Adhesive materials and methods of forming lignocellulosic composites using such adhesive materials

{
  "publication_number": "US9616590B2",
  "country": "US",
  "kind": "B2",
  "title": "Adhesive materials and methods of forming lignocellulosic composites using such adhesive materials",
  "abstract": "Provided are adhesive materials for fire resistant applications, methods of using these adhesive materials on lignocellulosic and other like substrates, and composite materials including lignocellulosic substrates and these adhesive materials. In addition to being fire-resistant, the composites formed from the substrates and adhesive materials may be also durable to moisture. The adhesive materials may include at least one proteinaceous-containing material and at least one magnesium oxychloride material. Other materials may be present as well, in some embodiments. For example, an adhesive material may include a solvent or a vinyl polymer. In some embodiments, water may be used as a solvent and the adhesive material may be referred to as an aqueous adhesive material. Some examples of suitable vinyl polymers include but are not limited to polyvinyl alcohol (PVOH), polyvinyl acetate (PVAc) and vinyl acetate/ethylene (VAE).",
  "claims": [
    "1. An aqueous adhesive material comprising: a magnesium oxychloride compound; and proteinaceous material comprising a protein, wherein a dry weight ratio of the protein in the proteinaceous material is at least about 40%, and wherein a dry weight ratio of the magnesium oxychloride compound and the proteinaceous material in the aqueous adhesive material is at least about 50%.",
    "2. The aqueous adhesive material of claim 1, wherein the magnesium oxychloride compound has a molar ratio of MgO to MgCl 2 of between about 1:1 and 30:1.",
    "3. The aqueous adhesive material of claim 1, wherein the magnesium oxychloride compound has a molar ratio of MgO to MgCl 2 of between about 5:1 and 20:1.",
    "4. The aqueous adhesive material of claim 1, wherein the magnesium oxychloride compound has a molar ratio of MgO to MgCl 2 of between about 10:1 and 15:1.",
    "5. The aqueous adhesive material of claim 1, further comprising a vinyl polymer.",
    "6. The aqueous adhesive material of claim 5, wherein the vinyl polymer is selected from the group consisting of polyvinyl alcohol (PVOH), polyvinyl acetate (PVAc) and vinyl acetate/ethylene (VAE), and mixtures thereof.",
    "7. The aqueous adhesive material of claim 5, wherein the vinyl polymer is polyvinyl acetate (PVAc).",
    "8. The aqueous adhesive material of claim 5, wherein the vinyl polymer is vinyl acetate/ethylene (VAE).",
    "9. The aqueous adhesive material of claim 5, wherein the vinyl polymer is a combination of VAE and PVAc.",
    "10. The aqueous adhesive material of claim 1, wherein the proteinaceous material is derived from one or more materials selected from the group consisting of soy, wheat, corn, cotton, rapeseed, peanut, algea, egg, milk, blood and mixtures thereof.",
    "11. The aqueous adhesive material of claim 1, wherein the proteinaceous material is derived from soy.",
    "12. The aqueous adhesive material of claim 1, wherein the proteinaceous material is derived from wheat.",
    "13. The aqueous adhesive material of claim 1, wherein the proteinaceous material is derived from corn.",
    "14. The aqueous adhesive material of claim 1, further comprising magnesium sulfate.",
    "15. The aqueous material of claim 1, further comprising a phosphate of at least one selected from the group consisting of ammonium, aluminum, zinc, calcium, and potassium.",
    "16. The aqueous adhesive material of claim 5, wherein a dry weight ratio of the vinyl polymer in the aqueous adhesive material is between about 1% and 30%.",
    "17. The aqueous adhesive material of claim 1, wherein a dry weight ratio of the vinyl polymer in the aqueous adhesive material is between about 5% and 20%.",
    "18. The aqueous adhesive material of claim 1, wherein a dry weight ratio of the vinyl polymer in the aqueous adhesive material is between about 10% and 15%.",
    "19. The aqueous adhesive material of claim 1, wherein a dry weight ratio of the proteinaceous material in the aqueous adhesive material is between about 5% and 50%.",
    "20. The aqueous adhesive material of claim 1, wherein a dry weight ratio of the proteinaceous material in the aqueous adhesive material is between about 20% and 30%."
  ],
  "description_excerpt": "The present disclosure relates generally to adhesive materials and method of using thereof, and more specifically to adhesive materials having magnesium oxychloride compounds, and proteinaceous materials and method of forming lignocellulosic composites using such adhesive materials, such that adhesive materials are water durable and fire resistant.\n\nLignocellulosic composites are made from small pieces of cellulosic materials that are bonded together using adhesives. In general, wood or other lignocellulosic materials are first processed to yield veneers, strands, fibers and chips. Adhesives are then added to the lignocellulosic materials. The resultant mixture is consolidated using pressure and heat to yield a lignocellulosic composite.\n\nOriented strand board (OSB) parallel strand lumber (PSL), laminated strand lumber (LSL) and softwood plywood (SWPW) are commonly bonded with thermosetting phenol formaldehyde (PF) or phenol resorcinol formaldehyde (PRF), commonly called “phenolic” resins. The phenolic resins provide excellent wet durability. Particleboard (PB), medium density fiberboard (MDF), hardboard and hardwood plywood (HWPW) have traditionally been bonded with urea formaldehyde. Urea formaldehyde can hydrolyze to produce formaldehyde emissions over the life of the product. Due to increased concern over long term formaldehyde emissions, much of the North American HWPW industry has turned to either soy-based adhesives or polyvinyl acetate (PVAc) as alternative adhesives. Several PB and MDF manufacturers have switched to polymeric methylene diphenyl diisocyanate (pMDI) adhesives as a no-added formaldehyde option.",
  "cpc": [
    "B27N 3/002",
    "B27N 9/00",
    "B32B 7/12",
    "C08K 3/22",
    "C08L 31/04",
    "C08L 89/00",
    "C08L 97/02",
    "C09J 189/00",
    "Y10T 428/24066"
  ],
  "ipc": [
    "B27N 9/00",
    "B32B 21/14",
    "C08K 3/16",
    "C09J 131/04",
    "B27N 3/00",
    "B32B 7/12",
    "C09J 189/00",
    "C08L 97/02"
  ],
  "assignees": [
    "Design Adhesives Inc"
  ],
  "inventors": [
    "Michael J. Birkeland",
    "Raymond Wu",
    "Sean Somers Weaver"
  ],
  "filing_date": "2014-12-02",
  "publication_date": "2017-04-11",
  "grant_date": "2017-04-11",
  "priority_date": "2013-12-02",
  "application_number": "US-201414557567-A",
  "family_id": "53264271",
  "cited_by_count": 44,
  "citations": [
    "US20050003189A1",
    "EP2236578A1",
    "WO2011089053A1",
    "WO2012040037A1",
    "US20130302631A1"
  ]
}