Recent Advances in Soyad® Adhesives

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Recent Advances in Soyad® Adhesives
Don Saylor & Dr. Jim Wescott
HPVA Meeting
Scottsdale, AZ
May 25, 2010
Outline
 Soyad Program Development
 Emissions
 Durability
 Summary / Path Forward
2
5+ years of growth
 14 North American HWPW-VC, HWPW-CC, &
EWF mills currently manufacture with Soyad®
adhesives
 Approximately 50% of the adhesives used to
manufacture domestic HWPW & EWF stock
panels are Soyad® adhesives
 Currently replacing over 75 million lbs of UF
adhesive in HWPW & EWF annually
3
Soyad Timeline
4
Soyad® Adhesive Technology
Soy Flour
+
Curing Resin
Process and Performance
Additives
CROSSLINKED ADHESIVE
5
Soyad Technical Advances
 Higher Solids
 Lower Viscosity
 Increased Stability
 Adhesion Performance Modifiers
 Crosslinker Advancements
- Lower VOC’s
- New technology allows for solids >50%
•Traditional Solids for paper chem 12-20%
- Lower viscosity technology has been developed
6
Why Choose Soyad?
 100% NAF Adhesive
 The most cost effective NAF option
 Wide operating window
 The Four S’s: Safe, Simple, Sticks, Stable
 Very easy to clean up
 Excellent durability- hot or cold water conditions
 Commitment to Excellence
7
Commitment to Excellence
600 Technical Service
Chemical Engineers in NA
available to support Soyad!
8
Why Choose Soyad?
 100% NAF Adhesive
 The most cost effective NAF option
 Wide operating window
 The Four S’s: Safe, Simple, Sticks, Stable
 Very easy to clean up
 Excellent durability- hot or cold water conditions
 Commitment to Excellence
9
Why Choose Soyad?
 100% NAF Adhesive
 The most cost effective NAF option
 Wide operating window
 The Four S’s: Safe, Simple, Sticks, Stable
 Very easy to clean up
 Excellent durability- hot or cold water conditions
 Commitment to Excellence
 Extremely low emissions under ALL conditions
10
Low Emissions Under ALL Conditions
 CARB specifies “Large Chamber ASTM E-1333”
as the primary test method
 E-1333 is conducted at only 25 C and 50% RH
- Most test are run at extremes… not this one!
 UF chemistry suffers from hydrolysis resulting in
the GENERATION and subsequent evolution of
ADDITIONAL formaldehyde
11
Emissions: Temp and Humidity Effects
 Static method in sealed bottles
- (modified EN 717-3)
 Varying levels of humidity and temperature
 Varying durations
 Soyad and ULEF samples tested (Both CARB II)
 ¾” 7-ply HWPW Construction
 Study was run at and in cooperation with the
Forest Products Laboratory
12
 Estimated CARB P2 level < 10
 ULEF Continues to generate additional CH2O
 ULEF at 96 hrs = 33X Soyad
13
 Soyad panels emit very little additional formaldehyde
after the first 24 hours
 ULEF rate is actually increasing exponentially
(scavenger is consumed?)
14
Similar Trend at 25 C
15
Durability in EWF
Stability Testing of EWF
 5-Ply Engineered Wood Flooring Panels
 Oak/Gum/Gum/Gum/Oak construction
 3/8” thickness
 Samples were subjected to an extreme range of
temperature/humidity combinations over 15 days
to probe durability
 Panels were cut into test pieces before beginning
test protocol to maximize exposure of bond lines
to environment.
 3-Cycle soak samples (2” X 5”)
 Shear samples (1” X 3”)
17
Stability Testing of EWF
Temperature/Humidity Cycling Protocol
Day #
Condition
Time
(hr)
Temperature
(°F)
Relative
Humidity
Theoretical
MC
Pre-Test
Conditioning
72
70
50%
9.2%
1
Hot/Wet
24
80
90%
20.2%
2
Cold/Moist
24
15
70%
13.5%
3
Hot/Dry
24
90
20%
4.3%
4
Cool/Wet
24
36
90%
21.0%
5
Hot/Dry
24
90
20%
4.3%
Post-Test
Conditioning
72
70
50%
9.2%
3X
18
Stability Testing of EWF
Shear and 3-Cycle Soak Test Results
Panel Testing
3-Cycle Soak
Shear Strength Testing
Dry
Std.
%
Wet
Std.
%
%
Shear
Dev.
Dry
Shear
Dev.
Wet
Type
Score
Pass
(psi)
(psi)
WF
(psi)
(psi)
WF
Control
0.81
100%
448
74
83
251
68
12
Cycled
0.38
100%
511
91
63
267
70
2
Bond lines 1 & 2 tested in shear tests (oak-gum-gum)
Dimensional Stability of Shear Test Samples
Length
(in)
Height
(in)
Width
(in)
Control Samples
3.282
0.997
0.380
Cycled Samples
3.282
0.998
0.380
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Continued Development
 Desire for higher % wet wood failure
- Requirement for EN-314
- Requirement for ANSI/HPVA Type I bond
 Lower cost system
 Enhanced bonding to challenging veneers
- Hickory, Fumed Yellow Birch
 Simpler system for small veneering and assembly
 Desire for a lighter cured glue color
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Summary
 Soyad has been accepted in North America as a
high performance, low cost, no-formaldehyde
alternative
 Soyad technology is developing rapidly
 Soyad emissions is a key differentiator vs. ULEF
 Soyad durability in EWF is excellent
 Soy-based NAF composite core is coming soon !
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