Lignin-phenol-formaldehyde resol for high pressure decorative laminates evaluation of lignin levels on final properties

Abstract

High pressure decorative laminates (HPDL) are composite materials made of core layers of Kraft papers impregnated with a resol type phenol-formaldehyde resin (PF) and a surface décor paper saturated with melamine-formaldehyde resin (MF). The set of saturated papers is cured by compression moulding at high pressure and high temperature. In the aim of replacing non-renewable petroleum-based phenol (P), among biomass components, lignin (L) seems to be an attractive substitute owing to its structural similarity to PF resins. In this sense, hardwood Eucalyptus spp species are the main source of Kraft L in South America. However, the poor solubility and reactivity limit its exploitation in resol resins making necessary a previous chemical modification such as hydroxymethylation in alkaline conditions [1]. Free F increased with L levels in resols being less than 2% for P replacements up to 60 wt%. The resistance to immersion in boiling water test exhibited higher increase in weight and thickness with higher L levels. Delamination and blister defects were observed for HPDLs with 70 and 80 wt% P replacement. Weight increments for HPDL with 0% and 60% P substitution were 5.66 (±0.37)% and 7.60 (±0.56)% meanwhile thickness increments were 8.97 (±1.60)% and 10.22 (±0.45)%, respectively. Gaining on weight and thickness comply the Australian/New Zealand Standard AS/NZS 2924.1:1998 specifications, thus demonstrating hardwood L as a high potential substitute for P in HPDLs manufacturing.