous solution containing 40% solids. This solution was then added to an advanced phenol formaldehyde resin in concentrations of 25%, 30% and 50% (based on total solids). The pH was adjusted using NaOH to a range from about 10.4 to 11.5. The extended glue system was sprayed on Douglas fir flakes using 8% by weight based on oven dry wood (O.D.). A control glue system of regular phenol formaldehyde was also prepared.

Three quarter inch test panels were prepared to secure a three layer board with a 0.660 g/cc density and about 7% by weight of moisture content after pressing. The glue systems as described were used in the face layer flakes. The panels were prepressed at 75 psi and then hot pressed at 320° to 340°F for 6 to 8 minutes at 225 psi. The results are listed in the following Table I.

                                  TABLE No. 1__________________________________________________________________________PHYSICAL PROPERTIES Vs. pH CHANGE IN HYBRID BOARDS WITH 3 LEVELS OFLIGNIN SULFONATE IN FACE LAYER__________________________________________________________________________%                                ****Sulfo-                           24    nate              **   ***   HourBoard    in       g/cc *   Face 24 Hour                            Water                                Stability1                                         Smoothness2No. Face pH  Density             I.B.                 Strength                      Swell %                            Abs.                                48 Hr.                                     7 Day                                         Start                                             48 Hr.                                                  7__________________________________________________________________________                                                  Day1   25%  10.5        .656 88  274  4.8   19.02   25%  10.7        .654 77  262  5.1   21.33   25%  11.0        .659 83  249  5.3   19.84   25%  11.3        .654 74  247  7.1   23.35   25%  11.5        .660 73  240  6.9   23.16    None    10.5        .651 64  244  6.0   21.27   50%  10.4        .693 104 299  7.5   20.98   50%  10.7        .692 103 290  6.6   19.99   50%  11.0        .695 105 270  8.1   20.610  50%  11.3        .689 111 290  8.4   22.111   None    10.5        .689 92  297  5.9   19.012  30%  10.4        .662 77  251  6.8   24.1                                .12  .24 425 667  70013  30%  10.7        .653 60  232  7.6   25.714  50%  10.4        .657 65  242  8.2   27.0                                .12  .22 392 633  75015  50%  10.7        .657 54  230  11.3  30.016   None    10.5        .659 61  250  6.7   24.1                                .17  .22 383 633  683__________________________________________________________________________ Hybrid Boards - A core and face layer of different materials, i.e. Dougla fir flakes in faces and fine splinter particles in core. Face layers from about 1/32" to 1/4" and core from about 1/6" to 2".   * I.B. Internal Bond (Tension perpendicular to surface to break board) A.S.T.M. D 1037-60T Sec. 27-32  ** Face Strength - Face strength of the surface layer. Tabs are glued to the surface and the perpendicular pull to break the surface from the core recorded. (P.S.I.)  *** 24 Hr. Swell - A.S.T.M. D 1037-60T Sec. 69-75 **** 24 Hr. Water Abs. A.S.T.M. D 1037-60T Sec. 69-75 1 Stability - A.S.T.M. D 1037- 60T Sec. 76-79 2 Smoothness - Relative measurement of increase in surface roughness after exposure to high relative humidity

From the foregoing it is apparent that excellent particleboards are secured when extending the phenol formaldehyde resin with sodium lignin sulfonate providing the pH is maintained relatively high.

EXAMPLE II

A second set of panels were prepared as described in Example I, using 30% to 50% by weight of sodium lignin sulfonate with the pH adjusted to 10.4 and 10.7 with caustic. Superior face properties were secured. The panels were tested at each level of extension, and stabilities and surface smoothness were taken after 2 days and 7 days at 70°F and 90% relative humidity (R.H.). Stability and surface roughening were about the same when using only phenol formaldehyde resin. Thus the phenolic resin can be extended up to about 50% with sodium lignin sulfonate if the pH is maintained above about 10.3 to 10.5. See data for boards 12, 14 and 16 (Table I).

EXAMPLE III

Additional panels were prepared as described in Example I. Pine and Douglas fir planer shavings were used. In all cases 8% by weight of resin was used based on the chips. A sodium lignin sulfonate content of various amounts was used in the phenol formaldehyde resin utilized in the face layers. The lignin sulfonate had a pH of 9.0 and the extended resin a pH of 10.3 to 10.5.

Three-eighths inch thick panels were prepared as described, pressing for about 6.5 minutes at 330°F at a psi of about 225. The face layers had a thickness of about 1/8 inch and the core layer a thickness of about 1/8 inch. The core layer was glued only with a urea formaldehyde resin.

Sections of each panel were placed in a humidity cabinet at 90% relative humidity (R.H.) at 90°F for three days to evaluate moisture resistance of the face layers. Thickness swells were measured and face strengths tested after this time. No significant decreases occurred from 30% to 60% by weight extension with the sodium lignin sulfonate.

Other operations were carried out using pine planer shavings in the face layers with 8% by weight of glue. Also higher levels of sodium lignin sulfonate were used. (30% to 90%). With the pine faces, a decrease in physical properties occurred as the percentage of sulfonate increased. A 50% level of extension is desirable. The results are listed in the following Table II.

                                  TABLE No. II__________________________________________________________________________    MAXIMUM EXTENSION ON TWO SPECIES                  **  Thickness                               Face StrengthBoard    g/cc        Extension                 Face Swell    3 Days   *           %Na Sul-No. Density    Material           fonate                 Strength                      3 Days Hi.R.H.                               Hi.R.H.  I.B.__________________________________________________________________________17  .661 D.Fir P.S.           30    274  4.2%     193      9918  .658 "      34    265  4.4      173      10819  .659 "      38    263  4.2      166      9520  .657 "      40    266  3.8      163      9421  .659 "      44    281  4.2      175      10222  .662 "      47    286  4.3      179      11323  .659 "      51    294  4.2      189      10324  .659 "      54    273  4.4      180      9025  .658 "      58    311  4.4      165      10726  .661 "      60    278  3.9      159      10427  .637 "      100    92  9.7      Failed   7528  .680 Pine P.S.           30    251  --       --       10429  .683 "      50    243  --       --       10430  .688 "      60    220  --       --       10531  .681 "      70    206  --       --       10732  .684 "      80    170  --       --       10633  .684 "      90    124  --       --       85__________________________________________________________________________ * See Table I **

EXAMPLE IV

In another series of tests 3/8 inch panels were prepared as described in Example I using 8% by weight of phenol formaldehyde resin in the face and a urea formaldehyde resin in the core. The chips in the face were Douglas fir shavings.

One set of panels was prepared using as the glue system a phenol formaldehyde resin containing 30% of sodium lignin sulfonate while the other set was prepared using a non-extended phenol formaldehyde resin. The results secured are listed in the following Table III.

                                  TABLE III__________________________________________________________________________COMPARISON OF 30% SODIUM LIGNIN SULFONATE AND 70% WT.PHENOL FORMALDEHYDE RESIN vs. PHENOL FORMALDEHYDE RESINAT DIFFERENT PRESS TEMPERATURES__________________________________________________________________________        PRESSBoard    g/cc % Sul-          Face InternalNo  Density    fonate        Temperature               Time Strength                         Bond__________________________________________________________________________34  .685  30%         230°F               10 min.                    174  10435  .699 30  250    10   225  12036  .699 30  270    10   248  12237  .698 30  290     8   255  12938  .684 30  320     6   251  12439  .723 None        230    10   235  11440  .710 None        250    10   251  12241  .707 None        270    10   263  11842  .704 None        290     8   258  11943  .697 None        320     6   270  119__________________________________________________________________________

From the above it is apparent that when using a phenol formaldehyde resin containing 30% by weight of sodium lignin sulfonate the press temperature should exceed about 270°F, preferably in the range of about 290°F to 320°F, such as about 300°F. The press cycle should range from about 6 to 10 minutes such as about 8 minutes. The longer press cycles do not help at the low temperatures.

EXAMPLE V

Other tests were conducted to determine the outdoor durability of the respective panels prepared as hereinbefore described. The results secured are listed in Table IV. The panels were 3/4 inch and the lignin sulfonate containing phenol formaldehyde resin had a pH of 9.0. Both panels had a 10% glue content in the face and 6% glue in the core. 1% wax was also sprayed on the core. Pine planer shavings were used as the face material and the panels were pressed as hereinbefore described.

The glue content based on the weight of the wood particles may vary appreciably depending on many manufacturing variables. Generally the glue content is in the range of about 4% to 15%, preferably about 7% to 9%.

                                  TABLE IV.__________________________________________________________________________OUTDOOR DURABILITY OF 35% SODIUM LIGNIN SULFONATEIN THE FACE -vs- PHENOLIC RESIN__________________________________________________________________________                         Thickness Swell    Dens-       24  24 Hr.    After                                   AfterBoard    Sulfon-    ity    Face Hour                    Water                         1 Hr 1    2No. ate  g/cc        I.B.           Strength                Swell                    Abs. Boil Cycle                                   Cycle__________________________________________________________________________44  35%  .657        85 284  15.3                    56.1 .042"                              .067"                                  .075"45  0    .660        93 319  14.8                    57.1 .046"                              .064"                                  .075"__________________________________________________________________________

The foregoing results show that the addition of the lignin sulfonate has only a slight effect on swell and water absorption.

EXAMPLE VI

Additional tests were conducted to determine the effect of sodium lignin sulfonate extended phenol formaldehyde glue systems at three different levels of glue content (10%, 9% and 8%). The results secured are shown in Table V. The particleboards were 3/4 inch thick and the press cycle was as hereinbefore described.

                                  TABLE V__________________________________________________________________________                                  LIGNIN SULFONATETABULATION OF BOARD PROPERTIES OF PHENOLIC * VS. PHENOLIC                                  RESINS__________________________________________________________________________                          24Board        Glue       I.B.                      Face                          Hr. Water        Warp DensityNo.  Glue Used        Con.           Type TM PSI                      Stgth.                          Swell                              Abs.                                  MOR MOE  Index                                                g/cc__________________________________________________________________________46   Pure Phenolic        10%           D.fir Flake                   79 278 10.4                              35.2                                  3170                                      504,-                                           5.5/65                                                .66147   Pure phenolic        9  "       79 277 10.8                              36.0                                  2790                                      455,-                                           5.0/64                                                .66148   Pure phenolic        8  "       81 264 11.8                              40.1                                  2890                                      491,-                                           7.0/64                                                .65925% Sulfonate49   75% Phenolic        10 "       77 258 14.9                              2990                                  479,-                                      6.0/64                                           .65450   Pure phenolic        9  "       79 252 13.9                              41.1                                  2790                                      467,-                                           7.0/64                                                .65251   Pure phenolic        8  "       69 254 15.8                              46.2                                  2830                                      439,-                                           7.0/64                                                .650__________________________________________________________________________ * Phenol formaldehyde resin

It is apparent from the foregoing that excellent results are secured with a 25% lignin sulfonate extended phenol formaldehyde resin.

In other tests the sodium lignin sulfonate extended phenol formaldehyde resin (up to 40%) was equivalent to the non-extended resin in properties such as compatibility with various fillers and sealers, and also ability to accept overlays. Fire retardant salts are also very compatible with the lignin sulfonate extended resin.

The preferred technique of preparing the extended lignin sulfonate phenol formaldehyde glue system is to prepare a lignin sulfonate formaldehyde prepolymer solution. This prepolymer solution is prepared by heating lignin sulfonate with caustic, such as NaOH at an elevated temperature in the range of about 80°C to 110°C for a time period in the range of about 15 to 45 minutes. This solution is preferably cooled and formaldehyde added, and then reheated and allowed to exotherm until the formaldehyde is consumed. Generally about 3% to 10% by weight of formaldehyde, such as about 6% is added based on the lignin sulfonate.

This prepolymer solution containing about 3% to 10% formaldehyde is allowed to cool and phenol is added. Then additional formaldehyde is added and the solution heated to a temperature in the range of about 80°C to 110°C for a time period of about 20 to 60 minutes.

While the foregoing technique produces a glue system having the strongest bonds and is much preferred, under certain conditions the lignin sulfonate formaldehyde prepolymer solution may be mixed with a finished phenol formaldehyde resin, or the solution may be added to a phenol formaldehyde resin, or the solution may be added to a phenol formaldehyde prepolymer and advanced to the desired viscosity, the preferred viscosity is in the range of 1000 to 1500 cps at 50% solids at 25°C. The following will illustrate the preferred technique for producing the glue system of the present invention.

EXAMPLE VII

a. 220 grams of 50% sodium lignin sulfonate was heated at 90°C ± 5°C for 30 minutes

110 g. sodium lignin sulfonate

110 g. H₂ O with 100 grams 50% N_a OH solution

50 N_a OH

50 h₂ o

b. The solution of (a) was cooled to 40°C, and sufficient grams of 37% formaldehyde added to secure a prepolymer solution containing from about 3% to 10% by weight of formaldehyde. This prepolymer solution was then heated to 90°C ± 5°C and allowed to exotherm until completion.

c. The lignin formaldehyde prepolymer solution was cooled to 60°C and 110-120 grams of 90% phenol added. Then an additional 250 grams of 37% formaldehyde was added and the mixture heated to 100°C for a period of 40 minutes. The pH of the final resin was 10.3 to 10.7. Caustic may be added during advancement to secure this pH level.

Another method of preparing a very satisfactory glue mix for exterior plywood is described in the following example:

EXAMPLE VIII

In a first step the following ingredients were mixed for 5 minutes

                           Grams______________________________________(a) Water                    1320(b) Anti-foam agent Parac 5609*                        10(c) Phenol formaldehyde resin 43%solids Amures 5587**         1600(d) Ground corn cobs filler  800(e) Wheat flour              400______________________________________

In a second step caustic was added and mixed for 10 minutes.

______________________________________(f) NaOH (50% aqueous solution)                         440Finally was added(g) Soda ash                  120with(h) X + Y grams of X phenol formal- dehyde resin 5587** Y of sodium lignin sulfonate (50%) to make a mix containing from 40% total weight of phenol formalde- hyde resin replaced with lignin sulfonate. This will equal 6960 grams of phenol formaldehyde for 0% extension level and 3520 grams of phenol formaldehyde resin plus 2960 grams of sodium lignin sulfonate (50%) for 40% extension level.______________________________________   *Trademark of Pacific Resins, Tacoma, Wash. **Pacific Resin - Tacoma, Wash. - trademark

The panels prepared as described, using mixers as described, are listed in Table VI. The glue spread is in pounds per 1000 square feet and is a single glue line (SGL).

                                  TABLE VI__________________________________________________________________________LIGNIN EXTENDER FOR EXTERIOR PLYWOOD PHENOLIC RESIN             Press Cycle        Shear Tests        Exten-        sion              Glue          VacuumBd.   Thick-    Level             Time Temp    Spread        Press   4 + 4 HourNo.   ness Species        Wt/Wt             Min. F°                      Press                          lbs/MSP                                Dry     Soak    Boil__________________________________________________________________________                      PSI Lbs.  PSI WF1                                        PSI WF  PSI WF1  5/8  D.Fir        0%   6.5  270 175 35    164  90 105 60   80 1002  5/8  D.Fir         5   6.5  270 175 (SG-L)                                221  95 230 60  153 1003  5/8  D.Fir        10   6.5  270 175 "     180  95 160 55  175  954  5/8  D.Fir        15   6.5  270 175 "     231  95 120 90  103 1005  5/8  D.Fir        20   6.5  270 175 "     246  90 200 55  123  906  5/8  W.Fir         0   7.0  285 175 35    245  95 240 95  200  957  5/8  W.Fir        10   7.0  285 175 35    161  95 120 95   90  958  5/8  W.Fir        20   7.0  285 175 35    230 100 150 100 155 1009  5/8  W.Fir        30   7.0  285 175 35    216 100 140 95  188  9010 5/8  W.Fir        40   7.0  285 175 35    250  95 120 80   90  9011 *3/8 W.Fir         0   6.5  310 175 35    160 100  94 100 130 10012 3/8  W.Fir        10   6.5  310 175 35    193 100 140 100 140 10013 3/8  W.Fir        20   6.5  310 175 35    215 100 180 90  175  9514 3/8  W.Fir        30   6.5  310 175 35    166  90 100 90  138  9015 11/8 W.Fir         0   12.5 310 175 35    187 100  80 95   73 10016 11/8 W.Fir        10   12.5 310 175 35    232 100  95 100 122 10017 11/8 W.Fir        20   12.5 310 175 35    198 100  30 100 128 10018 11/8 W.Fir        30   12.5 310 175 35    165 100  65 95   73 100__________________________________________________________________________ *Two per Daylight 1 Wood failure