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Deliverables
MUF resins are capable of imparting water resistance and do not release harmful formaldehydes as easily as UF resins. Unfortunately, MUF resins have several serious drawbacks which prevent their being more widely-used: above-all, they cost almost twice as much as normal UF resins; another, more serious drawback, however, is that they have less than half the bonding capacity on wooden particles as normal UF resins, which means that twice as much resin is required. This serious cost problem can only be overcome by reducing the quantity required whilst maintaining the technical benefits. Another important industrial objective - which will lead to reduced production costs, alongside the saving on binding raw materials - is energy savings, as on an overall calculation this accounts for approx. 20% of the cost of production of bonding resins (and above-all the energy consumed to produce ammonia and subsequently melamine), as well as approx. 18% of the cost of producing reconstructed wood (chipboard, Mdf, plywood) and approx. 16% of the cost of producing plastic laminates.
A Consortium of eight industrial companies and research institutes decided to tackle these problems by researching alternative chemical additives to those which are usually used to catalyse UF and MUF glues, as no other thorough research has been carried out in this specific field (catalysis of aminoresins with acid hardeners such as ammonium chloride, sulphate or nitrate).
The main results of the research were as follows:
-Considerable reduction of the surface tension of MUF resins, increasing their soaking effect and thus reduce the amount of MUF resins needed to bind each cubic meter of wood). This will result in the use of MUF resins becoming more widespread, providing considerable environmental-technical benefits and energy savings (saved resins = saved energy).
-Reduction in surface tension - i.e. the soaking effect of UF resins, thereby reducing the cost of manufactured articles and making them more competitive (saved resins = saved energy).
-Reducing the curing point by 10-15 degrees Celsius, thereby recovering energy in the production of both laminates and reconstructed wood panels (chipboard, Mdf, plywood, block wood).
-Replacing the use of catalysts used to harden the resins, seeking to improve the overall efficiency of the polymerisation.
-The additive designed and produced by this research costs about 0.8 ECU per kg. and 1.5% of the weight of the resin is used in a 60% solution.
-The effectiveness of this innovative additive has also benefited a whole range of the characteristics of manufactured articles, the most important of which are: improved mechanical resistance, improved resistance to water and minimised formaldehyde emissions.
-The additive which can also be sold as an independent chemical product to manufactured article producers. Together with water resistance, this will increase the total resistance of the resins to moisture).
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