Curing of low level melamine‐modified urea‐formaldehyde particleboard binder resins studied with dynamic mechanical analysis (DMA)

Effects of resin formulation, catalyst, and curing temperature were studied for particleboard binder‐type urea‐formaldehyde (UF) and 6 ～ 12% melamine‐modified urea‐melamine‐formaldehyde (UMF) resins using the dynamic mechanical analysis method at 125 ～ 160°C. In general, the UF and UMF resins gelled and, after a relatively long low modulus period, rapidly vitrified. The gel times shortened as the catalyst level and resin mix time increased. The cure slope of the vitrification stage decreased as the catalyst mix time increased, perhaps because of the deleterious effects of polymer advancements incurred before curing. For UMF resins, the higher extent of polymerization effected for UF base resin in resin synthesis increased the cure slope of vitrification. The cure times taken to reach the vitrification were longer for UMF resins than UF resins and increased with increased melamine levels. The thermal stability and rigidity of cured UMF resins were higher than those of UF resins and also higher for resins with higher melamine levels, to indicate the possibility of bonding particleboard with improved bond strength and lower formaldehyde emission. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 377–389, 2005     

Evaluation of melamine‐modified urea‐formaldehyde resins as particleboard binders

Particleboards bonded with 6 and 12% melamine‐modified urea‐formaldehyde (UMF) resins were manufactured using two different press temperatures and press times and the mechanical properties, water resistance, and formaldehyde emission (FE) values of boards were measured in comparison to a typical urea‐formaldehyde (UF) resin as control. The formaldehyde/(urea + melamine) (F/(U + M)) mole ratio of UMF resins and F/U mole ratio of UF resins were 1.05, 1.15, and 1.25 that encompass the current industrial values near 1.15. UMF resins exhibited better physical properties, higher water resistance, and lower FE values of boards than UF resin control for all F/(U + M) mole ratios tested. Therefore, addition of melamine at these levels can provide lower FE and maintain the physical properties of boards. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Hydroxymethylation and polycondensation reactions in urea–formaldehyde resin synthesis

Formaldehyde–urea (F/U) reaction products with molar ratios of 1.8, 2.1, and 2.4 were synthesized at pH 8.3, and the last one also at pH 4.5 using 45% formaldehyde aqueous solution. For obtaining the resin, the synthesis of F/U 2.1 was continued by acid‐catalyzed condensation at pH 4.5 and posttreatment with second part of U (F/U 1.05/1) at 70°C and pH 8.3. The products were analyzed using ¹³C‐NMR spectrometry. Higher excess of F increases the dihydroxymethyl content on account of smaller dimethylene ether content. Certain ¹³C chemical shifts in carbonyl and methylene region of spectra were assigned to trishydroxymethylurea, being the main trisubstituted urea compound in hydroxymethylated product. Acid catalyst promotes the formation of methylene groups by polycondensation of hydroxymethyl groups, against the background of similar content of dimethylene ethers in both catalytic conditions. The ratio of linear/branched chains is emphasized in characterizing the resin structure. Higher hydroxymethyl content in acid‐catalyzed polycondensation is an advantage of three‐step synthesis technology. The amount of binding methylene and dimethylene ether groups linked only to secondary amino groups can be increased by transhydroxymethylation with subsequent polycondensation in posttreatment with U in suitable reaction conditions. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 1673–1680, 2006     

Colloidal aggregation of aminoplastic polycondensation resins: Urea–formaldehyde versus melamine–formaldehyde and melamine–urea–formaldehyde resins

Colloidal particles formation followed by their clustering have been shown to be the normal way of ageing of aminoplastic resins, namely urea–formaldehyde (UF) resins, melamine–formaldehyde (MF) resins, and melamine–urea–formaldehyde (MUF) resins. Ageing or further advancement of the resin by other means such as longer condensation times causes whitening of the resin. This is a macroscopic indication of both the formation of colloidal particles and of their clustering. It eventually progresses to resins, which are mostly in colloidal, clustered state, followed much later on by a supercluster formation starting to involve the whole resin. The initial, filament‐like colloidal aggregates formed by UF resins have different appearance than the globular ones formed by MF resins. MUF resins present a short rod‐like appearance hybrid between the two. GPC has been shown to detect the existence of colloidal superaggregates in a UF resin, while smaller aggregates might not be detected at all. The star‐like structures visible in the colloidal globules of MF resins are likely to be light interference patterns of the early colloidal structures in the resins. These star‐like interference patterns become more complex with resin ageing or advancement due to the advancement of the resin to more complex aggregates, to eventually reach the stage in which filament‐like and rod‐like structures start to appear. The next step is formation of globular masses that are representative of the true start of physical gelation. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 1406–1412, 2006     

Hydrolytic stability of cured urea‐formaldehyde resins modified by additives

Urea‐formaldehyde (UF) resins are prone to hydrolysis that results in low‐moisture resistance and subsequent formaldehyde emission from UF resin‐bonded wood panels. This study was conducted to investigate hydrolytic stability of modified UF resins as a way of lowering the formaldehyde emission of cured UF resin. Neat UF resins with three different formaldehyde/urea (F/U) mole ratios (1.4, 1.2, and 1.0) were modified, after resin synthesis, by adding four additives such as sodium hydrosulfite, sodium bisulfite, acrylamide, and polymeric 4,4′‐diphenylmethane diisocyanate (pMDI). All additives were added to UF resins with three different F/U mole ratios before curing the resin. The hydrolytic stability of UF resins was determined by measuring the mass loss and liberated formaldehyde concentration of cured and modified UF resins after acid hydrolysis. Modified UF resins of lower F/U mole ratios of 1.0 and 1.2 showed better hydrolytic stability than the one of higher F/U mole ratio of 1.4, except the modified UF resins with pMDI. The hydrolytic stability of modified UF resins by sulfur compounds (sodium bisulfate and sodium hydrosulfite) decreased with an increase in their level. However, both acrylamide and pMDI were much more effective than two sulfur compounds in terms of hydrolytic stability of modified UF resins. These results indicated that modified UF resin of the F/U mole ratio of 1.2 by adding acrylamide was the most effective in improving the hydrolytic stability of UF resin. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

A very simple empirical kinetic model of the acid‐catalyzed cure of urea–formaldehyde resins

The hot pressing operation is the final stage in MDF (medium density fiberboard) manufacture; the fiber mat is compressed and heated up to promote the cure of the resin. The aim of the investigations is to study the curing reactions of UF (Urea–Formaldehyde) resins as commonly used in the production of MDF, and to develop a simplified kinetic model. This investigation has combined Raman spectroscopy to study the reaction cure and ¹³C‐NMR for the quantitative and qualitative characterization of the liquid and still uncured resin. Raman spectroscopy was found very interesting for the study of the resin cure and permitted to obtain kinetic data as the basis for a simple empirical model, considering a homogeneous irreversible reaction of a single kind of methylol group and ureas with rate constants depending on their degree of substitution. Although these results can provide a better understanding of the composition and the cure of an UF resin, several issues remain open, such as the influence of the reversibility of the reactions taking place during the curing process as well as the possible formation of cyclic groups in the resin. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 5977–5987, 2006     

Blocked melamine–urea–formaldehyde resins and their usage in agglomerated cork panels

Caprolactam and o‐p‐toluenesulfonamide are tested as chain‐growth blockers for melamine–urea–formaldehyde (MUF) resins, in an attempt to reduce the crosslinking density of the cured resin and hence improve its flexibility. Agglomerated cork panels, for which flexibility is a technical demand, were produced with the modified resins and tested. The blockers were added at three different steps in the synthesis process: methylolation, condensation, and at the end of the synthesis. Besides evaluation of standard properties, resins were characterized using gel permeation chromatography and Fourier transform infrared. Blocked resins showed better storage stability and improved water tolerance, especially when caprolactam was employed. When used as binders in agglomerated cork panels, the blocked resins allowed for significantly better flexibility, evaluated in terms of mandrel bending test. The tensile resistance of the panels remained well within the desired limits for this type of material. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46663.     

Upgrading melamine–urea–formaldehyde polycondensation resins with buffering additives. I. The effect of hexamine sulfate and its limits

Iminoamino methylene base intermediates obtained by the decomposition of hexamethylenetetramine (hexamine) stabilized by the presence of strong anions such as SO and HSO, or hexamine sulfate, were shown to markedly improve the water and weather resistance of hardened melamine–urea–formaldehyde (MUF) resins used as wood adhesives and of the wet internal bond strength performance of wood boards bonded with them. The effect was shown to be induced by very small amounts, between 1 and 5 wt % of this material on resin solid content. This strong effect allowed the use of MUF resins of much lower melamine content and also provided good performance of the bonded joints. Because the main effect was also present at the smaller proportion of hexamine as hexamine sulfate, it was not due at all to any increase in the molar ratio of the resin as a consequence of hexamine sulfate addition. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 203–214, 2003     

13C‐NMR study on the structure of phenol‐urea‐formaldehyde resins prepared by methylolureas and phenol

Phenol‐urea‐formaldehyde (PUF) resins were synthesized by reacting mixture of methylolureas (MMU), phenol, and formaldehyde. The structure of PUF cocondensed resins at different stages of reaction were analyzed by liquid ¹³C nuclear magnetic resonance (NMR) spectroscopy. The liquid ¹³C‐NMR analysis indicated that methylolureas had the dominant content in MMU with the reaction between urea and formaldehyde under the alkaline condition. The PUF cocondensed resins had no free formaldehyde. methylolureas were well incorporated into the cocondensed resins by reacting with phenolic units to form cocondensed methylene bridges. The second formaldehyde influenced the further reaction and the structure of the PUF resins. The resins with the prepared method of PUFB possessed relatively high degree of polymerization and low proportion of unreacted methylol groups. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Rheometry of aging of colloidal melamine–urea–formaldehyde polycondensates

Aged and whitened melamine–urea–formaldehyde (MUF) resins in a colloidal state were tested with parallel‐plate rheometry to determine the extent of their viscoelastic behavior. Only in advanced colloidal states, and so only when aggregated colloidal clusters occurred, did the resins present clear indications of viscoelastic responses, as illustrated by the crossover of elastic modulus and viscous modulus curves at lower strain percentages. These colloidal clusters were labile microstructures, which, broken by applied shear, justified the known thixotropic behavior of these resins sufficiently advanced by aging or other means. MUF resins already in the colloidal state, but for which colloidal clustering had not yet occurred, behaved exclusively as viscous liquids. Two different cases of physical gelation were observed, reversible physical gelation and irreversible physical gelation, underlying which a true gel situation possibly occurred. Physical gelation due to colloidal superstructures occurred in both, but the difference in the resin average molecular masses revealed if the physical gelation was reversible or irreversible and, therefore, if the liquid/cluster separation was defined as the terminal phase of physical gelation. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 96: 655–659, 2005     

Uron and uron–urea‐formaldehyde resins

The favored pH ranges for the formation of urons in urea‐formaldehyde (UF) resins preparation were determined, these being at pH's higher than 6 and lower than 4 at which the equilibrium urons ↔ N,N′‐dimethylol ureas are shifted in favor of the cyclic uron species. Shifting the pH slowly during the preparation from one favorable range to the other causes shift in the equilibrium and formation of a majority of methylol ureas species, whereas a rapid change in pH does not cause this to any great extent. UF resins in which uron constituted as much as 60% of the resin were prepared and the procedure to maximize the proportion of uron present at the end of the reaction is described. Uron was found to be present in these resins also as linked by methylene bridges to urea and other urons and also as methylol urons, the reactivity of the methylol group of this latter having been shown to be much lower than that of the same group in methylol ureas. Thermomechanical analysis (TMA) tests and tests on wood particleboard prepared with uron resins to which relatively small proportions of urea were added at the end of the reaction were capable of gelling and yielding bonds of considerable strength. Equally, mixing a uron‐rich resin with a low F/U molar ratio UF resin yielded resins of greater strength than a simple UF of corresponding molar ratio indicating that UF resins of lower formaldehyde emission with still acceptable strength could be prepared with these resins. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 72: 277–289, 1999     

Pyrolysis of melamine–formaldehyde and urea–formaldehyde resins

Pyrolysis of melamine–formaldehyde and urea–formaldehyde resins in helium and air was investigated by means of TG and gravimetry with isothermal heating, as well as elemental and HCN analyses. Weight loss curves suggest three kinds of reactions involved in the pyrolysis, namely, initiation reactions, reactions splitting off volatile fragments, and reactions forming stabilized structures. In TG, in both helium and air atmospheres, the active weight loss of the melamine resin was completed in two steps, and that of the urea resin was completed in one step, which, however, consisted of a few small successive steps. The isothermal heating weight losses progressed through a few stages of first- and zeroth-order reactions. Arrhenius parameters were obtained for the weight losses in TG and with isothermal heating. The residue from the melamine resin is rich in carbon and nitrogen, and poor in oxygen and hydrogen, while that from the urea resin is rich in carbon, and poor in nitrogen, oxygen, and hydrogen. The effects of temperature on HCN yield changed, depending on the amount of air fed. The melamine resin evolved much more HCN than the urea resin because of the more stable C—N linkages in the resin.     

Low‐volatility acetals to upgrade the performance of melamine–urea–formaldehyde wood adhesive resins

1,1,2,2‐Tetramethoxyethane (TME), a high boiling point acetal derived from glyoxol, lhas been shown to upgrade the performance of melamine‐urea‐formaldehyde (MUF) and some UF resins used for wood adhesives. This affords the possibility of decreasing the percentage of resin used in the preparation of wood panels without volatilizing the TME acetal used.     

Examination of selected synthesis and room‐temperature storage parameters for wood adhesive‐type urea–formaldehyde resins by 13C‐NMR spectroscopy. V

The effects of posttreatments of particleboard adhesive‐type urea–formaldehyde resins were studied. The resins were synthesized with formaldehyde/first urea (F/U₁) mol ratios of 1.40, 1.60, 1.80, 2.10, and 2.40 and then the second urea was added to give a final formaldehyde/urea ratio of 1.15 in alkaline pH. The resins were posttreated at 60°C for up to 13.5 h and the 2.5‐h heat‐treated resin samples were stored at room temperature for up to 27 days. Resins sampled during the posttreatments were examined by ¹³C‐NMR and evaluated by bonding particleboards. In the posttreatments, hydroxymethyl groups on the polymeric resin components dissociated to formaldehyde and reacted with the second urea, and methylene and methylene–ether groups were formed from reactions involving the second urea. Methylene–diurea and urea groups bonded to UF polymers were identified. As a result, the viscosity of the resins initially decreased but later increased along with the cloudiness of the resins. Bond‐strength and formaldehyde‐emission values of particleboard varied with posttreatment variables as well as with the F/U₁ mol ratios used in the resin syntheses. The results would be useful in optimizing resin synthesis and handling parameters. Various reaction mechanisms were considered. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 1896–1917, 2003     

Influence of acrylamide copolymerization of urea–formaldehyde resin adhesives to their chemical structure and performance

To lower the formaldehyde emission of wood‐based composite panels bonded with urea–formaldehyde (UF) resin adhesive, this study investigated the influence of acrylamide copolymerization of UF resin adhesives to their chemical structure and performance such as formaldehyde emission, adhesion strength, and mechanical properties of plywood. The acrylamide‐copolymerized UF resin adhesives dramatically reduced the formaldehyde emission of plywood. The ¹³C‐NMR spectra indicated that the acrylamide has been copolymerized by reacting with either methylene glycol remained or methylol group of UF resin, which subsequently contributed in lowering the formaldehyde emission. In addition, an optimum level for the acrylamide for the copolymerization of UF resin adhesives was determined as 1%, when the formaldehyde emission and adhesion strength of plywood were taken into consideration. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Copolymer resin. VII. 8‐hydroxyquinoline‐5‐sulfonic acid–thiourea–formaldehyde copolymer resins and their ion‐exchange properties

8‐Hydroxyquinoline‐5‐sulfonic acid–thiourea–formaldehyde copolymer resins were synthesized through the condensation of 8‐hydroxyquinoline‐5‐sulfonic acid and thiourea with formaldehyde in the presence of hydrochloric acid as a catalyst and with various molar ratios of the reacting monomers. The resulting copolymers were characterized with UV‐visible, IR and 1H‐NMR spectral data, employed to determine the reactivity of monomers. The average molecular weights of these resins were determined with vapor pressure osmometry and conductometric titration in a nonaqueous medium. The chelation ion‐exchange properties were also studied with the batch equilibrium method. The resins were proved to be selective chelating ion‐exchange copolymers for certain metals. The chelation ion‐exchange properties of these copolymers were studied for Cu²⁺, Ni²⁺, Co²⁺, Pb²⁺, and Fe³⁺ ions. The study was carried out over a wide pH range and in media of various ionic strengths. The copolymers showed a higher selectivity for Fe³⁺ ions than for Cu²⁺, Ni²⁺, Co²⁺, and Pb²⁺ ions. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Terpolymer resin–III: Synthesis and characterization of 8‐hydroxyquinoline–dithiooxamide–formaldehyde terpolymer resins

Terpolymer resins (8‐HQDF) were synthesized by the condensation of 8‐hydroxyquinoline (8‐HQ) and dithiooxamide (D) with formaldehyde (F) in the presence of acid catalyst and using varied molar ratios of reacting monomers. Terpolymer resins compositions have been determined on the basis of their elemental analysis and the number average molecular weights of these resins were determined by conductometric titration in non‐aqueous medium. Viscometric measurements in dimethyl formamide (DMF) have been carried out with a view to ascertain the characteristic functions and constants. The UV‐visible, FTIR, and proton nuclear magnetic resonance (H⁺ NMR) spectra were studied to elucidate the structure. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Terpolymer resin II: Synthesis,characterization, and ion‐exchange properties of 2,4‐dihydroxyacetophenone–dithiooxamide–formaldehyde terpolymers

Terpolymers have been prepared by the condensation of 2,4‐dihydroxyacetophenone (2,4‐HA) and dithiooxamide (D) with formaldehyde (F) in the presence of hydrochloric acid as catalyst with varying the molar proportions of the reactant. Compositions of the terpolymer have been determined by elemental analysis. The number average molecular weight has been determined by conductometric titration in nonaqueous medium. Intrinsic viscosities of the solution of the terpolymer have been determined in N,N‐dimethyl formamide (DMF). The terpolymers have been characterized by UV–visible, IR, and proton NMR spectra. Chelation ion‐exchange properties have also been studied employing the batch equilibrium method. It was employed to study selectivity of metal ion uptake over a wide pH range and in media of various ionic strength. The overall rate of metal uptake follows the order: Fe³⁺ > Cu²⁺ > Ni²⁺ > Co²⁺ = Zn²⁺. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Renewable polyol‐based polycarbamates and polycarbamate–formaldehyde thermosetting resins

Several polycarbamates and polycarbamate–formaldehyde (CF) resins were synthesized, and their properties were investigated aiming at developing of useful thermosetting polymer materials from simple polyols including those derived from renewable resources. Polycarbamates synthesized from polyols using two‐step laboratory routes showed good storage stabilities making them suitable as large volume industrial chemicals. Furthermore, syntheses and ¹³C‐NMR studies of CF resins showed the formation of oligomeric resins having hydroxymethyl and methylene groups with thermosetting curing properties that are similar to those of current urea–formaldehyde (UF) resins. Dynamic mechanical analysis studies showed somewhat slower curing rates for CF resins compared to UF resins. Bonding of particleboard and internal bond and free formaldehyde content measurements indicated high‐bond strength values and very low‐formaldehyde emission potentials for CF resins. The higher functionalities of CF resins appear to be the basis of good performances. Further investigations on scalable synthesis methods for polycarbamates and on the expansion of CF resins' bonding capabilities would need to be investigated in the future. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Modification of melamine‐formaldehyde resins by substances from renewable resources

In the present contribution, investigations on the chemical modification of thermosetting melamine formaldehyde resins by natural polyol compounds are presented. As representative agents soluble starch, sucrose, and glycerol were chosen to cover three different classes of polyols. The major aim was to use substances produced from natural bio‐renewable feedstock that are available in large quantities and may serve as environmentally innocuous and bio‐renewable substitutes for petro‐chemically derived and potentially hazardous materials. Different reaction conditions lead to resins with varying technical performance. For soluble starch no reaction conditions could be found that allow the adoption of this substitute for the laminate industry due to insufficient technological performance. Sucrose and glycerol on the other hand yielded impregnation resins with suitable performance. Chemical linkage of the modifying agent into the chain propagation by poly‐condensation however, was only found with glycerol. The covalent incorporation of glycerol in the network was observed with addition of glycerol at different stages during synthesis. The technological performance of the various modified thermosetting resins was assessed by determining flow viscosity, molar mass distribution, the storage stability, and in a second step laminating impregnated paper to particle boards and testing the resulting surfaces according to standardized quality tests. Spectroscopic evidence of chemical incorporation of glycerol was found by applying by ¹H, ¹³C, ¹H/¹³C HSQC, ¹H/¹³C HMBC, and ¹H DOSY methods. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011