LOW CORROSION RELEASE AGENT FOR LIGNO-CELLULOSIC COMPOSITES

Abstract

The present inversion provides a low corrosion external release agent for ligno-cellulose composite panels comprising two or more anionic surfactants selected from the following groups where at least one of the anionic surfactants is selected from a) or b):

an ethoxylated phosphate ester or a salt thereof having the formula

##STR00001##

wherein,

R, R.sup.1 and R.sup.2 are independently selected from the group consisting of H, and C6-C30 alkyl having an average of 1-20 moles of ethoxylation,

with the proviso that at least one of R, R.sup.1 and R.sup.2 is H and the other one or two of R, R.sup.1 and R.sup.2 is C6-C30 alkyl haying an average of 1-20 moles of ethoxylation, and

b) a phosphate ester or a salt thereof haying the formula.

##STR00002##

wherein,

R.sup.3, R.sup.4 and R.sup.5 are independently selected from the group consisting of H, and C6-C18 alkyl Chain,

with the proviso that at least one of R.sup.3, R.sup.4 and R.sup.5 is H and the other one or two of R.sup.3, R.sup.4 and R.sup.5 is C6-C18 alkyl chain, and

c) an organic sulfur containing anionic surfactant or a salt thereof.

Claims

1. A low corrosion external release agent for ligno-cellulosic composite panels comprising two or more anionic surfactants selected from the following groups where at least one of the anionic surfactants is selected from a) or b): a) ate ethoxylated phosphate ester or a salt thereof having the formula ##STR00015## wherein, R, R.sup.1 and R.sup.2 are independently selected from the group consisting of H, and C6-C30 alkyl chain haying an average of 1-20 moles of ethoxylation with the proviso that at least one of R, R.sup.1 and R.sup.2 is H and the other one or two of R, R.sup.1 and R.sup.2is C6-C30 alkyl chain having an average of 1-20 moles of ethoxylation, and b) a phosphate ester or a salt thereof having the formula ##STR00016## wherein, R.sup.3, R.sup.4 and R.sup.5 are independently selected from the group consisting of H, and C6-C18 alkyl chain, with the proviso that at least one of R.sup.3, R.sup.4 and R.sup.5 is H and the other one or two of R.sup.3, R.sup.4 and R.sup.5 is C6-C18 alkyl chain, and c) an organic sulfur containing anionic surfactant or a salt thereof.

2. The low corrosion external release agent as claimed in claim 1, wherein the release agent composition comprises (a) one or more phosphate esters selected from a), and (b) one or more phosphate esters selected from b).

3. The low corrosion external release agent as claimed in claim 2, wherein the release agent composition comprises (a) 2-45% by weight of one or more phosphate esters selected from a); (b) 2-45% by weight of one or more phosphate esters selected from b); and (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

4. The low corrosion external release agent as claimed in claim 2 wherein, the release agent composition comprises (a) 2-25% by weight of one or more phosphate esters selected from a); (b) 2-25% by weight of one or snore phosphate esters selected from b); and (c) 50-96% by weight water and optionally an agent to adjust the pH of the composition.

5. The low corrosion external release agent as claimed in claim 2 wherein, the release agent composition comprises (a) 5-20% by weight of one or more phosphate esters selected from a); (b) 2-15% by weight of one or more phosphate esters selected from b); and (c) 65-93% by weight water and optionally an agent to adjust the pH of the composition,

6. The low corrosion external release agent as claimed in claim 2 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:6 and 6:1.

7. The low corrosion external release agent as claimed in claim 2 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:4 and 4:1.

8. The low corrosion external release agent as claimed in claim 2 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:1 and. 3:1.

9. The low corrosion external release agent as claimed in claim 2, wherein one or two of R, R.sup.1 and R.sup.2 is C6-C12 alkyl having an average of 1-12 moles of ethoxylation and one or two of R.sup.3, R.sup.4 and R.sup.5is C8-C16 alkyl.

10. The low corrosion external release agent as claimed in claim 2 wherein, the phosphate ester of group a) is Poly(oxy-1,2-ethartediyl),-hydro--hydroxy-monoC6-C12-alkyl ethers, phosphates and the phosphate ester of group b) is a mixture of C8 and C10 alkyl phosphate esters.

11. The low corrosion external release agent as claimed in claim 1, wherein the organic sulfur containing anionic surfactant is a sulfonate, sulfate or a disulfonate.

12. The low corrosion external release agent as claimed in claim 11, wherein the suifonate has the formula ##STR00017## wherein R.sup.6 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation; wherein the sulfate has the formula ##STR00018## where R.sup.7 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation; and wherein the disulfonate has the formula ##STR00019## where R.sup.8 is a C6-C24 carbon chain which may he aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation.

13. The low corrosion external release agent as claimed in claim 12 wherein, the release agent composition comprises (a) one or more phosphate esters selected from a) and/or b); and (b) one or more organic sulfur containing anionic surfactants.

14. The low corrosion external release agent as claimed in claim 13, wherein the release agent composition comprises (a) 2-45% by weight of one or more phosphate esters selected from a) and/or b); (b) 2-45% by weight of one or more organic sulfur containing anionic surfactants; and (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

15. The low corrosion external release agent as claimed in claim 13 wherein, the release agent composition comprises (a) 2-25% by weight of one or more phosphate esters selected from a) and/or b); (b) 2-25% by weight of one or more organic sulfur containing anionic surfactants; and (c) 50-96% by weight water and optionally an agent to adjust the pH of the composition,

16. The low corrosion external release agent as claimed in claim 13 wherein, the release agent composition comprises 4-20% by weight of one or more phosphate esters selected from a) and/or b); (b) 2-25% by weight of the organic sulfur containing anionic surfactant; and (c) 55-94% by weight water and optionally an agent to adjust the pH of the composition.

17. The low corrosion external release agent as claimed in claim 13 wherein, R.sup.6 is a C12-C18 alpha olefin group, R.sup.7 is a C8-C16 alkyl group, R.sup.8 a C10-C16 alkyl group, and M is Na.

18. The low corrosion external release agent as claimed in claim 13 wherein, R.sup.6 is a C14-C16 alpha olefin group, R.sup.7 is a C12 alkyl group, R.sup.8 is a C12 alkyl group and M is Na.

19. The low corrosion external release agent as claimed in claim 17, wherein one or two of R, and R.sup.1is C6-C12 alkyl having an average of 1-12 moles of ethoxylation and one or two of R.sup.3, R.sup.4 and R.sup.5 is C8-C16 alkyl.

20. The low corrosion external release agent as claimed in claim 19 wherein, the phosphate ester of group a) is Poly(oxy-1,2-ethanediyl),-hydro--hydroxy-niono C6-C12-alkyl ethers, phosphates and the phosphate ester of group b) is a mixture of C8 and C10 alkyl phosphate esters.

21. A method for applying an external release agent to a ligno-cellulosic fiber, chip, strand or particle mat or metal surface of a press used in the manufacture of an engineered wood product, the method comprising: 1) providing an external release agent comprising two or more anionic surfactants selected from the following groups where at least one of the anionic surfactants is selected from a) or b): a) an ethoxylated phosphate ester or a salt thereof having the formula ##STR00020## wherein, R, R.sup.1 and R.sup.2 are independently selected from the group consisting of H, and C6-C30 alkyl chain having an average of 1-20 moles of ethoxylation, with the proviso that at least one of R, R.sup.1 and R.sup.2 is H and the other one or two of R, R.sup.1 and R.sup.2 is C6-30 alkyl chain having an average of 1-20 moles of ethoxylation, and b) a phosphate ester or a salt thereof having the formula ##STR00021## wherein, R.sup.3, R.sup.4 and R.sup.5 are independently selected from the group consisting of H, and C6-C18 alkyl chain, with the proviso that at least one of R.sup.3, R.sup.4 and R.sup.5 is H and the other one or two of R.sup.3, R.sup.4 and R.sup.5 is C6-C18 alkyl chain, and c) an organic sulfur containing anionic surfactant selected from a sulfonate having the formula ##STR00022## wherein R.sup.6 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation; a sulfate having the formula ##STR00023## where R.sup.7 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation; and disulfonate having the formula ##STR00024## where R.sup.8 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation. 2) loading the external release agent in an application system and 3) thereafter applying the external release agent to one or more of the ligno-cellulosic fiber, chip, strand or particle mat or metal surface of a press using said application system.

22. The method for applying an external release agent as claimed in claim 21, wherein the release agent composition comprises (a) one or more phosphate esters selected from a), and (b) one or more phosphate esters selected from b).

23. The method for applying an external release agent as claimed in claim 22, wherein the release agent composition comprises (a) 2-45% by weight of one or more phosphate esters selected from a); (b 2-45% by weight of one or more phosphate esters selected from b); and (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

24. The method for applying an external release agent as claimed in claim 22 wherein, the release agent composition comprises (a) 2-25% by weight of one or more phosphate esters selected from a); (b) 2-25% by weight of one or more phosphate esters selected from b); and (c) 50-96% by weight water and optionally an agent to adjust the pH of the composition.

25. The method for applying an external release agent as claimed in claim 22 wherein, the release agent composition comprises (a) 5-20% by weight of one or more phosphate esters selected. from a); (b) 2-15% by weight of one or more phosphate esters selected from b); and (c) 65-93% by weight water and optionally an agent to adjust the pH of the composition.

26. The method for applying an external release agent as claimed in claim 22 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:6 and 6:1.

27. The method for applying an external release agent as claimed in claim 22 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:4 and 4:1,

28. The method for applying an external release agent as claimed in claim 22 wherein, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:1 and 3:1.

29. The method for applying an external release agent as claimed in claim 22, wherein one or two of R, R.sup.1 and R.sup.2 is C6-C12 alkyl having an average of 1-12 moles of ethoxylation and one or two of R.sup.3, R.sup.4 and R.sup.5 is C8-C16.

30. The method for applying an external release agent as claimed in claim 22 wherein, the phosphate ester of group a) is Poly(oxy-1,2-ethanediyl),-hydro--hydroxy-monoC6-C12-alkyl ethers, phosphates and the phosphate ester of group b) is a mixture of C8 and C10 alkyl phosphate esters.

31. The method for applying an external release agent as claimed in claim 21 wherein, the release agent composition comprises (a) one or more phosphate esters selected from a) and/or b); and (b) one or more organic sulfur containing anionic surfactants.

32. The method for implying an external release agent as claimed in claim 31 wherein, the release agent composition comprises (a) 2-45% by weight of one or more phosphate esters selected from a) and/or b); (b) 2-45% by weight of one or more organic sulfur containing anionic surfactants; and (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

33. The low corrosion external release agent as claimed in claim 31 wherein, the release agent composition comprises (a) 2-25% by weight of one or more phosphate esters selected from a) and/or b); (b) 2-25% by weight of one or more organic sulfur containing anionic surfactants; and (c) 50-96% by weight water and optionally an agent to adjust the pH of the composition.

34. The method for applying an external release agent as claimed in claim 31 wherein, the release agent composition comprises (a) 4-20% by weight of one or more phosphate esters selected from a) and/or b); (h) 2-25% by weight of the organic sulfur containing anionic surfactant; and (c) 55-94% by weight water and optionally an agent to adjust the pH of the composition.

35. The method for applying an external release agent as claimed in claim 31 wherein, R.sup.6 is a C12-C18 alpha olefin group, R.sup.7 is a C8-C16 alkyl group, R.sup.8 a C10-C16 alkyl group, and M is Na,

36. The method for applying an external release agent as claimed in claim 31 wherein, R.sup.6 is a C14-C16 alpha olefin group, R.sup.7 is a C12 alkyl group, R.sup.8 is a C12 alkyl group and M is Na.

37. A low corrosion external release agent as claimed in claim 31, wherein one or two of R, R.sup.1 and R.sup.2 is C6-C12 alkyl having an average of 1-12 moles of ethoxylation and one or two of R.sup.3, R.sup.4 and R.sup.5 is C8-C16 alkyl.

38. The method for applying an external release agent as claimed in claim 35 wherein, the phosphate ester of group a) is Poly(oxy-1,2-ethanediyl),-hydro--hydroxy-monoC6-12-alkyl ethers, phosphates and the phosphate ester of group b) is a mixture of C8 and C10 alkyl phosphate esters.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0086] Preferred embodiments of the invention are shown in the drawings, wherein:

[0087] FIG. 1 illustrates the results of the corrosion tests.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0088] The present invention is directed to a low corrosion external release agent for ligno-cellulosic composite panels, particularly those formed using an isocyanate based adhesive such as pMDI. The external release agent of the present invention provides for release properties similar to or better than those of prior art formulations while providing significantly less corrosion of the metal surfaces of the presses. The release agent of the present invention can be used in any of the press operations commonly utilized in the art including continuous or multi-opening (daylight) presses.

[0089] The low corrosion external release agent composition for use with ligno-cellulosic composite panels utilizing a pMDI adhesive of the present invention comprises two or more anionic surfactants selected from the following groups where at least one of the anionic surfactants is selected from a) or b):

[0090] a) an ethoxylated phosphate ester or a salt thereof haying the formula

##STR00010##

[0091] wherein,

[0092] R, R.sup.1 and R.sup.2 are independently selected from the group consisting of H, and C6-C30 alkyl chain having an average of 1-20 moles of ethoxylation,

[0093] with the proviso that at least one of R, R.sup.1 and R.sup.2 is H and the other one or two of R, R.sup.1 and R.sup.2 is C6-C30 alkyl chain having an average of 1-20 moles of ethoxylation, and

[0094] b) a phosphate ester or a salt thereof haying the formula

##STR00011##

[0095] wherein,

[0096] R.sup.3, R.sup.4 and R.sup.5 are independently selected from the group consisting of H, and C6-C18 alkyl chain,

[0097] with the proviso that at least one of R.sup.3, R.sup.4 and R.sup.5 is H and the other one or two of R.sup.3, R.sup.4 and R.sup.5 is C6-C18 alkyl chain, and

[0098] c) an organic sulfur containing anionic surfactant or a salt thereof.

[0099] The phosphate ester as defined in group a) is preferably a long C chain phosphate ester haying a C6-C30 alkyl group with an average of 1 to 20 moles of ethoxylation. Preferably, the phosphate ester as defined in group a) is a phosphate ester having a C6-C22 alkyl group with an average of 1 to 16 moles of ethoxylation, more preferably C6-C18 alkyl group with an average of 1 to 14 moles of ethoxylation, more preferably between C6-C12. alkyl group with an average of 1 to 12 moles of ethoxylation, and most preferably a C8-C11 alkyl group with an average of 1 to 8 moles of ethoxylation. Straight or branched chains or cyclic groups of the phosphate ester may be used, The phosphate ester may be a mono-ester, a di-ester or a mixture of mono- and di-esters. An example of a preferred phosphate ester as defined in group a) is Poly(oxy-1,2-ethanediyl), -hydro--hydroxy-mono C6-C12-alkyl ethers, phosphates, (CAS 68921-24-4).

[0100] The phosphate ester defined in group b) is preferably a C6-C18 monoester or diester or a mixture of C6-C18 monoesters. More preferably, the phosphate ester defined in group b) is a C8-C16 monoester or diester or a mixture of C8-C16 monoesters. Most preferably, the phosphate ester defined in group b) is a mixture of C8 and C10 monoesters, (CAS 3921-30-0 and CAS 3991-73-9).

[0101] The organic sulfur containing anionic surfactant defined in group c) is preferably sulfonate, sulfate or a disulfonate.

[0102] The sulfonate preferably has the formula

##STR00012##

wherein R.sup.6 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation. R.sup.6 is preferably a C12-C18 alpha olefin group, most preferably a C14-C16 alpha olefin group.

[0103] The sulfate preferably has the formula

##STR00013##

wherein R.sup.7 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation. R.sup.7 is preferably a C8-C16 alkyl group, most preferably a C12 alkyl group.

[0104] The disulfonate preferably has the formula

##STR00014##

wherein R.sup.8 is a C6-C24 carbon chain which may be aliphatic or aromatic, linear or branched, saturated or unsaturated, ethoxylated or propoxylated or combinations thereof and M is a monovalent cation. R.sup.8 is preferably a C8-C16 alkyl group, most preferably a C12 alkyl group.

[0105] The salts of the components of the present invention are preferably monovalent cation salts. Preferably, the salts of the phosphate esters and M of the organic sulfur containing anionic surfactant are alkali metal salts, amines or other monovalent cations. More preferably, the salts and M are alkali metal salts, most preferably the salts and M are sodium or potassium.

[0106] In one preferred embodiment, the release agent composition comprises

[0107] (a) one or more phosphate esters selected from a); and

[0108] (b) one or more phosphate esters selected from b).

[0109] Preferably, the release agent composition comprises

[0110] (a) 2-45% by weight of one or more phosphate esters selected from a);

[0111] (b) 2-45% by weight of one or more phosphate esters selected from b); and

[0112] (c) 10-96% by weight water and. optionally an agent to adjust the pH of the composition,

[0113] Preferably, this embodiment of the release agent composition comprises

[0114] (a) 2-25% by weight of one or more phosphate esters selected from a);

[0115] (b) 2-25% by weight of one or more phosphate esters selected from b); and

[0116] (c) 50-96% by weight water and optionally an agent to adjust the pH of the composition.

[0117] More preferably, this embodiment of the release agent comprises

[0118] (a) 5-20% by weight of one or more phosphate esters selected from a);

[0119] (b) 2-15% by weight of one or more phosphate esters selected from b); and

[0120] (c) 65-93% by weight water and optionally an agent to adjust the pH of the composition.

[0121] In this embodiment, preferably the ratio of the phosphate ester selected from a) to the phosphate ester selected from h) is between 1:6 and 6:1, More preferably the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:4 and 4:1, more preferably between 1:2 and 4:1. Most preferably, the ratio of the phosphate ester selected from a) to the phosphate ester selected from b) is between 1:1 and 3:1.

[0122] In another embodiment of the invention, the release agent composition comprises

[0123] (a) one or more phosphate esters selected from a) and/or b); and

[0124] (b) one or more organic sulfur containing anionic surfactants.

[0125] In this embodiment, preferably the release agent composition comprises

[0126] (a) 2-45% by weight of one or more phosphate esters selected from a) and/or b);

[0127] (b) 2-45% by weight of one or more organic sulfur containing anionic surfactants; and

[0128] (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

[0129] More preferably, this embodiment of the release agent composition comprises

[0130] (a) 2-25% by weight of one or more phosphate esters selected from a) and/or b);

[0131] (b) 2-25% by weight of the organic sulfur containing anionic surfactant; and

[0132] (c) 10-96% by weight water and optionally an agent to adjust the pH of the composition.

[0133] Most preferably, the low corrosion external release comprises

[0134] (a) 4-20% by weight of one or more phosphate esters selected from a) and/or b);

[0135] (b) 2-25% by weight of the organic sulfur containing anionic surfactant; and

[0136] (c) 55-94% by weight water and optionally an agent to adjust the of the composition.

[0137] The release agents of the present invention may also utilize a mixture of more than two of the anionic surfactants.

[0138] In addition to the anionic surfactants, the composition will contain water and optionally an agent to adjust the pH to the preferred range of 4 to 12, most preferably a range of pH of about pH6 to about pH 10. These agents can include alkali metal hydroxides, or amines. Preferably, an alkali metal hydroxide, most preferably NaOH or KOH is used to adjust the pH.

[0139] In addition, the composition of the present invention may also contain other components so long as they do not affect the release and corrosion inhibition properties of the release agent. For example, the release agent of the present invention may include a suitable preservative such as 2-bromo-2-nitropropane-1,3-diol, 5-chloro-2-methyl-4-isothiazolin-3-one, 2-methyl-4-isothiazolin-3-one or 1,3-benzothiazol-2-ylsulfanylmethyl thiocyanate.

[0140] In addition, depending on the component ratios and concentrations utilized, the release agent of the present invention may also utilize additional surfactants or combinations thereof as emulsifiers or hydrotropes to form stable solutions so long as they do not affect the operation of the release agent in terms of release and corrosion protection. It is understood that the addition of these optional components does not take away from the scope of the invention. Some examples which would be familiar to those skilled in the art are alcohol ethoxylates, sodium xylene sulfonate, etc.

[0141] Once formulated, the composition of the present invention is used as a release agent for the manufacture of engineered wood products from ligno-cellulosic fibers, chips, strands or particles, in particular wood fibers or chips, utilizing pMDI as the adhesive, The composition of the present invention is applied to either the surface of the mat of ligno-cellulosic fibers, chips, strands or particles used to form the engineered wood product or to the surfaces of the metal caul plates, press platens, screens or belts used in the presses. The application method is dependent on the press style and capabilities. Typically, the release agent would be applied to the formed mat in multi-opening (daylight) presses whereas it is applied to the metal press surfaces in continuous style presses. In order to make the application process easier, it is preferred if the release agent composition is diluted with water before application. The composition is generally applied to the metal press surfaces in continuous presses at an application rate of at least about 0.05 g/m.sup.2 of the active ingredients and preferably at an application rate of at least about 0.1 g/m.sup.2 of the active ingredients. When applying the composition to the surface of the mat fibers, application rates of at least about 0.5 g/m.sup.2 of the active ingredients may be used. The composition of the present invention provides for excellent release of the finished wood product from the caul plates with reduced corrosion.

[0142] Those skilled in the art will appreciate the many possible variations within the scope of this invention. The following examples are illustrative of the preferred embodiments of the present invention, but the present invention is not limited to the examples.

[0143] Example 1Preparation of Emulsified Release Agent Composition

[0144] 65.4 gram of reverse osmosis (RO) water was weighed in a beaker and 12.3 gram of 45% KOH was added while mixing. Then 16.5 grams of Poly(oxy-1,2-ethanediyl), -hydro--hydroxy-monoC6-C12-alkyl ethers, phosphates (Interphone AEPE-Sialco materials LTD.) was added and mixed. 5.8 grams of a mixture of CS and CIO phosphate monoesters (Interphon MODPE Sialco materials LTD.) was added while mixing for 10 minutes. This formulation was AB-1 as set out in Table 1

[0145] Examples 2 to 13Preparation of other Embodiments and Prior Art Formulations

[0146] Using the above method, other formulations as set out in Table 1 were prepared. A, B and C are representative of a), b) and c) respectively as outlined in the summary of invention. In addition, c) is represented by C1 (sulfonate), C2 (sulfate), C3 (disulfonate). In the examples provided: A is Poly(oxy-1,2-ethanediyl),a-hydro-w-hydroxy-monoC6-C12-alkyl ethers, phosphates, (CAS 68921-24-4), Interphon AEPE-Sialco materials LTD.; B is a mixture of C8 and C10 phosphate monoesters, (CAS 3921-30-0 and CAS 3991-73-9), Interphon MODPE-Sialco materials LTD.; C1 is Sodium (C14-C16) olefin sulfonate, (CAS 68439-57-6), Bioterge AS-40-Stepan Company; C2 is Sodium dodecyl sulfate, (CAS 151-21-3), Stepanol WA-100-Stepan Company; and C3 is 1,1-oxybisbenzene tetrapropylene derivatives, sulfonated, sodium salt, (CAS 119345-04-9) Calfax DB45-Pilot Chemical Company. Single component formulations A, B, C1 and C3 were prepared for comparison purposes. In addition, prior art formulations were prepared and identified as F1 and F2, where F1 is Coconut Fatty Acid, potassium salt (COFA), (CAS 61789-30-8) and F2 is representative of a formulation covered under U.S. Pat. No. 3,309,503 which utilizes a combination of fatty acid and phosphate ester.

[0147] Example 14Testing of the formulations for Release

[0148] The formulations as set out in Table 1 were tested for their release properties as set out below. Test parameters varied depending on the type of press (multi-opening or continuous).

[0149] Orientated Strand Board (OSB) panels were manufactured with commercial OSB strands that were screened to 3.175 mm strand size fractions, using a 914 mm2438 mm BM&M deck screener. The screened strands were blended with a commercial fast cure pMDI resin at a rate of 6.0% solids and a commercial Emulsion wax (E-wax) at a rate of 1.5% solids. The resin and E-wax were applied in a drum blender with a spinning disk atomizer. The blended materials were formed into mats measuring 838 mm838 mm with a 55/45 surface to core weight ratio. Moisture content of the mats was targeted at 7% for the surface and 4% for the core.

[0150] The press was used to form Orientated Strand Board (OSB) in the following configurations; mild or stainless steel top plate, blended strands (formed mat), sealed screen (864 mm864 mm1178 mm), fixed aluminum bottom plate. The press was run using either a multi-opening configuration which meant that the release agent was sprayed on the top of the formed mat or a continuous operation where the release agent was sprayed on the top plate. Prior to preparing the first board with each release agent, the top plate was cleaned with a cup brush and washed with acetone. The top plate was then heated in the press. Pre-conditioning of the top plate was performed by spraying approximately 8 g/ft.sup.2 of the release agent diluted to 5% or 6.25% solids (continuous or multi-opening, respectively) into the press and allowing it to heat up and dry before proceeding.

[0151] The release agent was then sprayed at various application rates to either the top plate or the mat top surface prior to pressing. The panels were targeted for a density of 624 kg/m3 and a thickness of 11.0 mm, The panels were pressed at a temperature of 220C. for 160 seconds, typical for the industry. After pressing, the panels were trimmed to 711 mm711 mm and then measured for out-of-press thickness and density.

[0152] Results

[0153] The pressed panels were rated for the effectiveness of each release agent from (1) if the panel does not stick at all to the pressing plate to (4) if the panel is completely stuck to the pressing plate. Any press release rating is considered to be the application rate at which the formulation fails. Detailed release ratings were assigned as follows:

[0154] Category 1 Full Release

[0155] 1.00 No particles stuck to top plate

[0156] 1.10 Very few small particles stuck to top plate

[0157] 1.25 Small amount of particles stuck to top plate

[0158] 1.50 Medium amount of particles stuck to top plate

[0159] 1.75 Large amount of particles stuck to top plate

[0160] Category 2 Brief Hang-Up Release

[0161] 2.00 No particles stuck to top plate

[0162] 2.10 Very few small particles stuck to top plate

[0163] 2.25 Small amount of particles stuck to top plate

[0164] 2.50 Medium amount of particles stuck to top plate

[0165] 2.75 Large amount of particles stuck to top plate

[0166] Category 3 Manual Release

[0167] 3.00 No particles stuck to top plate

[0168] 3,10 Very few small particles stuck to top plate

[0169] 3.25 Small amount of particles stuck to top plate

[0170] 3.50 Medium amount of particles stuck to top plate

[0171] 3.75 Large amount of particles stuck to top plate

[0172] Category 4 Release Completely Stuck

[0173] 4.00 Panel completely stuck to top plate The results are shown in Tables 2 and 3:

[0174] The mixture of the phosphate esters from group a) and b) performs significantly better than the pure compounds and the prior art formulations in continuous press operations. Optimal ratio of a) to b) found in these experiments is preferably about 3:1. The combination of a phosphate ester and an anionic sulfur containing surfactant also performed better than the pure compounds and prior art formulations in continuous press processes, although not as well as the mixture of the phosphate esters. in the continuous press operation, the pure compounds performed almost as well as the prior art formulations.

[0175] The mixture of the phosphate esters from group a) and b) performs better than the pure compounds in multi-opening press processes. Optimal ratio of a) to b) ratio found in these experiments is preferably about 1:1. The combination of one or more phosphate esters and an anionic sulfur containing surfactant also performed better than the pure compounds in multi-opening press processes. They also performed as good as or better than the mixture of phosphate esters from group a) and b).

[0176] Example 15Testing the Corrosion Properties

[0177] The corrosion properties of the formulations were tested using the following method that mimicked the real multi-opening press process:

[0178] Using a 55 plywood form, a small mat is prepared from 110 g OSB strands treated with 1.3% Wax, 6% pMDI and water up to the desired moisture content. The mat is moved to a mild steel bottom plate covered by a teflon sheet and mat top surface is sprayed with about 4 g of a 10% solids release agent. Two pre-weighted mild steel coupons (carbon steel 1018) are placed on the top of the mat and sprayed again. A mild steel plate pre-heated to 220 C. is placed on top of the formed mat/coupons and moved quickly into the 220 C. heated Carver Press. The press is closed until the pressure gauge reads 12,500 lbs. The pressure is maintained at 12.5700 lbs for 70 seconds and then the pressure is slowly released, After 195 seconds, the press is de-gassed and after 210 seconds the press is opened. The pressed panel is removed, while the top plate remains in the heated press. The coupons are flipped over. The top surface of the OSB board and the coupons are sprayed again with 4 grams of release agent, the hot top mild steel plate is placed on top of the board/coupons and the pressing procedure repeated. This process is repeated until the panel has been pressed a total of 6 times. After 6 presses, the panel is discarded, a new OSB mat formed and the procedure above is repeated using the same coupons and release agent. After a total of 30 press cycles the coupons are cleaned with a caustic based detergent followed by hot water. They are then soaked in inhibited hydrochloric acid (10%) for 120 seconds in an ultrasonic bath, washed with hot water, neutralized using an alkaline soap solution and dried with acetone. The weight loss of the coupons is recorded and corrected for a blank coupon treated with the same cleaning procedure and net weight loss converted to MPY (mils per year). These corrosion rates are then normalized to the corrosion rate for RO water.

TABLE-US-00001 TABLE 4 Relative corrosion of the release agents of the present invention, compared to traditional release agents containing fatty acids. The corrosion of RO water is used as a reference. Relative Corrosion Release agent (mpy)/ Product ID RO Water (mpy) RO Water 1 A 0.23.sub.[JW8][JJ9] B 0.57.sub.[JW10] C1 1.91 AB-1 0.49 AB-2 0.66 AC1 0.51 AC3 0.54 BC1 0.440.sub.[PT11] ABC-1 0.77 F1 5.00 F2 3.73

[0179] The results of these tests dearly showed that:

[0180] a) The release agents of the present invention showed very low corrosion rates, even lower than the base line for RC) Water.

[0181] b) The results also show that the release agents of the present invention in fact inhibit the corrosion of water and vapors that are emitted during the pressing of composite panels.

[0182] The prior art products containing fatty acids in different proportions had very high corrosion, which will he aggressive especially to mild steel surfaces used in both continuous and multi-opening presses, such as the mild steel plates used in Multi-Opening presses,

[0183] The individual anionic surfactants on their own, not in combination, also demonstrated reduced corrosion as compared to the prior art, and, as set out above in Tables 2 and 3, also demonstrated acceptable release properties, although not as good as the formulations of the present invention. There may however be certain applications where the use of the individual anionic surfactant would be acceptable, based upon the application and the requirements as they provide release characteristics similar to the prior art formulations, while having lower corrosion.

[0184] The release agents of the present invention provide for release properties equivalent to or better than the prior art formulations while providing significantly reduced corrosion of the metal parts of the presses on their own without the addition of other anti-corrosion agents. The low corrosion release agents of the present invention provide for protection of the metal surfaces of the presses used in the pressing of composite panels. By accomplishing this without the addition of separate anti-corrosion agents, the cost and the complexity of manufacture of the release agents is reduced. This provides significant benefits to the industry.

[0185] Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art that variations may be made thereto without departing from the appended claims.