Lignocellulose composite products

Abstract

Lignocellulose composite products that include a hydrophobizing agent. The lignocellulose composite product can include a plurality of lignocellulose substrates, an at least partially cured binder composition, and a hydrophobizing agent. In one example, the hydrophobizing agent can include about 30 wt % to about 98 wt % of a fatty acid compound, about 0.1 wt % to about 15 wt % of a rosin acid compound, and about 1 wt % to about 40 wt % of an unsaponifiable compound. In another example, the hydrophobizing agent can include a tall oil pitch and a fatty acid composition.

What is claimed is: 
     
         1 . A lignocellulose composite product, comprising:
 a plurality of lignocellulose substrates;   an at least partially cured binder composition; and   a first hydrophobizing agent comprising a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, wherein the first hydrophobizing agent has an acid value of about 20 to about 85, as measured according to ASTM D465-05(2010).   
     
     
         2 . The lignocellulose composite product of  claim 1 , wherein the lignocellulose composite product comprises about 1 wt % to about 10 wt % of the at least partially cured binder composition, based on a dried weight of the plurality of lignocellulose substrates. 
     
     
         3 . The lignocellulose composite product of  claim 1 , wherein the lignocellulose composite product comprises about 0.1 wt % to about 5 wt % of the first hydrophobizing agent, based on a dried weight of the plurality of lignocellulose substrates. 
     
     
         4 . The lignocellulose composite product of  claim 1 , wherein the first hydrophobizing agent comprises:
 about 5 wt % to about 55 wt % of the fatty acid compounds, based on a total weight of the first hydrophobizing agent,   about 5 wt % to about 35 wt % of the rosin acid compounds, based on the total weight of the first hydrophobizing agent, and   up to about 70 wt % of the unsaponifiable compounds, based on the total weight of the first hydrophobizing agent   
     
     
         5 . The lignocellulose composite product of  claim 1 , wherein the first hydrophobizing agent comprises:
 up to about 30 wt % of the fatty acid compounds, based on a total weight of the first hydrophobizing agent,   up to about 25 wt % of the rosin acid compounds, based on the total weight of the first hydrophobizing agent, and   at least 46 wt % of the unsaponifiable compounds, based on the total weight of the first hydrophobizing agent.   
     
     
         6 . The lignocellulose composite product of  claim 1 , wherein the at least partially cured binder composition, prior to curing, comprises a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-urea-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol formaldehyde resin, a methylene diphenyl diisocyanate, a polymeric methylene diphenyl diisocyanate, a polyurethane, a polyamide-epihalohydrin resin, a styrene maleic anhydride, a cationic styrene maleimide, an emulsified polymer isocyanate adhesive, or a mixture thereof. 
     
     
         7 . The lignocellulose composite product of  claim 1 , wherein:
 the fatty acid compounds comprise one or more fatty acids, one or more fatty acid esters, one or more fatty acid glycerides, one or more fatty acid salts, or a mixture thereof,   the rosin acid compounds comprise one or more rosin acids, one or more rosin acid esters, one or more rosin acid glycerides, one or more rosin acid salts, or a mixture thereof, and   the unsaponifiable compounds comprise hydrocarbons, sterols, or a mixture thereof.   
     
     
         8 . The lignocellulose composite product of  claim 1 , wherein the acid value of the first hydrophobizing agent is about 20 to about 50, as measured according to ASTM D465-05(2010). 
     
     
         9 . The lignocellulose composite product of  claim 1 , wherein the first hydrophobizing agent has a softening point of about 20° C. to about 60° C., as measured according to ASTM D6090-12. 
     
     
         10 . The lignocellulose composite product of  claim 1 , wherein the acid value of the first hydrophobizing agent is about 30 to about 50, as measured according to ASTM D465-05(2010), and wherein the first hydrophobizing agent has a softening point of about 25° C. to about 40° C., as measured according to ASTM D6090-12. 
     
     
         11 . The lignocellulose composite product of  claim 1 , further comprising a second hydrophobizing agent, wherein the second hydrophobizing agent comprises a wax. 
     
     
         12 . The lignocellulose composite product of  claim 11 , wherein the wax comprises slack wax. 
     
     
         13 . The lignocellulose composite product of  claim 11 , wherein the wax comprises paraffin wax. 
     
     
         14 . The lignocellulose composite product of  claim 11 , wherein the lignocellulose composite product comprises about 0.1 wt % to about 5 wt % of the second hydrophobizing agent, based on a dried weight of the plurality of lignocellulose substrates. 
     
     
         15 . The lignocellulose composite product of  claim 11 , wherein:
 the binder composition, prior to at least partially curing, comprises a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-urea-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol formaldehyde resin, or a mixture thereof,   the wax comprises slack wax, paraffin wax, or a mixture thereof,   the first hydrophobizing agent comprises tall oil pitch,   the first hydrophobizing agent has an acid value of about 20 to about 50, as measured according to ASTM D465-05(2010), and   the first hydrophobizing agent comprises:
 up about to 30 wt % of the fatty acid compounds, based on a total weight of the first hydrophobizing agent, 
 up about to 25 wt % of the rosin acid compounds, based on the total weight of the first hydrophobizing agent, and 
 at least 46 wt % of the unsaponifiable compounds, based on the total weight of the first hydrophobizing agent. 
   
     
     
         16 . A lignocellulose composite product comprising:
 a plurality of lignocellulose substrates;   about 1 wt % to about 10 wt % of an at least partially cured binder composition, based on a dried weight of the plurality of lignocellulose substrates;   about 0.1 wt % to about 5 wt % of a first hydrophobizing agent comprising a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, based on the dried weight of the plurality of lignocellulose substrates, and   about 0.1 wt % to about 5 wt % of a second hydrophobizing agent comprising a wax, based on the dried weight of the plurality of lignocellulose substrates, wherein:
 the binder composition, prior to curing, comprises a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-urea-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol formaldehyde resin, or a mixture thereof, 
 the first hydrophobizing agent has an acid value of about 20 to less than 85, as measured according to ASTM D465-05(2010), 
 the first hydrophobizing agent comprises:
 up to about 30 wt % of the fatty acid compounds, based on a total weight of the first hydrophobizing agent, 
 up to about 25 wt % of the rosin acid compounds, based on the total weight of the first hydrophobizing agent, and 
 at least 46 wt % of the unsaponifiable compounds, based on the total weight of the first hydrophobizing agent, and 
 
 the wax comprises slack wax, paraffin wax, or a mixture thereof. 
   
     
     
         17 . A process for making a lignocellulose composite product, comprising:
 contacting a plurality of lignocellulose substrates with a binder composition and a first hydrophobizing agent to produce a mixture, wherein the first hydrophobizing agent comprises a mixture of fatty acid compounds, rosin acid compounds, and unsaponifiable compounds, and wherein the first hydrophobizing agent has an acid value of about 20 to about 85, as measured according to ASTM D465-05(2010); and   at least partially curing the binder composition in the mixture to produce the lignocellulose composite product.   
     
     
         18 . The process of  claim 17 , wherein the plurality of lignocellulose substrates is contacted with the binder composition, the first hydrophobizing agent, and a second hydrophobizing agent to produce the mixture, wherein the second hydrophobizing agent comprises a wax. 
     
     
         19 . The process of  claim 18 , wherein the mixture comprises about 1 wt % to about 10 wt % of the binder composition, about 0.1 wt % to about 5 wt % of the first hydrophobizing agent, and about 0.1 wt % to about 5 wt % of the second hydrophobizing agent, based on a dried weight of the plurality of lignocellulose substrates. 
     
     
         20 . The process of  claim 19 , wherein the binder composition comprises a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin, a melamine-urea-formaldehyde resin, a phenol-melamine-urea-formaldehyde resin, a resorcinol-formaldehyde resin, a phenol-resorcinol formaldehyde resin, or a mixture thereof.