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Title: Fire-retardant particle board and binder therefor from aminoplast with ammonium polyphosphate-formaldehyde product
Claims: What is claimed is: 1. A fire retardant aminoplast binder resin solution containing not more than 30 percent by weight water consisting of A. a substantially neutral aqueous solution of a low molecular weight urea-formaldehyde resin of a mol ratio of from about 3.0 to 3.5 formaldehyde to urea, a viscosity of from about 60 to 100 cps and a percent solids of at least 70 percent, B. sufficient urea to reduce the formaldehyde to urea ratio to from about 1.2 to 2.0, and C. a stable concentrated aqueous solution having a percent solids of at least 55 percent of ammonium polyphosphate reacted with from 5 to 12.5 percent by weight formaldehyde adjusted to a pH of from 4.7 to 6.2 to produce a concentration of dissolved ammonium polyphosphate of from about 40 to 56 percent by weight in said binder resin solution. 2. A fire-retardant aminoplast binder resin solution containing not more than 30 percent by weight water consisting of A. a substantially neutral aqueous solution of a low molecular weight urea-formaldehyde resin of a mol ratio of from about 3.0 to 3.5 formaldehyde to urea, a viscosity of from about 60 to 100 cps and a percent solids of at least 70 percent, B. sufficient urea to reduce the formaldehyde to urea ratio to from about 1.2 to 2.0, C. a stable concentrated aqueous solution having a percent solids of at least 55 percent of ammonium polyphosphate reacted with from 5 to 12.5 percent by weight formaldehyde adjusted to a pH of from 4.7 to 6.2 to produce a concentration of dissolved ammonium polyphosphate of from about 40 to 56 percent by weight in said binder resin solution and D. from 15 to 25 percent by weight based on the urea-formaldehyde resin of a methylolated melamine-formaldehyde resin. 3. The binder resin solution of claim 2 wherein the dissolved ammonium polyphosphate is selected from 10-34-0 and 11-37-0 ammonium polyphosphates. 4. The binder resin solution of claim 2 wherein the ammonium polyphosphate formaldehyde reaction product contains, on a 100 percent solids basis, 79-92 percent ammonium polyphosphate, 7 to 16.5 percent formaldehyde and 1.4 to 4 percent caustic. 5. The binder resin solution of claim 2 wherein the melamine-formaldehyde and urea-formaldehyde resin solutions comprise from about 25 to about 40 weight percent of said solution. 6. A process for production of a fire-retardant aminoplast binder resin solution containing not more than 30 percent by weight water which comprises A. mixing with a substantially neutral aqueous solution of a low molecular weight urea-formaldehyde resin of a mol ratio of from about 3.0 to 3.5 formaldehyde to urea, a viscosity of from about 60 to 100 cps and a percent solids of at least 70 percent, B. sufficient urea to reduce the formaldehyde to urea ratio to from about 1.2 to 2.0, and C. a stable concentrated aqueous solution having a percent solids of at least 55 percent of ammonium polyphosphate reacted with from 5 to 12.5 percent by weight formaldehyde adjusted to a pH of from 4.7 to 6.2 to produce a concentration of dissolved ammonium polyphosphate of from about 40 to 56 percent by weight in said binder resin solution. 7. The process of claim 6 wherein there is mixed with the urea-formaldehyde resin solution of (A) from about 15 to 25 percent by weight thereof of an aqueous solution of at least 50 percent solids of a methylolated melamine-formaldehyde resin so as to produce a melamine-urea-formaldehyde resin solution of at least 70 percent solids. 8. The process of claim 7 wherein the melamine-urea-formaldehyde resin solution is subjected to distillation to concentrate same to a solids content of at least 70 percent. 9. The process of claim 7 wherein the solution of ammonium polyphosphate is an aqueous solution of a reaction mixture on a solids basis of from 79 to 92 percent ammonium polyphosphate, from 7 to 16.5 percent formaldehyde and from 1.4 to 4 percent caustic. 10. The process of claim 7 wherein the formaldehyde-reacted ammonium polyphosphate solution is subjected to distillation to concentrate same to a solids content of at least 70 percent. 11. The process of claim 7 wherein the urea-formaldehyde resin solution has a solids content of at least 85 percent, wherein the methylolated melamine-formaldehyde resin solution has a solids content of at least 60 percent and is present in an amount of about 20 percent of the weight of the urea-formaldehyde resin, wherein the solution of ammonium polyphosphate comprises a 60 to 66 percent solution of ammonium polyphosphate reacted with 10 to 25 parts formalin solution and 2 to 6 parts caustic solution, and the mixed binder resin solution has a solids content of at least 75 percent. 12. The process of claim 7 wherein the urea-formaldehyde resin solution has a solids content of at least 85 percent, wherein the methylolated melamine-formaldehyde resin solution has a solids content of at least 60 percent and is present in an amount of about 20 percent of the weight of the urea-formaldehyde resin, wherein the solution of ammonium polyphosphate comprises about 100 parts of a 66 percent 11-37-0 ammonium polyphosphate solution, about 15 parts of a 50 percent formaldehyde solution and about 4 parts of a 50 percent caustic solution concentrated to a solids content of about 75 percent, and the mixed binder resin solution has a solids content of at least 75 percent. 13. A fire-retardant particle board comprising wood particles bonded with a composition of claim 2. 14. The fire-retardant particle board of claim 13 wherein the aminoplast resin binder is a melamine-urea-formaldehyde resin and the ammonium polyphosphate is selected from 10-34-0 and 11-37-0 ammonium polyphosphates. 15. The fire-retardant particle board of claim 14 wherein the ammonium polyphosphate is present in an amount of from 12 to 16.8 percent by weight. Other info: Inventors: Brown, Gordon E. (Eugene, OR, US) Application Number: 503890 Filing Date: 1974-09-06 Publication_date: 1976-02-17 Assignee: Monsanto Company (St. Louis, MO) Primary Class(es): 524/127 260/DIG24, 428/528, 428/921, 524/597, 525/472 Other Classes: US Patent Ref:
Other Refs: Primary Examiner: Tillman, Murray Assistant Examiner: Koeckert, A. H. Attorney: Nelson; Joseph S., Grattan; Edward P., Logomasini; James C. |
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