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     

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     

Synthesis–structure–performance relationship of cocondensed phenol–urea–formaldehyde resins by MALDI‐ToF and 13C NMR

Matrix assisted laser desorption ionization time of flight (MALDI‐ToF) mass spectrometry has consistently confirmed on a number of PUF resins that phenol–urea cocondensates exist in phenol–urea–formaldehyde (PUF) resins. A noticeable proportion of methylene‐linked phenol to urea cocondensates were detected in all the PUF resins tried, alongside methylene bridges connecting phenol to phenol and urea to urea. The PUF, PF, and UF oligomers formed were identified. Variations of the PUF preparation procedure did always yield a certain proportion of the mixed phenol to urea cocondensates. Their relative proportion was determined and related the synthesis procedure used. Comparison of the MALDI‐ToF results with a ¹³C NMR investigation showed that in a real PUF resin in which phenol to urea cocondensates were identified the methylene bridge NMR signal at 44 ppm, characteristic of phenol to urea unsubstituted model compound cocondensates, does not appear at all. This confirmed that this peak cannot be taken as an indication of the existence of phenol and urea condensation under actual resin preparation conditions. The peak indicating cocondensation in PUF resins in which the phenolic nuclei and urea are substituted appears instead at 54.7–55.0 ppm. Thermomechanical analysis has again confirmed that the resin gel times greatly accelerates with increasing urea molar content. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Influence of nanoclay on urea‐formaldehyde resins for wood adhesives and its model

The addition of small percentages of Na⁺‐montmorillonite (NaMMT) nanoclay appears to improve considerably the performance of thermosetting urea‐formaldehyde (UF) resins used as adhesives for plywood and for wood particleboard. X‐ray diffraction (XRD) studies indicated that NaMMT loses the periodic atomic structure when mixed in small proportions in the acid‐curing environment characteristic of the curing of UF resins. This can be interpreted as becoming exfoliated under such conditions. The partly crystalline structure of the ordered zones of the UF resins is maintained but at a slightly lower level. Differential scanning calorimetry (DSC) indicated that NaMMT has an accelerating effect on the curing of the UF resin. It also appears to lead to a more controlled rate of crosslinking implying a more regular hardened network. The influence of NaMMT addition was particularly noted in plywood by the increase in water resistance of the UF‐bonded panel. In the case of wood particleboard even the dry internal bond strength of the panel, a direct indication of the performance of the resin, improved with small additions of NaMMT. A hypothesis and model of the reasons why such improvement to the performance of UF resins by addition of nanoclay should occur has been presented. This is based on the application of percolation theory to the networking capability of the clay nanoplatelets. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Morphology and chemical elements detection of cured urea–formaldehyde resins

As a part of understanding the hydrolysis of cured urea–formaldehyde (UF) resins that has been known as responsible for the formaldehyde emission, leading to sick building syndrome, this study attempted to investigate the morphology and to detect chemical elements of the cured UF resins of different formaldehyde/urea (F/U) mole ratios and hardener (NH₄Cl) levels, using field emission‐scanning electron microscopy and energy‐dispersive spectroscopy. Cured UF resins of low F/U mole ratio showed spherical structure whose diameter increased with an increase in the hardener level, whereas this was not observed for high F/U mole ratio UF resins regardless of the hardener levels. The energy‐dispersive spectroscopy results showed five different chemical elements such as carbon, nitrogen, oxygen, chloride, and sodium in cured UF resins. The chloride distribution assumed as the presence of residual acid in the cured UF resins suggested that the hydrolysis of cured UF resins could initiate at the sites of chlorides on the surface of the spherical structures. As the hardener level increased, the quantities of both carbon and oxygen decreased, whereas those of nitrogen and chloride increased as expected. But the quantity of sodium was within measurement error. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

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.     

Effects of acid hydrolysis on microstructure of cured urea‐formaldehyde resins using atomic force microscopy

This study investigated the effect of acid hydrolysis on the microstructure of cured urea‐formaldehyde (UF) resins using atomic force microscopy (AFM) to better understand its hydrolytic degradation process which has been known to be responsible for the formaldehyde emission of wood‐based composite panels. The AFM was scanned on both outer surface and facture surfaces of the thin films of cured UF resins that had been exposed to the etching of dilute hydrochloric acid to simulate their hydrolysis process. The AFM images showed two distinctive parts, which were classified as the hard and soft phases in cured UF resins. For the first time, this study reports the presence of thin filament‐like crystalline structures on the fracture surface of cured UF resin. The soft phase of cured UF resins by ammonium chloride was much more easily hydrolyzed than those cured by ammonium sulfate, indicating that hardener types had a great impact on the hydrolytic degradation behavior of cured UF resins. The surface roughness measurement results also supported this result. The results of this study suggested that the soft phase was much more susceptible to the hydrolysis of cured UF resin than the hard phase. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Low addition of melamine salts for improved melamine‐urea‐formaldehyde adhesive water resistance

The addition of melamine acetate salts to an adhesive glue mix can allow the use of melamine–urea–formaldehyde (MUF) resins of lower melamine contents (rather than just urea–formaldehyde resins) and lower total amounts of melamine. Performances can be obtained that are characteristic of the top‐of‐the‐line, generally higher melamine content MUF adhesive resins for the preparation of wood particleboard panels. Improvements in the panel internal‐bond strength of greater than 30% can be obtained by the addition of melamine acetate salts to top‐of‐the‐line MUF resins. The approach to the concept of increased melamine solubility with a melamine salt is compatible with the approach of increasing melamine solubility with solvents such as acetals (e.g., methylal). However, the synergy advantage of using the two approaches jointly is not very marked. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 287–292, 2003     

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     

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     

Production of melamine fortified urea‐formaldehyde resins with low formaldehyde emission

Melamine can be incorporated in the synthesis of urea‐formaldehyde (UF) resins to improve performance in particleboards (PB), mostly in terms of hydrolysis resistance and formaldehyde emission. In this work, melamine‐fortified UF resins were synthesized using a strong acid process. The best step for melamine addition and the effect of the reaction pH on the resin characteristics and performance were evaluated. Results showed that melamine incorporation is more effective when added on the initial acidic stage. The condensation reaction pH has a significant effect on the synthesis process. A pH below 3.0 results on a very fast reaction that is difficult to control. On the other hand, with pH values above 5.0, the condensation reaction becomes excessively slow. PBs panels produced with resins synthesized with a condensation pH between 4.5 and 4.7 showed good overall performance, both in terms of internal bond strength and formaldehyde emissions. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

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     

Syntheses and properties of low‐level melamine‐modified urea–melamine–formaldehyde resins

Syntheses of urea–melamine–formaldehyde (UMF) resins were studied using 2–12% melamine levels and UF base resins that were preadvanced to various different extents. The melamine reaction was carried out at pH 6.3 with F/(U + M) mole ratio of 2.1 until a target viscosity of V was reached (Gardener–Holdt) and then the second urea added at pH 8.0 to give a final F/(U + M) mole ratio of 1.15. Analyses with ¹³C‐NMR and viscosity measurements showed that MF components react fast and the UF components very slowly in the melamine reaction. Therefore, as the extent of preadvancement of UF base resin was decreased, the reaction time to reach the target viscosity became longer and the MF resin components showed high degrees of polymerization. The overpolymerization of MF components resulted in increasingly more opaque resins, with viscosity remaining stable for more than a month. As the preadvancement of UF base resin was increased, the extent of advancement of MF components decreased, to give clearer resins, with viscosity slowly increasing at room temperature. Overall, preadvancing the UF base resin components to an appropriate extent was found to be a key to synthesizing various low‐level melamine‐modified UMF resins. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 2559–2569, 2004     

The structure of urea—formaldehyde resins

Fourier transform infrared (FTIR) spectroscopy has been used as a modern analytical tool to elucidate the structure of urea—formaldehyde (UF) resins. Several low molecular weight condensation products of urea and formaldehyde were synthesized and characterized. Structural differences were observed for prepolymers prepared in alkaline and acidic media. Plausible mechanistic routes are proposed to explain the prepolymer structural differences prepared in different experimental conditions. The structural elucidation of the UF resins is considerably increased and improved by using absorbance magnification to further enhance the observed signals.     

Testing by fourier transform infrared species variation during melamine–urea–formaldehyde resin preparation

The preparation of an industrially used sequential formulation of a melamine–urea–formaldehyde resin was followed with Fourier transform infrared (FTIR). The analysis allowed us to identify the increases and decreases of the main groups in the resin and to compare this system of resin analysis with results previously obtained by ¹³C‐NMR analysis. The FTIR analysis, although considerably more limited than ¹³C‐NMR analysis, allowed us nonetheless to identify and follow the appearance, increase, decrease, and disappearance of several of the main chemical groups during the preparation of the initial urea–formaldehyde (UF) phase of the reaction and the subsequent reaction of melamine with the UF resin that was formed. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Comparative 13C‐NMR and matrix‐assisted laser desorption/ionization time‐of‐flight analyses of species variation and structure maintenance during melamine–urea–formaldehyde resin preparation

The preparation of an industrially used sequential formulation of a melamine–urea–formaldehyde resin was followed by matrix‐assisted laser desorption/ionization time‐of‐flight mass spectrometry and ¹³C‐NMR analysis. The analysis allowed us to identify and follow the appearance, increase, decrease, and disappearance of a multitude of chemical species during the preparation of both the initial urea–formaldehyde (UF) phase of the reaction and the subsequent reaction of melamine with the UF resin that formed. The analysis indicated that (1) the increase and decrease in the species that formed proceeded through a cycle of the formation and degradation of species occurring continuously through what appeared to be a series of complex equilibria, (2) even at the end of the reaction a predominant proportion of methylene ether bridges was still present, (3) some small proportion of methylene bridges already had formed in the UF reaction phase of the resin even under rather alkaline conditions, and (4) the addition of melamine to the UF prepolymer induced some noticeable rearrangement of methylene ether bridges to methylene bridges. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

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     

Effects of diatomite inorganic fillers on the properties of a melamine–urea–formaldehyde resin

In this study, a low‐cost diatomite was used to partly substitute wheat flour as one type of melamine–urea–formaldehyde (MUF) resin filler. Five‐ply plywood was fabricated, and its performance was measured. The crystallinity, fracture surface, and functional groups were tested to determine the effects of diatomite on the performance of the MUF resin. The results show that diatomite was well distributed in the MUF resin system and formed an embedding structure; this improved the wet shear strength of the resulting plywood by 33% to 1.36 MPa. Diatomite captured the free formaldehyde in the resin and the microporous structure formed in the resin accelerate formaldehyde release of the plywood. Consequently, the formaldehyde emission of the plywood was reduced. The diatomite partly replaced wheat flour as an MUF resin filler and could be applied in the plywood industry. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44095.     

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     

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.