Resin compositions comprising lignin derivatives

Abstract

The present invention provides derivatives of native lignin having a certain ethoxy content. Surprisingly, it has been found that phenolic resins comprising derivatives of native lignin having certain ethoxy contents have acceptable performance characteristics such as bond-strength.

1 . A lignin derivative having an ethoxy content of 0.45 mmol/g or greater. 
     
     
         2 . The lignin derivative according to  claim 1 , wherein the derivative has an ethoxy content of about 0.5 mmol/g or greater. 
     
     
         3 . The lignin derivative according to  claim 1 , wherein the derivative has an ethoxy content of about 0.6 mmol/g or greater. 
     
     
         4 . The lignin derivative according to  claim 1 , wherein the derivative has an aliphatic hydroxyl content of from about 0.001 mmol/g to about 8 mmol/g. 
     
     
         5 . The lignin derivative according to  claim 1 , wherein the lignin is derived from hardwood biomass. 
     
     
         6 . The lignin derivative according to  claim 1 , wherein the lignin is derived from softwood biomass. 
     
     
         7 . The lignin derivative according to  claim 1 , wherein the lignin is derived from annual fibre biomass. 
     
     
         8 . The lignin derivative according to  claim 1 , wherein the lignin is derived from biomass comprising  Populus  spp,  Eucalyptus  spp.,  Acacia  spp., or combinations/hybrids thereof. 
     
     
         9 . The lignin derivative according to  claim 1 , wherein the biomass comprises  Populus tremuloides, Eucalyptus globulus, Acacia dealbata , or combinations/hybrids thereof. 
     
     
         10 . The lignin derivative according to  claim 1 , wherein the lignin is derived from biomass comprising pine; spruce; and combinations/hybrids thereof 
     
     
         11 . The lignin derivative according to  claim 1 , wherein the lignin is derived from biomass comprising  Pinus radiata, Pinus taeda , BC spruce, or combinations/hybrids thereof. 
     
     
         12 . The lignin derivative according to  claim 1 , wherein the lignin is derived from biomass comprising wheat straw, bagasse, corn cobs, or combinations/hybrids thereof. 
     
     
         13 . The lignin derivative according to  claim 1 , wherein the derivative has an ethoxy content of about 3.5 mmol/g or less. 
     
     
         14 . A hardwood lignin derivative having an ethoxy content of from 0.45 mmol/g to about 1.4 mmol/g. 
     
     
         15 . A softwood lignin derivative having an ethoxy content of from about 0.35 mmol/g to about 1.4 mmol/g. 
     
     
         16 . An annual fibre lignin derivative having an ethoxy content of from about 0.25 mmol/g to about 1.4 mmol/g. 
     
     
         17 . A phenol composition comprising the lignin derivative according to  claim 1 , wherein the weight ratio of lignin:phenol is from about 1:4 to about 4:1. 
     
     
         18 . A phenol-formaldehyde resin composition comprising from about 0.5% to about 20%, by of the lignin derivative according to  claim 1 . 
     
     
         19 . A method of producing a lignin derivative according to  claim 1 , said method comprising:
 a) pulping a fibrous biomass in a vessel with an organic solvent/water solvent solution to form a liquor, wherein:
 i. the solution comprises about 30% or greater, by weight, of organic solvent; and 
 ii. the pH of the liquor is from about 1 to about 6; 
   b) heating the liquor to about 100° C. or greater;   c) maintaining the elevated temperature and pressure for 1 minute or longer;   d) separating the cellulosic pulps from the pulping liquor; and   e) recovering derivatives of native lignin.