The present invention provides bonding systems comprising a formaldehyde-based (urea-/melamine-/phenol-/resorcinol-formaldehyde or other combination) and/or a polymeric isocyanate resin system composition for bonding ligno-cellulosic materials to form panels and/or shaped products, which contain a resin hardener, also referred to as resin catalyst, characterised in that the hardener is activated by heat.

The invention relates to systems and techniques for manufacturing articles containing cellulosic material, a tackifier, and a binder, and related processes of making and using the cellulosic articles. In particularly exemplary embodiments, the manufactured articles are door skins, sometimes known as door facings, and doors made from the door skins. The article contains a lipophilic cellulosic material, a tackifier, and a binder.

The present invention provides polymer modified aqueous urea formaldehyde resin (UF resin) binder compositions useful in making a treated glass mat, e.g., for roofing shingles, wherein the polymer modifier is an multistage aqueous emulsion acorn copolymer comprising one protuberant polymer stage containing phosphorous acid groups and one or more other polymer stage comprising an addition copolymer incompatible with the protuberant polymer stage, wherein the multistage aqueous emulsion copolymer has a measured Tg of from 60 to 25 C., or, preferably from 30 to 12 C. and, further wherein the weight ratio of the total of monomers used to make the one or more other polymer stage to the total amount of monomers used to make the protuberant polymer stage ranges from 3:1 to 50:1, or, preferably, from 3:1 to 30:1 or, more preferably, from 3:1 to 20:1, or, even more preferably, from 8:1 to 12:1.

The present invention provides polymer modified aqueous urea formaldehyde resin (UF resin) binder compositions useful in making a treated glass mat, e.g., for roofing shingles, wherein the polymer modifier is an multistage aqueous emulsion acorn copolymer comprising one protuberant polymer stage containing phosphorous acid groups and one or more other polymer stage comprising an addition copolymer incompatible with the protuberant polymer stage, wherein the multistage aqueous emulsion copolymer has a measured Tg of from 60 to 25 C., or, preferably from 30 to 12 C. and, further wherein the weight ratio of the total of monomers used to make the one or more other polymer stage to the total amount of monomers used to make the protuberant polymer stage ranges from 3:1 to 50:1, or, preferably, from 3:1 to 30:1 or, more preferably, from 3:1 to 20:1, or, even more preferably, from 8:1 to 12:1.

The present invention provides polymer modified aqueous urea formaldehyde resin (UF resin) binder compositions useful in making a treated glass mat, e.g., for roofing shingles, wherein the polymer modifier is an multistage aqueous emulsion acorn copolymer comprising one protuberant polymer stage containing phosphorous acid groups and one or more other polymer stage comprising an addition copolymer incompatible with the protuberant polymer stage, wherein the multistage aqueous emulsion copolymer has a measured Tg of from 60 to 25 C., or, preferably from 30 to 12 C. and, further wherein the weight ratio of the total of monomers used to make the one or more other polymer stage to the total amount of monomers used to make the protuberant polymer stage ranges from 3:1 to 50:1, or, preferably, from 3:1 to 30:1 or, more preferably, from 3:1 to 20:1, or, even more preferably, from 8:1 to 12:1.

A system and a method of manufacturing continuous glass filament fiberglass media comprises melting glass within a temperature controlled melter. Molten glass exits through orifices in a bushing plate. The resulting fiberglass filaments are received on a rotating drum and sprayed with binder and aqueous solution. The resulting fiberglass mat is placed onto a let-off table then sprayed with aqueous solution before further processing.

A system and a method of manufacturing continuous glass filament fiberglass media comprises melting glass within a temperature controlled melter. Molten glass exits through orifices in a bushing plate. The resulting fiberglass filaments are received on a rotating drum and sprayed with binder and aqueous solution. The resulting fiberglass mat is placed onto a let-off table then sprayed with aqueous solution before further processing.

A temperature-curable aminoplastic adhesive resin that is a (poly)-condensate of: (i) at least one aminoplast-forming chemical; (ii) 5-hydroxymethylfurfural (5-HMF), its oligomers and/or its isomers; and, (iii) at the least one second (poly-)condensable chemical. Composite boards, such as wood-based panels, can be produced using this adhesive resin. The production of the aminoplastic adhesive resin includes the reaction of urea with 5-hydroxymethylfurfural (5-HMF) and glyoxal. The adhesive resin can be used in the production of wood-based panels such as particleboards, fiberboards and products usually called, among others, plywood and/or blockboards.

A temperature-curable aminoplastic adhesive resin that is a (poly)-condensate of: (i) at least one aminoplast-forming chemical; (ii) 5-hydroxymethylfurfural (5-HMF), its oligomers and/or its isomers; and, (iii) at the least one second (poly-)condensable chemical. Composite boards, such as wood-based panels, can be produced using this adhesive resin. The production of the aminoplastic adhesive resin includes the reaction of urea with 5-hydroxymethylfurfural (5-HMF) and glyoxal. The adhesive resin can be used in the production of wood-based panels such as particleboards, fiberboards and products usually called, among others, plywood and/or blockboards.

According to various aspects of the instant disclosure, a multi-layer engineered wood product can include a first face layer, a second face layer, and a core layer disposed between the first face layer and the second face layer. At least one of the first face layer, the second face layer, and the core layer include a plurality of wood components and a reaction product of a binder reaction mixture dispersed about the plurality of wood components. The mixture of the wood components and binder reaction mixture has a moisture content in a range of 9 wt % to 20 wt %.