Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G4/00—Condensation polymers of aldehydes or ketones with polyalcohols; Addition polymers of heterocyclic oxygen compounds containing in the ring at least once the grouping —O—C—O—
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C47/00—Compounds having —CHO groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G6/00—Condensation polymers of aldehydes or ketones only
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/26—Condensation polymers of aldehydes or ketones with phenols only from mixtures of aldehydes and ketones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/28—Chemically modified polycondensates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/28—Chemically modified polycondensates
  • C08G8/32—Chemically modified polycondensates by organic acids or derivatives thereof, e.g. fatty oils
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
  • H05K1/00—Printed circuits
  • H05K1/02—Details
  • H05K1/03—Use of materials for the substrate

Definitions

• the present invention relates to methods for the production of a resin such as a thermosetting resin, particularly a bioresin, components for use in the methods, and products obtained from the methods.
• a resin such as a thermosetting resin, particularly a bioresin
• Resins such as thermosetting resins are widely used in industry for example in timber board composites, insulation, foundry castings, automotive applications, laminates, coatings, and agricultural fibre composites. Resins may be used for example for their properties as adhesives or for their ability to serve as a matrix filler in composites made from fibres, particles, etc. Resins may be formed by combining an aldehyde with a cross-linking agent (also known in the art as a "cross-linker”) such as phenolic compounds (including resorcinol, i.e. 1 ,3-dihydroxy benzene; CAS 108 ⁇ 46-3), urea (CAS 57-13-6), amines or polyols.
• a cross-linking agent also known in the art as a "cross-linker”
• cross-linker such as phenolic compounds (including resorcinol, i.e. 1 ,3-dihydroxy benzene; CAS 108 ⁇ 46-3), urea (
• aldehydes may be derived from the oxidative cleavage of an unsaturated bond in plant or animal oils. Oxidative cleavage may be effected by ozone, followed by the catalytic reduction of the oxidised intermediates to form a mixture of reactive aldehydes (also known as "aldehyde oil”), for example as disclosed in Pryde et al. (1961 , J. Am. Oil Chem. Soc. 38: 375-379), WO00/78699 and WO03/050081.
• Aldehydes for use in resin formation may also be derived using hydroformylation, in which a formyl group (CHO) and a hydrogen atom are added across a carbon-carbon double bond present in unsaturated fatty acids using a catalyst such as rhodium or cobalt.
• hydroformylation to form aldehydes from vegetable oils, for example soybean oil, has been described in Guo et al. (2002, J. Polymers Environ. 10: 49-52), andanarachchi et al. (2002, J. Mol. Catal. A: Chem. 184: 65-71 ) and WO2008/073729.
• an aldehyde oil is produced by reductive ozonolysis from an "idealised" vegetable oil in the form of pure glyceryl ester of oleic acid (i.e. triolein)
• the products would be primarily glyceride-bound aldehyde (C30H50O9) and nonanal (C 9 H 18 0), as shown in Fig. 1.
• suitable vegetable oils are usually a mixture of at least glyceryl esters of monounsaturated oleic acid, polyunsaturated linoleic and linolenic acids, with some saturated acids such as stearic and palmitic acids.
• the products upon reductive ozonolysis, are more diverse but comprise mainly glyceride-bound aldehydes (for example but not limited to C30H5 0 O9) plus (nonanal), C 6 Hi 2 0 (hexanal), C 3 H 6 0 (propanal).
• glyceride-bound aldehydes for example but not limited to C30H5 0 O9 plus (nonanal), C 6 Hi 2 0 (hexanal), C 3 H 6 0 (propanal).
• rapeseed oil-derived product of reductive ozonolysis for example, there will be around 70-75% glyceride-bound aldehydes, 16-22% nonanal, 1-3% hexanal and traces of propanal, heptanal and malonaldehyde (as called malondialdehyde).
• these acids would be C30H50O12 (glyceride-bound acids) and C 9 H 18 0 2 (nonanoic acid), as depicted in Fig. 2.
• these acids will, in addition, be traces of hexanoic acid, propanoic acid and formic acid.
• the present invention provides alternative methods of producing a resin such as a thermosetting bioresin, as well as components for use in, and products obtained from, these methods.
• a method of forming a resin comprising the steps of:
• a non-volatile aldehyde for example a glyceride-bound aldehyde such as from an aldehyde oil
• a method of forming a resin from an aldehyde oil comprising a volatile aldehyde and a non-volatile aldehyde comprising the steps of:
• a key feature of the invention is the presence of an aldehyde-cross-linking agent condensate (also referred to herein as a "precondensate") formed by reacting a volatile aldehyde with a cross-linking agent.
• the volatile aldehyde is typically covalently bonded with the cross- linking agent to form the precondensate.
• the precondensate itself may have cross-linking activity although this is usually and advantageously a modified activity compared to the cross-linking activity of the cross-linking agent used to form the precondensate.
• the precondensate may have slower or faster cross-linking activity compared to the cross-linking agent, whichever is more controllable and/or suitable for the formation of a desired resin.
• a precondensate formed using tannin such as mixed tannins (generally, but not always, a slower cross-linking agent than resorcinol) may have higher cross-linking activity than the tannin per se
• a precondensate formed using phloroglucinol generally a faster cross-linking agent than tannin or resorcinol
• phloroglucinol generally a faster cross-linking agent than tannin or resorcinol
• the methods of the invention thus allow the use of previously unsuitable cross-linking agents for resin formation via use of the precondensate of the invention.
• the precondensate may furthermore be more stable than unreacted volatile aldehyde and/or cross-linking agent, as some polymerisation has taken place, allowing improved storage and handling of the precondensate for formation of a resin.
• the precondensate is formed from the volatile aldehyde of an aldehyde oil
• more of the aldehyde oil is utilised in the end product resin for example compared to systems where only non-volatile aldehyde was used or where a significant ratio of non-volatile aldehyde to a non-aldehyde cross-linking agent was required to form a resin.
• the formation of a precondensate also means that less volatile organic compounds (VOCs) to which volatile aldehydes contribute may be emitted in step safer.
• VOCs may be defined as organic compounds with a boiling point below 250°C at a standard atmospheric pressure of 101.3 kPa.
• the non-volatile component in all aspects of the invention may comprise about 0.5-90% residual VOCs (such as residual VOCs from the volatile aldehyde), for example about 1-20% VOCs, about 1 -10% VOCs, about 1-5% VOCs, about 10% VOCs, about 5% VOCs, about 1% VOCs or about 0.5% VOCs.
• the non-volatile component may comprise less than 10%, less than 5%, or less than 1 % VOCs.
• VOCs in the non-volatile component are removed during or following its formation. This is because, in practice, it may be that the most volatile VOCs (say, the initial 10% to 15% of VOCs) are most odorous and/or harmful. Removal of further VOCs beyond an initial 10% to 15% may be advantageous in improving the properties of the non-volatile component. However, an amount of VOCs in the non-volatile component may be useful, for example to improve solubility and/or viscosity.
• the reaction of the volatile aldehyde with a cross-linking agent, particularly tannins, during formation of the aldehyde-cross-linking agent condensate of the invention may reduce or eliminate harmful and/or noxious odours associated with the volatile aldehyde. Also, with such odours reduced or eliminated, residual and more pleasant and/or positive odours (such as wood and/or leather odours, particularly from tannins) may be more prevalent and/or accentuated in the aldehyde-cross-linking agent condensate (and/or cross-linking agent, resin, or solid composite material) formed thereform.
• a cross-linking agent particularly tannins
• the precondensate and non-volatile aldehyde can be combined in different stoichiometries to influence the characteristics (such as rigidity versus flexibility) of the formed resin.
• a further advantage of the invention is that resins formed accorded to the methods have a broad range of applications.
• resin refers to a cross-linked polymer resulting from the combination of a non-volatile aldehyde with an aldehyde-cross-linking agent condensate, optionally in the presence of an additional cross-linking agent and/or polymerisation catalyst (see below). Other cross-linking components, for example resulting from the formation of the aldehyde oil, may also be present in the resin.
• resin as used herein encompasses cured resins and prepolymers (uncured resins), primers, fillers (such as matrix fillers for composites), plastic matrices, adhesives, putties and gels.
• the resin may be a bioresin and/or a thermosetting resin.
• bioresin refers to a resin whose constituents are derived in total or in part from biological material, particularly renewable sources. Although aldehydes derived from vegetable oils have been used previously in resin formation, the most widely used cross- linking agents were derived from non-biological materials, and the bioresins produced were typically less than 100% or even 80% biological (for example, comprising around 75% biological material).
• the aldehyde-cross-linking agent condensate (precondensate) of the present invention allows, but is not limited to, biological, renewable material to be used as a cross-linking agent (in the form of the precondensate) and thus formation of pure or a substantially pure bioresin (containing for example more than 95% biological material).
• Bioresins made according to the present invention can replace existing petrochemical derivatives whilst meeting the emerging legislative and consumer demand for safer products based on sustainable technology.
• the aldehyde oil may be derived from a vegetable or animal oil, for example by reductive ozonolysis or by hydroformylation.
• the aldehyde oil may be derived from a plant oil including any one or more of the group consisting of an algal oil, an unsaturated plant oil such as tung oil, a mono-, di-, and tri-glyceride oil such as rapeseed oil, linseed oil, soya oil, olive oil, castor oil, mustard oil, ground nut (e.g. peanut) oil, and a phenolic oil such as cashew nut shell liquid (CNSL).
• the aldehyde oil may also be derived from wood oil, sunflower oil, cottonseed oil, palm oil and corn oil.
• Oxidation of the plant oil to form an aldehyde oil may be effected by ozonolysis, although other oxidative methods suitable for cleaving unsaturated linkages present in the oils to form aldehyde oils may also be used. Reference is made to the methods for effecting oxidation of plant and animal oils for the formation of suitable aldehyde oils disclosed in WO00/78699 and WO03/050081 . Formation of aldehyde oils from vegetable oils or other fatty acid oils using hydroformylation has been described in Guo et al. (2002, supra), Kandanarachchi et al. (2002, supra) and WO2008/073729.
• an aldehyde oil obtained by hydroformylation is used in a method for the formation of a resin, for example by addition of a cross-linking agent (with or without a precondensate).
• the resin obtainable from this method is also envisaged.
• the volatile aldehyde may comprise a Ci-Ci 8 aldehyde (such as a Ci-Ci 8 mono-aldehyde), for example nonanal, hexanal and/or propanal.
• the volatile aldehyde may additionally or alternatively be defined as an aldehyde removable from a fatty acid oil (such as a vegetable oil or an animal oil) by a separation process, for example vacuum distillation.
• the non-volatile aldehyde may comprise a glyceride-bound aldehyde.
• the non-volatile aldehyde may additionally or alternatively be defined as an aldehyde which is not removable from a fatty acid oil (such as a vegetable oil or an animal oil) by a separation process, for example vacuum distillation.
• a fatty acid oil such as a vegetable oil or an animal oil
• the glyceride-bound aldehyde may be C 30 H 5 o0 9 (obtainable for example following reductive ozonolysis of triolein) and/or higher C forms of glyceride-bound aldehyde.
• the cross-linking agent is typically a nucleophile and may be selected for example from any one or more of the group consisting of tannin (such as pine, spruce or quebracho tannin), urea, resorcinol, lignin and phloroglucinol.
• the cross-linking agent may also be an aromatic, phenol and homologues thereof, polyphenols, glycols and polyols such as ethylene glycol, glycerol and carbohydrates (e.g. sugars and sugar alcohols), amines, amides, thiourea, dicyandiamide, melamine, isocyanates such as MDI, heterocyclic compounds such as furfural, furfuryl alcohol, pyridine and phosphines.
• the cross-linking agent may be a "natural" or “biological” cross-linking agent. It is also envisaged that the cross-linking agent may be the aldehyde-cross-linking agent of the invention, which (as discussed elsewhere herein) may itself have cross-linking activity.
• the cross-linking agent may be formulated with water in combination with an organic solvent such as, but not limited to, isopropanol, ethylene glycol, propylene glycol, glycerol, diethylene glycol and/or dipropylene glycol.
• an alkali such as sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate and/or potassium bicarbonate may be employed to further assist dissolution.
• More than one cross-linking agent i.e. a mixture of different cross-linking agents may be used in the reaction with the volatile aldehyde.
• the aldehyde-cross-linking agent condensate may be formed at a temperature of about 0°C- 250°C, such as about 85 °C or about 95°C. Lower temperatures may be suitable where more reactive cross-linking agents are used to form the aldehyde-cross-linking agent condensate.
• the aldehyde-cross-linking agent condensate may comprise unreacted (or "excess") cross- linking agent.
• the methods of forming a resin according to the invention may thus include reacting the volatile aldehyde with an excess of cross-linking agent.
• there is a deficiency of the volatile aldehyde compared to the cross-linking agent so that all the volatile aldehyde is consumed in the formation of the precondensate but full polymerisation is not possible. This means that the aldehyde component in the precondensate is fully reacted.
• the shelf life of the precondensate is therefore extended, and the precondensate is only able to polymerise fully or further when combined with additional aldehyde, for example the non-volatile aldehyde, such as when the resin is formed.
• Additional cross-linking agent may be added during the formation of a resin in step 3 of the methods, for example a cross-linking agent selected from any of the cross-linking agents listed above.
• the volatile aldehyde may comprise nonanal
• the cross-linking agent comprises resorcinol
• the aldehyde-cross-linking agent condensate may then comprise a linear resorcinol dimer (structure II of Fig.
• oligomers such as a trimer, tetramer, pentamer, etc., and/or a cyclic resorcinol tetramer linked with nonanal in a 1 :1 stoichiometric ratio (i.e. a resorcinarene).
• Other cyclic oligomers may be present. Structures analogous to structure II of Fig. 3 and the further oligomers described above are also expected to be formed when phloroglucinol replaces resorcinol as the cross-linking agent.
• the volatile aldehyde and the non-volatile aldehyde may be derived from the same aldehyde oil.
• forming the precondensate from the volatile aldehyde prior to forming the resin allows more of the carbon content of the originating aldehyde oil to be incorporated into the final resin, compared with prior art systems such as Pryde et al. (1961 , supra).
• the aldehyde-cross-linking agent condensate and/or the non-volatile aldehydes for use in the formation of resins according to the present invention may be in the form of oils or solids at ambient temperatures and can subsequently be used either in an undiluted state, or dissolved or dispersed in a suitable solvent or presented as an aqueous emulsion, for example.
• Addition of an alkali e.g. NaOH
• a water soluble or emulsifiable compound possibly a hydrate of the aldehyde
• an acid catalyst e.g. NaOH
• the invention provides an aqueous emulsion or an aqueous alkaline solution containing an aldehyde-cross-linking agent condensate and a non-volatile aldehyde (and optionally peroxides and hemiacetals) and/or mixtures thereof.
• the invention further provides a curable composition comprising this aqueous emulsion and/or aqueous alkaline solution.
• the invention additionally provides a cured composition of the aforesaid type, for example an acid catalysed cured composition.
• Step (3) of the method for forming a resin encompasses in one aspect "curing" of the resin, which may be performed in a variety of different ways.
• the resin may be capable of undergoing self-crosslinking through a range of chemistries.
• the properties of the resulting cured resins are influenced by the molecular size of the compounds making up the aldehyde-cross-linking agent condensate and non-volatile aldehyde and the number of reactive sites.
• Cross-linking mechanisms may include aldehyde polymerisations, polymerisation reactions with residual reducing sugars (e.g. glucose) and/or condensations (e.g. aldol condensations).
• Curing of the resins may also be effected by the formation of heteropolymers if present in the mixture, for example with compounds such as amines or phenols having free amino or hydroxyl groups, or other nucleophiles.
• Heteropolymer coupling partners may be incorporated either during the preparation of the aldehydes or at the curing stage. Suitable species are generally nucleophiles that can cross-link and become incorporated into the resin structure. Such heteropolymers have modified properties resulting from changes to the cross-linking sites and molecular size of the precursors. Useful properties that can be controlled by the choice of additive include: elasticity, rigidity, brittle fracture, toughness, shrinkage, resistance to abrasion, permeability to liquids and gases, UV resistance and absorbance, biodegradability, density and solvent resistance.
• the properties of the uncured resins may also be usefully modified using additives to control, for example, the viscosity and flow characteristics of the resin on a filler surface or through spray jets.
• additives for example, the viscosity and flow characteristics of the resin on a filler surface or through spray jets.
• materials that can be added to the resins of the invention include aromatics, phenol, resorcinol and other homologues of phenol, CNSL, lignins, tannins and plant and other polyphenols, proteins such as soy protein, gluten, casein, gelatin, and blood albumin; glycols and polyols such as ethylene glycol, glycerol and carbohydrates (e.g.
• sugars and sugar alcohols include amines, amides, urea, thiourea, dicyandiamide, and melamine; isocyanates such as MDI; heterocyclic compounds such as furfural, furfuryl alcohol, pyridine and phosphines.
• Step (3) of the method for forming a resin may be conducted at a temperature about 10°C to 250°C, for example to produce a cured resin.
• Curing may proceed over periods of 30 seconds or longer (for example up to many hours). Longer curing times aid moulding and spinning for example.
• the gel time i.e. onset of setting during the curing process
• the cured resins of the invention may demonstrate excellent water resistance and be impermeable to water at 0- 100°C.
• the heat stability of the cured compositions may be high, for example with degradation temperatures falling within the range 180°C-250°C.
• the cured resins and composites made therefrom may have good thermal insulation properties and hence be useful in block or foams form as insulating materials.
• the cured resins and composites of the invention may have excellent thermal insulation properties.
• One particular use of the resins of the invention is in the manufacture of timberboard.
• the step (3) may be conducted in the presence of a catalyst, for example an alkaline catalyst (such as an alkali metal hydroxide or alkaline earth metal hydroxide, for example sodium hydroxide and potassium hydroxide) or an acid catalyst (such as a sulphonic acid, particularly a substituted sulphonic acid such as an aromatic sulphonic acid, e.g. para- toluenesulphonic acid or methanesulphonic acid).
• a catalyst for example an alkaline catalyst (such as an alkali metal hydroxide or alkaline earth metal hydroxide, for example sodium hydroxide and potassium hydroxide) or an acid catalyst (such as a sulphonic acid, particularly a substituted sulphonic acid such as an aromatic sulphonic acid, e.g. para- toluenesulphonic acid or methanesulphonic acid).
• a catalyst for example an alkaline catalyst (such as an alkali metal hydroxide or alkaline earth metal hydroxide, for example
• catalysts include Lewis acids such as zinc chloride and zinc acetate, aluminium compounds such as aluminium chloride and boron compounds such as boron trifluoride (e.g. in its trifluoroboroetherate form). Still further examples of catalysts include radical initiators such as dibenzoylperoxide or AIBN.
• a method for modifying the cross-linking reactivity of a cross-linking agent for resin formation comprising the step of reacting the cross-linking agent with a volatile aldehyde (for example, from an aldehyde oil) to form an aldehyde-cross-linking agent condensate which has modified cross-linking reactivity compared with unreacted cross-linking agent.
• a volatile aldehyde for example, from an aldehyde oil
• modification of the cross- linking agent encompasses increasing or decreasing cross-linking activity, as desired.
• a cross-linking agent comprising an aldehyde-cross-linking agent condensate obtained by reacting a volatile aldehyde (for example, from an aldehyde oil) with a cross-linking agent.
• the aldehyde-cross-linking agent condensate may be as defined here for other aspects of the invention.
• the aldehyde-cross-linking agent condensate i.e. the volatile aldehyde and/or cross-linking agent components thereof
• may be derived from a vegetable oil. Advantages of the aldehyde-cross-linking agent condensate (the "precondensate") are discussed above.
• a kit for forming a resin comprising:
• an aldehyde-cross-linking agent condensate obtained by reacting a volatile aldehyde with a cross-linking agent obtained by reacting a volatile aldehyde with a cross-linking agent
• the kit may be in the form of a two-pack system wherein a first pack comprises the aldehyde-cross-linking agent condensate and a second pack comprises the triglyceride- bound aldehyde.
• the kit may further comprise an additional cross-linking agent, for example as a component of a or the first and/or a or the second pack and/or in a third pack.
• an additional cross-linking agent for example as a component of a or the first and/or a or the second pack and/or in a third pack.
• the invention encompasses a two part resin system, comprising a first part including an aldehyde-cross-linking agent condensate obtained by reacting a volatile aldehyde with a cross-linking agent, and a second part including a triglyceride-bound aldehyde.
• an additional cross-linking agent may be present, for example as a component of the first and/or second part and/or in a third part.
• Features of the system may be as described for other aspects of the invention.
• the invention provides an improvement over known kits and two part systems for the formation of a resin because the precondensate in particular may be more stable than unreacted volatile aldehyde and/or cross-linking agent used separately in the prior art.
• Components of the kit may be designed to produce a resin with particular properties, for example by increasing or decreasing the cross-linking reactivity of precondensate and/or additional cross-linking agent and/or by modifying the chemical constituents to allow greater control over the resin formation reaction when the packs or parts are combined.
• the precondensate has reduced VOCs so the kit and system is safer than known equivalents.
• the invention also encompasses a resin obtainable by the methods described herein.
• Resins such as bioresins of the invention have a large number of applications, and examples of uses of the resins include the formation and manufacture of moulded panels, non-woven materials, fibre-glass and other fibre and glass reinforced products, boards, paper treatments, fabric treatments, spun textiles, toys (e.g.
• a solid composite material comprising the resin as defined above is envisaged.
• the resin here may be in the form of a cured thermosetting resin.
• the solid composite material may further comprise a particulate or fibrous material.
• the particulate or fibrous material may be an organic material, for example a lignocellulosic material such as a material selected from wood, straw, hemp, jute, flax, coconut fibre, rice straw and maize.
• a particularly suitable lignocellulosic material comprises wood particles or wood fibre.
• particulate or fibrous materials from natural sources are suitable, it is also possible to use fibres or particulate materials of man-made type. For example, such fibres or particles can be formed from polymer compositions, examples being recycled plastics.
• the particulate or fibrous material may alternatively (or additionally) be an inorganic material, for example an inorganic material selected from charcoal, marble (e.g. crushed marble), mineral fibre, mineral particles, ceramics, crushed rock, clay, coal, slate and glass, e.g. fibre glass.
• an inorganic material selected from charcoal, marble (e.g. crushed marble), mineral fibre, mineral particles, ceramics, crushed rock, clay, coal, slate and glass, e.g. fibre glass.
• the solid composite material can take various forms such as, for example, sheet form or moulded form.
• Examples of composite materials in sheet form are boards and panels, particular examples being wood fibre boards such as chipboard, medium density fibre board (MDF), multilayer boards such as plywood, and building boards and panels.
• MDF medium density fibre board
• the measured properties of test wood particle boards in which the binder used has been derived from an aldehyde of the present invention may meet or exceed those required for boards to be of a standard acceptable in the marketplace and meet or exceed the European Standards for Internal Bond Strength, Thickness Swell, and Bending Strength (Standards EN 319, EN 317, and EN 310, respectively).
• the invention provides a solid foam material comprising a matrix formed from a resin of the present invention.
• the foam material typically is formed by reacting the oxidative cleavage product with an isocyanate, for example methylene diphenyl diisocyanate (MDI).
• an isocyanate for example methylene diphenyl diisocyanate (MDI).
• MDI methylene diphenyl diisocyanate
• Foams formed in accordance with the invention can be used as inter alia insulating materials, upholstery padding and packaging.
• cross-linking agent refers to a compound which is a nucleophile and which is capable of reacting with an aldehyde (for example, either or both of the volatile aldehyde or the non-volatile aldehyde of the invention) and/or other resin-forming compounds to form a polymer product.
• the polymer product may, for example, be the aldehyde-cross-linking agent condensate or the resin of the invention.
• Different cross-linking agents may be combined to form the aldehyde-cross-linking agent condensate and/or the polymer product.
• Fig. 1 shows the chemical structures of glyceride-bound aldehyde and nonanal as generated from the reductive ozonolysis of an idealised triolein vegetable oil (prior art);
• Fig. 2 shows the minority products glyceride-bound acid and nonanoic acid as generated from the reductive ozonolysis of an idealised triolein vegetable oil (prior art);
• Fig. 3 shows certain of the condensation reaction products formed by reaction of nonanal and resorcinol in the presence of excess resorcinol
• Fig. 4 is a graph showing reduction of nonanal (an indicator of VOCs) during formation of various aldehyde-cross-linking agent condensates.
• the x-axis represents incubation time at 85°C (in hours) and the y-axis the percentage of nonanal remaining. The numbered lines are explained in Example 2 below;
• Fig. 5 is a graph showing reduction of nonanal (an indicator of VOCs) during formation of aldehyde-cross-linking agents from pine and mimosa tannins.
• the x-axis represents incubation time at 85°C (in hours) and the y-axis the percentage of nonanal remaining. The numbered lines are explained in Example 2 below; and
• Fig. 6 is a graph showing reduction of nonanal (an indicator of VOCs) during formation of aldehyde-cross-linking agents from phloroglucinol.
• the x-axis represents incubation time at 85°C (in hours) and the y-axis the percentage of nonanal remaining. The numbered lines are explained in Example 6 below. Examples
• a known bioresin-producing system using aldehyde oil derived from a vegetable oil combined with resorcinol as a cross-linking agent and alkali catalysis provides satisfactory performance in many applications but has some disadvantages as noted above. Improvements relating to the present invention are elaborated below.
• a system which employs a natural cross-linking agent of non-petrochemical origin (such as tannin) instead of resorcinol is one desirable aspect of the present invention and is investigated in certain of the experiments below.
• a number of bioresin formulations using tannin as cross-linking agent were prepared, using a reduced VOCs or low odour approach of forming an aldehyde-cross-linking agent condensate (also referred to herein as a "precondensate”) from volatile aldehydes of an aldehyde oil, and to study the associated physical performance of the formulations.
• Bioresins according to the invention formed using resorcinol as cross-linking agent are also exemplified and characterised.
• Aldehyde oil obtained from commodity rape seed oil using the optimised reductive ozonoiysis process described in WO03/0500081 was fractionated by rotary evaporation to separate the volatile aldehyde components from the non-volatile aldehydes.
• the volatile fraction (VF", or volatile aldehyde fraction; principally nonanal) was then recombined variously with tannin extracted from mimosa bark and incubated at 85°C or 95°C over a period of up to 67 hours, and the reduction in volatile aldehydes determined by measurement of nonanal using gas chromatography-mass spectrometry (GC-MS).
• GC-MS gas chromatography-mass spectrometry
• a 1g sample of the precondensate incubation was prepared as a 10% w/w solution in methanol/water (1 :1 ).
• the sample was spiked with 50 ⁇ n-octanal internal standard, then 0.5 ⁇ samples (split 100:1) were analysed by GC-MS using a Hewlett Packard 5890 II gas chromatograph linked to a VG-TRIO 1 mass spectrometer.
• the GC column used was a 60 m x 0.32 mm I.D. 5.0 pm df DB1 capillary column, programmed from 35°C (1 min.) to 250°C (14.4 min.) at 25°C/min.
• Electron ionisation mass spectrometry was performed by scanning m/z 25 to m/z 250. The data are shown below in Table 1.
• compositional detail for samples 1 to 5 in Tablel is:
• the numbered lines in Fig. 4 represent: (1 ) quebracho tannin with 3% w/w sodium hydroxide catalyst; (2) spruce tannin with 2% w/w sodium hydroxide catalyst; (3) spruce tannin with no added catalyst (4) Chestnut tannin with 3%w/w sodium hydroxide catalyst; (5) quebracho tannin with 1%w/w sodium hydroxide catalyst; (6) quebracho tannin with no added catalyst; and (7) chestnut tannin with 1 %w/w sodium hydroxide catalyst.
• Fig. 5 The results are shown in Fig. 5, in which the horizontal axis represents the incubation time at 85°C (hours) and the vertical axis the percentage of nonanal remaining, as determined by the periodic removal of sub samples and quantitative analysis by GC-MS using octanal as a spiked internal standard.
• the numbered lines represent: (1 ) pine tannin with no added catalyst; (2) mimosa tannin with no added catalyst.
• a bioresin formed inter alia from the precondensate and tannin was prepared as described in Example 1 and selected to have minimal VOCs as determined by GC analysis.
• the bioresin was prepared using a two-pack system comprising the following components: (1 ) a aldehyde-cross-linking agent condensate in the form of a tannin/nonanal precondensate (TN), 58.36% solids in water; and (2) a non-volatile aldehyde in the form of an aldehyde oil glyceride fraction (AOG), 100% solids.
• TN tannin/nonanal precondensate
• AOG aldehyde oil glyceride fraction
• the bioresin was prepared from the two components by mixing AOG and TN in the ratio 1 :4.46 (AOG:TN) to be equivalent to the overall composition of a control mixture of tannin and aldehyde oil in the ratio 2:1 (tannin:aldehyde oil). As mixed, the bioresin had 65.6% solids. 3.1 Physical Properties
• Resin was prepared by mixing the components of the two-pack system and diluting it to 50% resin solids with water. The viscosity of the solution was determined across a range of temperatures and the results are shown in Table 2. Table 2. The effect of temperature on the viscosity of bioresin formed using precondensate
• the viscosity of the bioresin is highly sensitive to temperature and handling can be improved significantly by heating from ambient to 40 - 50°C.
• bioresin was tested across a range of binder formulations to determine the rate of curing and the strength of the resulting binder.
• Formulations were standardised on the mass of resin solids, and controls were included for comparison from standard resorcinol-catalysed bioresin systems and non-precondensed (i.e. unfractionated) aldehyde oil/tannin mixtures.
• Binder strength was assessed by preparing sand/resin composite discs.
• the discs were prepared by mixing sand with resin formulated as a 30% resin solids emulsion in water to provide a loading on the sand of 3% w/w.
• the breaking force under test was recorded as a measure of the binder strength.
• Binders were formulated from AOG/TN combined as above together with variable additions of sodium hydroxide catalyst, 1% - 7%, and urea, 0% - 10% on a resin basis. Earlier work with resorcinol resins had indicated the effect of urea on increasing the curing rate of binders.
• Binder formulations were prepared at 30% resin solids as emulsions in water and applied to sand to give a loading of 3% resin on the test disc. Control formulations had equivalent loadings.
• Test discs 2.5cm diameter x 0.5cm thick, were prepared by filling the wet sand/binder mix into steel moulds and heating them for the required time on a hotplate set to the required curing temperature. Discs were allowed to cool and subjected to the mechanical test. The results obtained for curing at 150°C for 10, 20, 30 or 40 minutes, together with the formulation details for urea and alkali are shown in Table 3 and compared with controls.
• the results demonstrate a range of binder quality based on the strength achieved under the chosen curing conditions.
• the PCR control is the target with high strength achieved in 20 minutes.
• the benefit of precondensation i.e. the formation of an aldehyde-cross-linking agent condensate
• the non-precondensed mixture achieves a similar strength to PCR but requires a longer curing time.
• the results for AO/T1 indicate the relatively poor performance for tannin binder without precondensation. Even increased catalyst and urea addition are not able to improve that performance sufficiently, as shown by AO/T2.
• the tannin precondensate bioresins show significant improvement over the straight mixtures AO/T resins.
• the acid cured system was inferior to the alkali binders discussed above even though much higher addition levels were used for the acid system. Reducing the acid addition to 7% resulted in a further decrease in performance. Addition of urea was ineffective at increasing the strength of the binder at 150°C as was further addition of acid up to 20% where there was evidence of hydrolysis damage to the cured resin after 40 minutes heating. The poor performance of the urea-supplemented binder was unexpected given the positive effect of urea under alkaline curing conditions.
• the gel time test was modified to accommodate the very high reactivity of the phloroglucinol precondensate (PGN; i.e. phloroglucinol pre-condensed with the volatile fraction removed from rapeseed oil-derived bioresin aldehyde oil) with AOG (i.e. the non-volatile glyceride residue following the removal of the volatile fraction of the vegetable oil-derived bioresin aldehyde oil).
• PGN phloroglucinol precondensate
• AOG i.e. the non-volatile glyceride residue following the removal of the volatile fraction of the vegetable oil-derived bioresin aldehyde oil
• Fig. 6 demonstrates that a faster reduction of VOCs can be achieved during formation of an aldehyde-cross-linking agent condensate using a higher incubation temperature, and that certain precodensates such as PCN do not require catalyst for their formation.
• Example 7 Characteristics of products made from PGN-derived and other resins
• a 3 ply, 9 cm x 3 cm composite panel was prepared using chopped glass mat (c. 300 g/m 2 ).
• the binder was prepared by mixing PGN with AOG and adding catalyst as 30% sodium hydroxide to give the required catalyst level. Binder was applied to the mat and subsequent layers built up. The composite was cured at 80°C for 2 hours upwards.
• the panels, together with a control using resorcinol as a cross- linking agent, were compared for Modulus of Rigidity (GPa).
• GPa Modulus of Rigidity
• a formulation was prepared also containing 30% isopropanol.
• phloroglucinol such as for pre- condensation with the volatile fraction from bioresin aldehyde oil
• water in combination with organic solvents such as, but not limited to, isopropanol, ethylene glycol, propylene glycol, glycerol, diethylene glycol, dipropylene glycol.
• alkalis such as sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate and so on, can be employed to further assist dissolution.
• the improved solution/dispersibility afforded by the use of isopropyl alcohol solvent was sufficient to elevate the performance of the composite panel to that of the resorcinol control.
• Table 9 shows panels made with resins based on mimosa tannin cross-linking agent alone, phloroglucinol cross-linking agent alone, and with combinations of both.
• the % BOR is the percentage addition based on total resin solids. Under these test conditions, chosen to be discriminatory, the TN performance could be enhanced considerably by a relatively modest addition of PG (PT1 ) to give a performance comparable to and possibly exceeding that of PG alone.
• Table 9 Mechanical data for composite panels
• nonanal the principal constituent of the volatile aldehyde fraction removed from aldehyde oil
• resorcinol a 1 :2 stoichiometric ratio (nonanal:resorcinol) at 85°C in a solvent-free system.
• the nonanal was consumed in less than 5 hours yet, as shown in Table 6, the resorcinol continues to be consumed until it steadies after around 24 hours with around 40% remaining unreacted.
• resorcinol The consumption of >50% resorcinol suggests that some of the dimer also remains. The fact that resorcinol reaches a point where little more is consumed suggests that the end product is limited to an oligomer which does not polymerise further in the absence of free aldehyde, rather than a linear polymer.
• the nonanal-resorcinol precondensate would also comprise structures such as larger linear oligomers, for example trimers, tetramers, pentamers, etc. (not shown in Fig. 3). Table 10. Resorcinol depletion during formation of a nonanal-resorcinol condensate starting with 2:1 molar excess over nonanal
• mimosa tannin 200g of a 50% solution in water, is mixed with 10g of its volatile fraction. Catalyst is added as 7g of 30% sodium hydroxide solution and the mixture is incubated at 85°C for 25 hours. Phloroglucinol, 30g, and its volatile fraction, 17g, is added to the mixture which is incubated for a further 5 hours at 85 C. The mixture is cooled to ambient temperature and formulated with 110g of non-volatile glyceride-bound aldehyde (AOG) fraction to make a thermosetting resin.
• AOG non-volatile glyceride-bound aldehyde
• the resin is prepared by first precondensing the volatile fraction with a mixture of tannin and phloroglucinol at the same time rather than preparing two separate cross-linking agents (TN and P) for formulation with AOG.
• This approach is beneficial as only one cross- linking agent needs to be prepared and blended with AOG rather than two (as shown for example for "PT1" in Example 7 above).
• Aldehyde oil was fractionated into volatile and non-volatile components by rotary evaporation.
• the volatile component (1 part) was precondensed with resorcinol (1.75 parts) by incubation at 85 deg C for 22 hours, and the resulting precondensate combined with the non-volatile fraction in the ratio 8.0 (non-volatile) to 5.5 (precondensate) to form a bioresin.
• the bioresin was formulated into a binder emulsion with water to 30% solids and added to sand at 10% giving a loading of 3% w/w on the basis of sand.
• Catalyst was included as sodium hydroxide at 1% w/w on the basis of resin solids.
• the sand was moulded into discs 2.5 cm diameter x 0.5 cm thick.
• the discs were cured at 200°C for 10 minutes, cooled and then subjected to a breaking test as described earlier for the tannin precondensates.
• the breaking force of the bioresin was equivalent to that obtained with a similar loading of a phenol formaldehyde resin.

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