One part woodworking adhesive composition

Abstract

An adhesive composition that includes a) an emulsion that includes a multi-stage polymer that includes a first stage polymer having a Tg from −20° C. to 90° C. and including from about 0.5% by weight to about 3% by weight latent crosslinking monomer based on the first stage monomer weight, and a second stage polymer having a Tg from 40° C. to 140° C., the second stage polymer being different from the first stage polymer, b) formaldehyde-based crosslinking agent, and c) catalyst, the composition being capable of passing the DIN EN 204 Test Method.

What is claimed is:  
     
         1 . An adhesive composition comprising: 
 a) an emulsion comprising a multi-stage polymer comprising 
 a first stage polymer having a Tg from −20° C. to 90° C. and comprising from about 0.5% by weight to about 3% by weight latent crosslinking monomer based on the first stage monomer weight, and  
 a second stage polymer having a Tg from 40° C. to 140° C., said second stage polymer being different from said first stage polymer;  
   b) formaldehyde-based crosslinking agent; and    c) catalyst,    said adhesive composition being capable of passing the DIN EN 204 Test Method.    
     
     
         2 . The adhesive composition of  claim 1 , wherein said adhesive composition passes the WATT-91 Test Method.  
     
     
         3 . The adhesive composition of  claim 1 , wherein said adhesive composition passes the WATT-91 Test Method aging in a sealed container for at least 30 days at 23° C.  
     
     
         4 . The adhesive composition of  claim 1 , wherein said adhesive composition passes the WATT-91 Test Method after aging in a sealed container for at least 2 months at 23° C.  
     
     
         5 . The composition of  claim 1 , wherein said adhesive composition passes the DIN EN 204 Test Method after aging in a sealed container for at least 2 months at 23° C.  
     
     
         6 . The composition of  claim 1 , wherein said adhesive composition passes the WATT-91 Test Method after aging in a sealed container for at least 3 months at 23° C.  
     
     
         7 . The composition of  claim 1 , wherein said adhesive composition passes the WATT-91 Test Method after aging in a sealed container for at least 6 months at 23° C.  
     
     
         8 . The adhesive composition of  claim 1 , wherein said second stage polymer comprises from about 0.1% by weight to about 10% by weight latent crosslinking monomer based on the second stage monomer weight.  
     
     
         9 . The composition of  claim 1 , wherein said catalyst comprises an acid catalyst.  
     
     
         10 . The composition of  claim 1 , wherein said catalyst is selected from the group consisting of hydrochloric acid, sulfuric acid, phosphoric acid, p-toluene sulfonic acid, and combinations thereof.  
     
     
         11 . The composition of  claim 1 , wherein said catalyst comprises Lewis acid.  
     
     
         12 . The composition of  claim 1 , wherein said catalyst is selected from the group consisting of aluminum chloride, iron chloride, zirconium oxychloride, chromic nitrate, chromic perchlorate, aluminum nitrate, iron nitrate and zinc nitrate.  
     
     
         13 . The composition of  claim 1 , wherein said first stage polymer has a Tg from 0° C. to 70° C.  
     
     
         14 . The composition of  claim 1 , wherein said first stage polymer has a Tg from 20° C. to 50° C.  
     
     
         15 . The composition of  claim 1 , wherein said first stage polymer comprises vinyl ester.  
     
     
         16 . The composition of  claim 1 , wherein said first stage polymer comprises vinyl acetate.  
     
     
         17 . The composition of  claim 16 , wherein said first stage polymer further comprises vinyl ester other than vinyl acetate.  
     
     
         18 . The composition of  claim 16 , wherein said first stage polymer further comprises vinyl ester of versatic acid.  
     
     
         19 . The composition of  claim 1 , wherein said second stage polymer has a Tg from 60° C. to 120° C.  
     
     
         20 . The composition of  claim 1 , wherein said second stage polymer has a Tg from 80° C. to 120° C.  
     
     
         21 . The composition of  claim 1 , wherein said second stage polymer comprises methyl methacrylate.  
     
     
         22 . The composition of  claim 1 , wherein said second stage polymer comprises styrene, acrylonitrile, vinyl pivalate, or a combination thereof.  
     
     
         23 . The composition of  claim 18 , wherein said second stage polymer comprises methyl methacrylate.  
     
     
         24 . The adhesive composition of  claim 1 , wherein said multi-stage polymer comprises from 0.5% by weight to 60% by weight second stage polymer based on the weight of said first stage polymer.  
     
     
         25 . The adhesive composition of  claim 1 , wherein said multi-stage polymer comprises from 1% by weight to about 30% by weight second stage polymer based on the weight of said first-stage polymer.  
     
     
         26 . The adhesive composition of  claim 1 , wherein said multi-stage polymer comprises from 1% by weight to 10% by weight second stage polymer based on the weight of said first-stage polymer.  
     
     
         27 . The composition of  claim 1 , further comprising coalescing agent, urea, alcohol, plasticizer, antifoam, filler, biocide, tackifier, fire retardant, thickener, preservative, or a combination thereof.  
     
     
         28 . The composition of  claim 1 , wherein said first stage polymer comprises from about 1% by weight to about 2.5% by weight latent crosslinking monomer based on the first stage monomer weight.  
     
     
         29 . The composition of  claim 1 , wherein said multi-stage polymer comprises from about 1% by weight to about 2% by weight latent crosslinking monomer based on the first stage monomer weight.  
     
     
         30 . The composition of  claim 1 , wherein said formaldehyde-based crosslinking agent is selected from the group consisting of resorcinol formaldehyde, urea-formaldehyde, melamine-formaldehyde, phenol-formaldehyde, trimethylol phenol, acrylamide-formaldehyde adducts, and combinations thereof.  
     
     
         31 . The composition of  claim 1 , comprising from about 1% by weight to about 10% by weight formaldehyde-based crosslinking agent.  
     
     
         32 . The composition of  claim 1 , further comprising alcohol.  
     
     
         33 . An adhesive composition comprising: 
 a) an emulsion comprising a multi-stage polymer comprising 
 a first stage polymer having a Tg from −20° C. to 90° C.,  
 a second stage polymer having a Tg from 40° C. to 140° C., said second stage polymer being different from said first stage polymer, and  
 latent crosslinking monomer;  
   b) formaldehyde-based crosslinking agent; and    c) catalyst,    said adhesive composition being capable of passing the DIN EN 204 Test Method after having been stored in a sealed container at 23° C. for at least 30 days.    
     
     
         34 . The adhesive composition of  claim 33 , wherein said adhesive composition passes the WATT-91 Test Method.  
     
     
         35 . The adhesive composition of  claim 33 , wherein said adhesive composition passes the WATT-91 Test Method after aging in a sealed container for at least 30 days at 23° C.  
     
     
         36 . The adhesive composition of  claim 33 , wherein said adhesive composition passes the WATT-91 Test Method after aging in a sealed container for at least 2 months at 23° C.  
     
     
         37 . The composition of  claim 33 , wherein said adhesive composition passes the DIN EN 204 Test Method after aging in a sealed container for at least 2 months at 23° C.  
     
     
         38 . The composition of  claim 33 , wherein said adhesive composition passes the WATT-91 Test Method after aging for at least 3 months at 23° C.  
     
     
         39 . The composition of  claim 33 , wherein said adhesive composition passes the DIN EN 204 Test Method after aging in a sealed container for at least 3 months at 23° C.  
     
     
         40 . The composition of  claim 33 , wherein said adhesive composition passes the WATT-91 Test Method after aging for at least 6 months at 23° C.  
     
     
         41 . The composition of  claim 33 , wherein said adhesive composition passes the DIN EN 204 Test Method after aging in a sealed container for at least 6 months at 23° C.  
     
     
         42 . The composition of  claim 33 , wherein said adhesive composition, after aging in a sealed container for at least 2 months at 23° C., passes the DIN EN 204 Test Method and the WATT-91 Test Method.  
     
     
         43 . The composition of  claim 33 , wherein said adhesive composition, after aging in a sealed container for at least 3 months at 23° C., passes the DIN EN 204 Test Method and the WATT-91 Test Method.  
     
     
         44 . The composition of  claim 33 , wherein said adhesive composition, after aging in a sealed container for at least 6 months at 23° C., passes the DIN EN 204 Test Method and the WATT-91 Test Method.  
     
     
         45 . An article comprising: 
 a substrate; and    an adhesive composition comprising the reaction product of 
 a) an emulsion comprising a multi-stage polymer comprising 
 a first stage polymer having a Tg from −20° C. to 90° C. and comprising from about 0.5% by weight to about 3% by weight latent crosslinking monomer based on the first stage monomer weight, and  
 a second stage polymer having a Tg from 40° C. to 140° C., said second stage polymer being different from said first stage polymer;  
 
 b) formaldehyde-based crosslinking agent; and  
 c) catalyst,  
   said adhesive composition being capable of passing the DIN EN 204 Test Method.    
     
     
         46 . The article of  claim 45 , wherein said substrate comprises wood.  
     
     
         47 . The article of  claim 45 , comprising a second substrate, said first substrate being bonded to said second substrate through said adhesive composition.  
     
     
         48 . An article comprising: 
 a substrate; and    an adhesive composition comprising the reaction product of 
 a) an emulsion comprising a multi-stage polymer comprising 
 a first stage polymer having a Tg from −20° C. to 90° C.,  
 a second stage polymer having a Tg from 40° C. to 140° C., said second stage polymer being different from said first stage polymer, and  
 latent crosslinking monomer,  
 
 b) formaldehyde-based crosslinking agent, and  
 c) catalyst,  
   said adhesive composition being capable of passing the DIN EN 204 Test Method after aging in a sealed container at 23° C. for 30 days.    
     
     
         49 . A method of bonding substrates, said method comprising: 
 a) contacting a first substrate with the adhesive composition of  claim 1;  and    b) contacting said adhesive composition with a second substrate.    
     
     
         50 . The method of  claim 49 , further comprising applying pressure to said substrate construction to bond said first substrate to said second substrate through said adhesive composition.  
     
     
         51 . The method of  claim 49 , further comprising applying heat to said substrate construction to bond said first substrate to said second substrate through said adhesive composition.  
     
     
         52 . The method of  claim 49 , further comprising applying radio frequency to said substrate construction.  
     
     
         53 . A method of bonding substrates, said method comprising: 
 a) contacting a first substrate with the adhesive composition of  claim 33;  and    b) contacting said adhesive composition with a second substrate.