In one embodiment, a method for making a high density structural composite includes depositing a plurality of fibrous materials on or adjacent a first plate or surface. A polymer liquid is deposited onto the plurality of fibrous materials to form a composite mixture. A first cyclic pressure is applied onto the composite mixture to compress the composite mixture. In some embodiments, the cyclic pressure may then be reduced to a valley pressure to complete a pressurization cycle. In some instances, the valley pressure may be below atmospheric pressure to induce trapped air and volatile gases to escape from the composite mixture before curing. The pressurization cycle may be repeated. A second pressure, which may be a constant pressure in some embodiments, may be applied to the composite mixture using, in some embodiments, a second plate until the polymer liquid has at least partially cured or partially solidified.

The formaldehyde-free binder for materials containing cellulose contains a hydroxy aldehyde resin polycondensed with an ammonium salt, the resin being obtained, in especially preferred embodiments, from glycerin, in situ, with the aid of hydrogen peroxide. A protein component consisting of animal blood is added. The binder is urea-free and can be used as a one-component or two-component binder. It binds materials such as wood, paper and other natural fibres to form high-quality composite material products.

The present invention relates to an activated lignin composition, its manufacture and its use thereof. It also relates to a resin comprising lignin, its manufacture and use.

The present invention relates to a process for preparing a bonding resin, wherein a resin prepared from lignin, phenol and formaldehyde is mixed with a resin prepared from phenol and formaldehyde to achieve a mixture useful as a bonding resin useful in the manufacture of laminates, mineral wool insulation and wood products such as plywood, laminated veneer lumber (LVL), medium density fiberboards (MDF) and particle boards.

The present invention relates to a process for preparing a bonding resin, wherein a resin prepared from lignin, phenol and formaldehyde and comprising a formaldehyde scavenger, is mixed with a resin prepared from phenol and formaldehyde and comprising a formaldehyde scavenger to achieve a mixture useful as a bonding resin useful in the manufacture of oriented strand board (OSB).

A lignocellulosic composite article includes a plurality of lignocellulosic pieces and an adhesive system disposed on the plurality of lignocellulosic pieces for bonding the plurality of lignocellulosic pieces. The adhesive system comprises a binder component and an additive component. The binder component comprises a diphenylmethane diisocyanate (MDI), a polymeric diphenylmethane diisocyanate (pMDI), and combinations thereof. The additive component comprises an amine compound and water. The amine compound can be imidazole. The additive component is useful for reducing the amount of press time required during manufacture of the composite article.

The present invention relates to a process for preparing a bonding resin, wherein lignin is provided in the form of an aqueous solution and mixed with one or more of glycerol diglycidyl ether, polyglycerol diglycidyl ether, polyglycerol polyglycidyl ether, glycerol triglycidyl ether, sorbitol polyglycidyl ether, alkoxylated glycerol polyglycidyl ether, trimethylolpropane triglycidyl ether, trimethylolpropane diglycidyl ether, polyoxypropylene glycol diglycidylether, polyoxypropylene glycol triglycidyl ether, diglycidylether of cyclohexane dimethanol, resorcinol diglycidyl ether, isosorbide diglycidyl ether, pentaerythritol tetraglycidyl ether, ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether having 2-9 ethylene glycol units, propylene glycol diglycidyl ether having 1-5 propylene glycol units, and/or diglycidyl ether of terminal diol having a linear carbon chain of 3-6 carbon atoms; and optionally one or more additives. The bonding resin is useful for example in the manufacture of laminates, mineral wool insulation and wood products such as plywood, oriented strandboard (OSB), laminated veneer lumber (LVL), medium density fiberboards (MDF), high density fiberboards (HDF), parquet flooring, curved plywood, veneered particleboards, veneered MDF or particle boards.

A composite of the present disclosure contains a fiber and a thermoplastic starch fused to the fiber. A method for producing a molded product of the present disclosure includes a molding raw material preparing step of preparing a molding raw material containing a fiber and a thermoplastic starch, and a molding step of molding the molding raw material into a predetermined shape by heating and pressurizing the molding raw material.

Adhesives, methods of producing adhesives, and cellulosic products formed with the adhesive are provided. In an exemplary embodiment, an adhesive includes a protein, a first reactant that has a plurality of isocyanate moieties, and a second reactant with one or more of a chlorohydrin moiety, an azetidinium moiety, and an epoxy moiety. The protein is reacted with the first reactant to form a functionalized protein intermediate, and the functionalized protein intermediate is then reacted with the second reactant.

A method for forming an engineered wood product includes grinding an MDI (methylene diphenyl di-isocyanate) binder together with water in a grinder to form a ground MDI dispersion. The ground MDI dispersion is fed into a wood production machine in which are lignocellulosic materials. The lignocellulosic materials are bound together by the ground MDI dispersion to form an engineered wood product.