Lignosulfonate-phenol-formaldehyde resin binder

Abstract

A method of manufacturing a lignosulfonate-phenol-formaldehyde resin includes heating a mixture of phenol, formaldehyde, lignosulfonate and alkali at a temperature of 60° C. to 100° C. and a pH of 8-13. The lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate and the lignosulfonate is mixed with said phenol and formaldehyde before substantial reaction between said phenol and said formaldehyde. Also disclosed are fibrous articles manufactured using this resin as a binder.

What is claimed: 
     
       1. A method of manufacturing a lignosulfonate-phenol-formaldehyde resin comprising heating a mixture of phenol, formaldehyde, lignosulfonate and alkali wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate.Iadd., said lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process, .Iaddend.and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before substantial reaction between said phenol and said formaldehyde; and   heating said mixture to form a lignosulfonate-phenol-formaldehyde polymer.   
     
     
       2. The method of claim 1 wherein said mixture is heated at a temperature of 60° C. to 100° C. and at a pH of 8-13 to form said polymer. 
     
     
       3. The method of claim 1 wherein said phenol, formaldehyde and lignosulfonate are mixed prior to heating. 
     
     
       4. The method of claim 1 wherein said lignosulfonate comprises abouit 30% to about 60% by total weight of lignosulfonate, phenol and formaldehyde. 
     
     
       5. The method of claim 1 wherein said lignosulfonate comprises about 40% to about 50% by total weight of lignosulfonate, phenol and formaldehyde. 
     
     
       6. A method of manufacturing a man-made board comprising contacting a plurality of fibers with a lignosulfonate-phenol-formaldehyde resin and hot pressing said resin contacted fibers together to cause said fibers to adhere to each other in a desired configuration, wherein said resin is formed by heating a mixture of lignosulfonate, phenol and formaldehyde, .Iadd.said lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process, .Iaddend.said lignosulfonate being added to said phenol and formaldehyde under alkaline conditions before a substantial amount of reaction between said phenol and said formaldehyde and heating said mixture to form said polymer. 
     
     
       7. The method of claim 6 wherein said mixture is heated at a pH of 8-13 for a period of time sufficient that said polymer has a viscosity in the range of 10 to 200 centipoises and then cooling the reaction mixture to retard further polymerization. 
     
     
       8. A method of molding a fibrous object having a predetermined configuration comprising disposing a fiber-resin composition in a mold cavity, closing said mold cavity and applying heat and pressure to said composition to adhere said composition together into said predetermined configuration, wherein said fiber-resin composition comprises a plurality of fibers and a lignosulfonate-phenol-formaldehyde resin formed by mixing a lignosulfonate, phenol and formaldehyde to form a reaction mixture adding alkali incrementally to control the temperature rise of the mixture during reaction and heating said mixture to polymerize said mixture, .Iadd.said lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process, .Iaddend.said lignosulfonate being added to said mixture under alkaline conditions before a substantial amount of reaction between said said phenol and said formaldehyde. 
     
     
       9. The method of claim 8 wherein said lignosulfonate comprises about 50% to about 80% by total weight of lignosulfonate, phenol and formaldehyde in said resin mixture. 
     
     
       10. The method of claim 9 wherein said lignosulfonate comprises about 40% to about 60% by total weight of lignosulfonate, phenol and formaldehyde in said resin mixture. 
     
     
       11. The method of claim 8 including heating said resin mixture at a temperature of about 85° to about 95° C. to form said polymer. 
     
     
       12. An article of manufacture comprising a plurality of fibers adhered together under heat and pressure with a lignosulfonate-phenol-formaldehyde resin wherein said resin is formed by mixing a lignosulfonate, phenol, formaldehyde, and an alkali to form a reaction mixture and heating said mixture to polymerize said mixture, .Iadd.said lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process, .Iaddend.said lignosulfonate being added to said reaction mixture before a substantial amount of reaction between said phenol and said formaldehyde. 
     
     
       13. The article of claim 12 wherein said lignosulfonate comprises about 30% to about 60% by total weight of lignosulfonate, phenol and formaldehyde in said resin mixture. 
     
     
       14. The article of claim 12 wherein said lignosulfonate comprises about 40% to about 50% by total weight of lignosulfonate, phenol and formaldehyde in said resin mixture. 
     
     
       15. The article of claim 12 wherein fibers include cellulosic fibers. 
     
     
       16. The article of claim 15 wherein said cellulosic fibers are wood fibers. 
     
     
       17. The article of claim 12 wherein said fibers include fiberglass. 
     
     
       18. A lignosulfonate-phenol-formaldehyde resin formed by heating a mixture of phenol, formaldehyde, a lignosulfonate and alkali wherein said lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate.Iadd., said lignosulfonate consisting essentially of the lignosulfonates in a waste sulfite or sulfited cooking liquor as recovered from a pulping process, .Iaddend.and wherein said lignosulfonate is mixed with said phenol and formaldehyde under alkaline conditions before a substantial amount of reaction between said phenol and said formaldehyde; and   heating said mixture at a temperature of 60° C. to 100° C. to form a lignosulfonate-phenol-formaldehyde polymer;   cooling said reaction mixture when the viscosity reaches 10 to 200 centipoises to retard further polymerization.   
     
     
       19. The resin of claim 18 wherein the reaction mixture is diluted to 10 to 30% solids after the viscosity of the reaction mixture reaches 10 to 200 centipoises to prevent further polymerization. 
     
     
       20. The resin of claim 19 wherein the reaction mixture is diluted with water.