Q. Jl. Rubb. Res. Inst.

Ceylon (1972) 49, 3748

THE USE OF NATURAL RUBBER LATEX-RESIN BLENDS AS AN ADHESIVE FOR PLYWOOD *

BY W . G . WEERARATNE*, M . NADARAJAH, D . A . R . E LIATAMBY *, U . P . P . AMARASINGHE* AND N . LTYANAGE*. SUMMARY

Approximately 1,300 tons of urea formaldehyde (UF) and 100 tons of phenol formaldehyde (PF) resins involving a foreign exchange expenditure ofl\ million rupees are expected to be imported annually into Sri Lanka for bonding plywood. This project is an endeavour to substitute part if not all of this with a locally available adhesive. The basis of this work is the use of natural rubber (NR) latex-UF resin blends or of NR latex-PF resin blends as the adhesive for plywood. China clay or wheat flour or a mixture of both is used as the extender and it is found that a minimum adhesive total solids content of 5 5 % is necessary to obtain minimum plywood bond strength specifications. Formaldehyde is used as the stabilizer .for NR latex as its use enables the blending of UF resin with NR latex without any coagulation of the latex and gives an acidic pH which is necessary to cause polymerization of the UF resin. Using NR latex-UF resin blends, it should be possible to substitute satisfactorily 2\1rds of the imported UF resins by NR. This would result in an annual saving to the Plywoods Corporation of Rs. 800,000 and of a foreign exchange involvement of approximately 1 million rupees. It also finds a new use for NR in Sri Lanka. Using NR latex-PF resin blends it should be possible to replace half of the imported PF resin for use in commercial plywood. This would result in an annual saving of approximately Rs. 100,000 to the Ceylon Plywoods Corporation and of a foreign exchange involvement of approximately Rs. 100,000.
INTRODUCTION

P l y w o o d consists o f three o r some o d d n u m b e r o f thin sheets o f w o o d called veneers glued together face t o face, alternate veneers o r plies being arranged w i t h their grain at right angles t o each other a n d cured under pressure a n d heat. T h e success o f p l y w o o d depends o n effective gluing t o a great extent. I f the b o n d is badly m a d e u p o r i f it fails in service, the board gets reduced t o a mass o f splinters, f o r individual veneers are extremely weak ( K n i g h t , 1952). T h e ratio b y weight o f timber t o glue in p l y w o o d is 10 : 1 (Buttrey, 1964). T h e characteristic feature is the application o f a thin layer o f adhesive as thin as is practicable. Pressure is applied t o ensure close a n d u n i f o r m contact between surfaces a n d a predetermined temperature and time applied w i t h a degree o f precision ensures proper curing. T h e m a i n resin used b y the C e y l o n P l y w o o d s C o r p o r a t i o n ( C P C ) is urea formaldehyde ( U F ) . F o r m u l a t i o n s o f glue mixtures are given i n T a b l e I.
* Ceylon Plywoods Corporation.

% Paper presented at the 28 th Annual session of the Ceylon Association for the Advancement of Science on 15-12-72.

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W. G. WEERARATNE, M. NADARAJAH D. A. R. ELIATAMBY, U. P. P. AMARASINGHE AND N. L1YANAGE

TABLE

Formulation of glue mixtures (by weight) Glue formulation for tea chest panels: Urea formaldehyde Water Extender (flour or kaolin or a mixture of both) Water Ammonium chloride Glue formulation for commercial plywood : (1) Ordinary Non water proof Urea formaldehyde Water Ammonium chloride (2) 100 60 0.2 100 60 75 80

0.05

Waterproof
Urea formaldehyde Water Ammonium chloride 100 60 0.5

(3)

Weather & Boil proof

Phenol formaldehyde Water . Paraformaldehyde 50 40 0.5

T h e annual requirement o f synthetic resin o f the C P C is approximately 1,400 tons as urea a n d phenol formaldehyde w i t h their c o r r e s p o n d i n g hardeners involving a foreign exchange expenditure o f 21' million rupees. T h i s project was designed t o find whether a t least part, i f n o t all o f the imported glue could be substituted with a locally available adhesive. Since the r a w materials f o r synthetic resin adhesives are n o t manufactured i n Sri L a n k a it is necessary t o consider natural adhesives. T h e natural adhesives are a n i m a l glues, b l o o d a l b u m i n , casein, s o d i u m silicate, starch derivatives, vegetable p r o t e i n derivatives a n d natural rubber latex. T h e most suitable and readily available local r a w material is natural rubber ( N R ) latex. T h e r e is n o published data o n the use o f N R field latex as a n adhesive for p l y w o o d . H o w e v e r , centrifuged latexcasein mixtures have been used i n the manufacture o f p l y w o o d f o r i n d o o r applicat i o n , (Salzberg, 1 9 6 2 ; W a k e , 1967). T h e C e y l o n Institute o f Scientific a n d Industrial Research has also d o n e w o r k (Silva, 1 9 7 1 p r i v a t e communication) o n the use o f c o m p o u n d e d centrifuged a m m o n i a preserved latex as the probable adhesive for plywood.

THE USE OF NATURAL RUBBER LATEXRESIN BLENDS AS AN ADHESIVE FOR PLYWOOD

39

T h e usual stabilizer f o r field latex against bacterial action is a m m o n i a . M c G a v a c k (1959) has recommended the use o f 0.15 t o 0 . 2 0 % formaldehyde, a n d after 15 t o 30 h , the addition o f a m m o n i a . I n this project, formaldehyde is used alone as the stabilizer. S o d i u m h y d r o x i d e at 0.01 % o n the latex is m i x e d w i t h the formalin, before its addition t o the latex. T h e addition o f a very small a m o u n t o f formaldehyde kills within a f e w minutes (about 15 m i n ) all the bacteria present i n the tapped latex. F i e l d latex has a b o u t 2 % t o 3 % protein a n d the formaldehyde present reacts w i t h this t o f o r m a formaldehyde-protein complex, that enhances the stability o f t h e latex. Neutralised formaldehyde at 0.2 t o 0 . 3 % o f the latex is used alone f o r stabilization a n d this is claimed b y us t o be a n e w m e t h o d o f stabilization. T h e treated latex is stable even after o n e year's storage. I f N R latex is used as the adhesive, it will be necessary t o reinforce it t o get the necessary b o n d strength t o meet p l y w o o d specifications. L e Bras & Piccini (1951) were the first t o show the possibility o f obtaining direct reinforcement o f latex b y mixing resin dispersion o r solutions o f various, types, t o stabilized latex, these resins being preformed a t a l o w stage o f condensation. V a n A l p h e n (1954) has described the preparation o f resin/rubber masterbatches. T h e resins were f o r m e d in situ in acidified latex, stabilized w i t h n o n ionic o r cationic stabilizers a n d then coagulated. A simple possible m e t h o d o f reinforcing N R latex is t o m i x it w i t h U F resin a n d permit the p o l y m e r i z a t i o n t o take place i n the latex. H o u w i n k & V a n A l p h e n (1955) state that during the f o r m a t i o n o f the resin i n the aqueous phase o f the latex, it builds u p a somewhat cagelike structure. T h i s rigid structure reinforces latex films. F o r a noticeable reinforcement b y resins, chemical bonds between the rubber a n d the resin particles are desirable. I n U F the free N H group is o f great importance in the formation o f such chemical bonds.
2

A n adhesive system that contains a mixture o f a resin a n d a n elastomer is called a t w o p o l y m e r adhesive. A l t h o u g h each c o m p o u n d has adhesive properties b y itself, considered overall the conjoint system f o r m s a stronger a n d m o r e versatile adhesive. T h e t w o p o l y m e r systems have been particularly successful as film a d hesives. T h e use o f synthetic rubber as the elastomer has been studied ( R a y n e r , 1965). I n this project N R has been used as the elastomer. O n the basis o f the w o r k d o n e , a Sri L a n k a patent has been applied f o r o n the " T h e use o f natural rubber-resin blends as a n adhesive f o r p l y w o o d " ( E l i a t a m b y , N a d a r a j a h , A m a r a s i n g h e & L i y a n a g e , 1972). Stabilization of field latex for blending with urea formaldehyde resin A latex stabilizer must prevent bacterial activity, suppress e n z y m e action a n d preserve the latex protein which is the stabilizing factor o f the rubber h y d r o c a r b o n . T h e use o f f o r m a l d e h y d e as a preservative has been attributed t o its reaction w i t h the a m i n o groups i n protein f o r m i n g a protein-formaldehyde complex. T h i s is less liable t o bacterial o r enzymatic action. T h e formaldehyde-protein complex does n o t break d o w n even o n intense heating. A d r o p i n p H has been observed w i t h the addition o f formaldehyde, which is caused b y the release o f free carboxyl groups i n the protein. T h e lower p H completely eliminates a n y oxidation ( M c G a v a c k , 1959). N a d a r a j a h et al. ( 1 9 7 2 ) , have s h o w n that tocotrienols are i m p o r t a n t antioxidants present i n N R a n d that alkali has a n adverse effect o n the anti-oxidant action o f tocotrienols. Alkalies act o n the tocotrienols only slowly a n d treatment f o r longer periods has been f o u n d t o have a m o r e adverse effect. H e n c e the failing load o f p l y w o o d bonded w i t h casein a n d a m m o n i a preserved centrifuged latex w o u l d be expected t o decrease w i t h storage time. T h i s adverse effect will n o

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W. G. WEERARAtME, M. NAD ARAM ft D. A. R. ELIATAMBY, U. P. P. AMARASINGHE AND N. L1YANAGE

be expected i n formaldehyde preserved field o r centrifuged latex. I t is noted that at least 0 . 2 % f o r m a l d e h y d e is necessary t o preserve latex f o r periods over a m o n t h , b u t percentages a b o v e 0 . 3 % tend t o reduce t o some extent the viscosity o f the final glue mixture. I t is possible t o use fresh field latex with U F resin as the stabilizer, b u t the storage properties h a v e n o t been satisfactory. F r e s h unstabilized field latex has been m i x e d w i t h U F resin a n d used as the adhesive i n mixtures containing 6 5 % N R a n d 35 % U F resin. B o n d strengths o f 150 psi were obtained. T h o u g h this m e t h o d is suitable f o r laboratory experiments, it is unsuitable f o r commercial application. I n t h e experiments conducted, b o t h field a n d centrifuged latex, containing 0.3 % f o r m a l d e h y d e , h a v e been used. A f t e r centrifuging t h e formaldehyde content is b r o u g h t u p t o 0 . 3 % o n t h e centrifuged latex. F i e l d latex containing 0 . 3 % formaldehyde is allowed t o stand f o r a t least t w o days before being used as an adhesive f o r p l y w o o d o r before centrifuging, t o enable the formaldehyde t o react w i t h the a m i n o g r o u p i n the protein present i n the. field latex t o f o r m a protein formaldehyde complex. Use of kaolin as the extender B u t t r e y (1964) states that for 7 0 parts o f U F resin, extenders like china clay, slate p o w d e r o r flour could b e used at 1 0 t o 50 parts. Since china clay (kaolin) is a locally available r a w material its use as the extender has been evaluted. EXPERIMENTAL 1) Use of UF resin-NR latex blends

Increasing proportions o f U F as a dispersion were blended w i t h field latex, d r y r u b b e r content (d.r.c.) 3 2 . 5 % , a n d w i t h centrifuged latex (d.r.c.) 5 2 . 5 % . These blends were used i n b o n d i n g p l y w o o d a n d tested f o r b o n d strength. 2) Use of UF resin-NR latex-kaolin blends for plywood manufacture

T h e m e t h o d o f m i x i n g the N R latex, U F resin a n d kaolin is i m p o r t a n t and it was done as follows : U F resin is m a d e i n t o a suspension w i t h sufficient water. T h e extra water necessary t o m a i n t a i n total solids content at 5 5 % i n the final m i x is calculated a n d added t o the suspension; kaolin is stirred into the U F resin suspension a n d the U F . resin-kaolin slurry is r u n i n t o the N R latex a n d m i x e d . These blends were used i n ' b o n d i n g p l y w o o d a n d tested f o r b o n d strength. 3 ) . Replacement of 25 % UF resin by melamine formaldehyde T w e n t y five percent o f the U F resin i n a U F r e s i n - N R - k a o l i n blend was replaced b y melamine f o r m a l d e h y d e ( M F ) a n d its effect o n the b o n d strength o f the w o o d species, RubberMalabodaRubber and BomieKokumBomie investigated. 4) Use of PF resin-NR latex blends

O n e part o f P F resin as a suspension was blended w i t h o n e part o f N R as centrifuged f o r m a l d e h y d e stabilized latex. T h e blend was used i n b o n d i n g p l y w o o d a n d tested f o r b o n d Strength.

THE USE OF NATURAL RUBBER LATEXRESIN BLENDS AS AN ADHESIVE FOR PLYWOOD RESULTS AND DISCUSSION

41

Use of UF resin-NR latex blends

T h e results o f b o n d strengths b y the use o f U F r e s i n - N R latex blends are given in T a b l e 2.

TABLE 2

PHYSICAL PROPERTIES OF GLUE LINE USING DIFFERENT PROPORTIONS OF ^/RUBBER BLENDS

Type of UF/Rubber latex ratio 10/90 25/75 35/65 50/50

Total solids of the glue as % 34.5 38.4 42 45.2

Glue adhesion in psi 36 70 92 .252

* >

Water resistance failed medium good excellent

Field latex

Malaboda Thiniyg
Centrifuged latex 0/100 15/85 25/75 35/65 50/50 52.5 51 55 55 55 68 214 164 276 210 81 100 90 168 excellent excellent excellent excellent

The minimum failing load is.150 psi as according to I .S. 101964

I t will be n o t e d that the total solids content is an i m p o r t a n t factor f o r b o n d strength. M a n y battles between adhesive materials are being w o n o r lost o n the basis o f a difference i n solids content o f a few percent (Skeist, 1962). B y using centrifuged formaldehyde stabilized latex it was possible t o maintain desired total solids content o f the U F r e s i n - N R latex glue b y the addition o f water, a n d t h e results o f b o n d strengths are also given in T a b l e 2.

Use of UF resin-NR field latex-kaolin blends for plywood manufacture

T h e results f o r b o n d strengths using U F r e s i n - N R field latex-kaolin blends as the adhesive are given in T a b l e 3:

42

W.

G. WEERARATNE,

M. NADARAJAH N. LIYANAGE

D. A. R. ELIATAMBY,

U. P. P. AMARASINGHE AND
TABLE 3

EFFECT OF KAOLIN AND %

T O T A L SOLIDS C O N T E N T O N B O N D S T R E N G T H S

F I E L D L A T E X O F D . R . C . 32.0%

USED

Ratio of Resin : Rubber : China clay 35 35 35 35 35 : 65 0 : 65 35 :65 47 (silica) : 65 70 :65 100 0 35 70 75

Total solids content % 42 46 50 52 56 43 57 56 56

Failing load psi 78 57 176 127 188 107 162 250 300

50 : 50 50 : 50 50 : 50 100 : 0

Results show that i f a total solids content o f 5 5 % a n d over is maintained it w o u l d be easier t o obtain b o n d strengths o f over 150 psi. I n using field latex, it w o u l d b e easier t o obtain the total solids content o f over 55 %, i f the ratio o f U F resin t o rubber is 1 : 1 . F u r t h e r , it is necessary t o use an extender such as kaolin t o raise the total solids percentage. Results also indicate that precipitated silica is a m u c h better reinforcing filler than kaolin. Use of UF resin: NR latex: Kaolin blends at 5 5 % total solids for plywood manufacture T h e results f o r b o n d strengths obtained b y using field latex (total solids 3 5 . 4 % ) a n d centrifuged latex (total solids 5 2 . 5 % ) as the adhesive f o r p l y w o o d with a blend o f U F resin a n d kaolin are given in T a b l e 4 .
TABLE 4 %)

E F F E C T O F T H E U S E O F U F R E S I N : N R L A T E X : K A O L I N B L E N D S O N B O N D S T R E N G T H ( T O T A L S O L I D S 55

Type of latex & dry rubber content

Ratio of Resin : Rubber: Kaolin

Additional water ml

Total volume ml

Viscosity (Bore Dia. 4mm) sec

Viscosity after 6h sec

Failing load psi 162 220 194 219 170 174

Field (35.4)

35:65: 70 35:65:100 35:65: 0 50:50: 0 35:65: 70 35:65:100

20 45 23 37 80 105 170 260 285

35 26 25

35 42.5 39

Centrifuged (52.5)

THE USE OF NATURAL RUBBER LATEXRESIN BLENDS AS AN ADHESIVE FOR PLYWOOD

43

N o difficulty was experienced i n getting adequate b o n d strength even w i t h o u t kaolin, w h e n centrifuged latex was used. . F u r t h e r enhancement o f b o n d strength is possible b y m i x i n g w i t h kaolin. T h e initial viscosity o f creamed latex is higher ( T a b l e 4) t h a n w h e n kaolin is used as the extender, b u t w i t h time the acidity o f kaolin causes condensation o f U F resin resulting i n increased viscosity. I n the case o f field latex blends, the use o f m o r e kaolin ( 1 0 0 instead o f 70) has given a higher failing load, b u t is n o t recommended f o r commercial use because o f m i x i n g problems. These problems d o n o t exist w h e n the centrifuged latex blend is extended w i t h 1 0 0 % kaolin, the additional water being m o r e than sufficient t o m i x the kaolin into the U F resin. H o w e v e r , f o r commercial purposes t h e use o f kaolin as an extender a t m o r e t h a n . 7 0 % is n o t n o r m a l l y recommended. Replacement of UF by melamine formaldehyde V a n A l p h e n ( 1 9 5 7 ) has f o u n d the mechanical properties o f rubber containing U F resin becomes better w h e n a small part o f the urea (25 % ) is replaced b y melamine. T a b l e 5 confirms this reinforcement in that replacement o f 25 % U F resin b y melamine formaldehyde ( M F ) gives an increased failing load, for example in the case where the w o o d species is Rubber/Malaboda/Rubber ( R / M / R ) .
TABLE . E I - F E C T O F R E P L A C E M E N T O F 25% S U F RESIN B Y M E L A M I N E

Type of latex & dry rubber content % Field (35.4)

Ratio of Resin: Rubber: Kaolin

% melamine in Resin

Failing load of wood species psi

35:65: 70 35:65: 70 35:65: 70 35:65: 70 35:65: 0 35:65 : 0 35:65:100 35:65:100 35:65:100

0 25 0 25 0 25 0 25 (no hardener) 25 (hardener)

R/M/R 162 208 170 222 194 250

B/K/B 112 114 145 152 189 189

M/M/M

Centrifuged (52.05)

204 98 239

Wood species R/M/R is Rubber/Malaboda/Rubber Wood species B/K/B/ is Bomie/Kokum/Bomie Wood species M/M/M/ is Malaboda/Malaboda/Malaboda

L i s t o f timber species used w i t h their corresponding botanical names is given in T a b l e 6.

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W. G. WEERARATNE, M. NADARAJAH D. A. R. EL1ATAMBY, U. P. P. AMARASINGHE AND N. LIYANAGE

TABLE 6 LIST OF TIMBER SPECIES USED

Local Name

Botanical Name

Aridda Bomie Hulanidda Hora Kokum Kirihembiliya Kolta-puhmg Malaboda Natau Rubber Thiniya Waldivul

Campnosperma zeylanica Litsea glutinosa Shorea stipularis Dipterocarpus zeylanicus Kokoona zeylanica Palaquium petiolare Eriodendron antractuosum Myristica dactyloides Xylopia parvifolia Hevea brasiliensis Doona congestiflora Hydnocarpus vanenata

I t m u s t be mentioned that n o hardener was used a n d the acidity was obtained f r o m w o o d . H e n c e t o obtain o p t i m u m results f r o m n o t t o o acidic w o o d s , it will be necessary t o use a hardener. V a n A l p h e n ( 1 9 5 7 ) has also f o u n d that w h e n 2 5 % o f the urea is replaced b y melamine, the properties are n o t further enhanced a n d that they are at least as g o o d as those o f rubber containing pure M F resin. T h e m o s t i m p o r t a n t aspect was that the resin should be f o r m e d i n the latex at as high a temperature as possible w i t h o u t coagulating the latex. I t was further observed that the entire replacement o f U F w i t h M F i n the U F / N R / k a o l i n blend causes coagulation, indicating that M F does n o t stabilize kaolin as U F does. Acidity of timber M o s t timbers i n S r i L a n k a are acidic a n d it is expected that i f the timber was sufficiently acidic, i.e. w i t h extracts h a v i n g a p H o f below 4 , n o hardener, will be required i f the adhesive is U F o r contains U F . I f the acidity o f w o o d is insufficient, then the rate o f curing will be slow. T h e degree o f condensation is quite important since i f insufficient, the resin w o u l d be absorbed into the w o o d a n d thus be unavailable t o act as a n adhesive. T h e results o f b o n d strength with n o hardener o n ten species o f timbers i n Sri L a n k a are given i n T a b l e 7 .
TABLE 7 EFFECT ON BOND STRENGTH USING DIFFERENT WOOD SPECIES

NR Wood species

U F : Kaolin is 65:35:100 Failing load psi 241 218 204 198 191 172 168 152 134 93 Wood failure

%
100 100 30 40 60 . 0 0 100 10 0

Aridda Kokum Malaboda Waldivul Thiniya Hulanidda Hora Kirihembiliya Kotta-pulung Natau

THE USE OF NATURAL RUBBER LAtEXREIN BLENDS AS AN ADHESIVE FOR PLYWOOD

45

T h e ratio o f N R : U F : K a o l i n was 6 5 : 3 5 : 100 a n d this formulation ( T o t a l solids 5 5 % ) can be used successfully o n all species o f timber used f o r p l y w o o d manufacture w i t h the exception o f the less acidic timbers like Natau a n d D i y a t h a liya. F o r universal application it is r e c o m m e n d e d that a hardener e.g. a m m o n i u m chloride b e used at o n e fifth part per 1 0 0 parts o f resin. PF resin - NR latex blends T h e P F resin obtained b y condensing one molecule o f p h e n o l with t w o molecules o f f o r m a l d e h y d e , is c o m p o s e d o f linear molecules, relatively short in length and capable o f being dissolved i n water. T h e solution is alkaline i n reaction, a n d further heating o r addition o f suitable catalysts e.g. p a r a f o r m a l d e h y d e , completes crosslinking (Buttrey, 1964). T h e use o f P F r e s i n - N R latex blends should be feasible as adhesives f o r plyw o o d . A c c o r d i n g t o Stern ( 1 9 6 7 ) , phenolic resins, p r o b a b l y as the result o f interaction between h y d r o x y l groups in the o r t h o position and the double b o n d o f the rubber molecule t o give a c h r o m a n e ring, can crosslink with natural rubber. A c c o r d i n g t o Scott (1962), the adhesion o f rubber t o textiles is i m p r o v e d if the latter are impregnated with a mixture o f N R latex a n d resorcinol formaldehyde resin a n d the investigation o f the mechanism o f adhesion suggests that mechanical rather than chemical factors are m o r e important. O n e part o f P F as a solution (1 part P F i n 4/5 parts water) was blended with one part o f N R (d.r.c. 5 3 . 7 % ) centrifuged formaldehyde stabilized latex. I n one o f the experiments, sodium h y d r o x i d e solution was added t o bring the p H u p t o 1 1 - 1 2 . P a r a f o r m a l d e h y d e was used as the hardener a t 5 % a n d a t 1 0 % o n the N R / P F m i x . T h e results f o r b o n d strengths obtained are given in T a b l e 8.
TABLE 8 55%)

E F F E C T O F T H E USE O F P F RESIN-NR L A T E X B L E N D S O N B O N D S T R E N G T H S ( T O T A L SOLIDS

PF

Ratio of : Rubber : Kaolin

Paraformaldehyde % 5 10 5

Failing load psi 279.1 295.0 243.3 274.1 268.3 295.8

50:50 0 (NaOH solution added) 50:50 0 50:50:20

T h e b o n d strengths are satisfactory f o r commercial p l y w o o d . Samples boiled at 100 C f o r 120 h withstood de'lamination. H e n c e commercial p l y w o o d o f M o i s t u r e Resistant ( M R ) , B o i l Resistant ( B R ) a n d W e a t h e r and Boil P r o o f ( W B P ) could b e m a d e using P F / N R blends. Factory trials Sri L a n k a requires 4$ million tea chests annually. O n l y o n e third o f t h e requirement o f tea chests are produced locally, the balance being i m p o r t e d . W i t h the K o s g a m a P l y w o o d C o m p l e x c o m i n g i n t o full operation i n the near future, S r i L a n k a should b e self sufficient i n p l y w o o d f o r tea chests. A p p r o x i m a t e l y 8 5 % o f p l y w o o d manufactured i n Sri L a n k a is f o r use i n tea chests.

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W. G. WEERARATNE, M. NADARAJAH D. A. R. ELIATAMBY, U. P. P. AMARASINGHE AND N. LIYANAGE

F a c t o r y scale trials were carried o u t w i t h U F centrifuged formaldehyde stabilized N R latex (d.r.c. 5 0 % ) blends. Satisfactory samples were obtained w i t h blends in the ratio 1 : 1 . A n average m e a n o f 2 1 3 psi has been obtained f o r b o n d strength. F a c t o r y scale trials were also carried o u t w i t h U F / N R blends (d.r.c. 5 5 % ) i n the ratio o f 1 : 2 b u t extended w i t h 3 0 % flour. A n average m e a n o f 190 psi has been obtained f o r the b o n d strength. Mechanism of adhesion
K

W o o d b o n d i n g w i t h adhesives i n the case o f synthetic resin is mainly physical w i t h only 20 % o f chemical adhesion. T h e imperfect nature o f the w o o d surface does n o t permit a state o f absolute contact f o r molecular attraction. T h e b o n d i n g effect should be such as t o fill all the imperfections i n the w o o d surfaces t o achieve a state o f perfect mechanical adhesion. U r e a formaldehyde has a suitable molecular structure that w o u l d assist i n this. I t has either N H o r O H o r b o t h these groups freely dispersed i n the molecule. These groups are polar a n d are attracted towards the O H groups o f the cellulose. I n the glue line the urea formaldehyde hardens b y chemical reactionpolymerisation, w i t h little loss o f water. Polymerisation takes place i n a n acid m e d i u m p H 2-3, w h i c h is p r o v i d e d b y :
2

(1) (2) (3)

F o r m a l d e h y d e used in stabilizing the latex, reacting with the proteins in the N R latex. M i n e r a l fillerchina clay. Acidity o f wood.

T h e evaporation o f solvent water i n the urea formaldehyde resin plays a relatively secondary part t o achieve full glue strength. O n e o f the fundamental properties required o f a w o o d glue is g o o d wetting characteristics i n order t o allow intimate contact. T h e most successful w o o d glues are water based, being suitable f o r filling gaps o f approximately 0.05 m m i n between surfaces. T h e O H groups i n cellulose have a high attraction f o r water a n d water therefore readily wets w o o d . W h e n natural rubber latex is used f o r w o o d gluing, the necessary film f o r m i n g is achieved b y the water o f the latex evaporating. W o o d assists i n absorbing this water f r o m the glue line. I n rubber latices t o o , mechanical adhesion t o other surfaces is o f m a j o r importance b u t specific adhesion also plays a secondary role. C o h e sion o f film i n unmodified N R latices is high, while adhesion is low. T h i s is i m p r o v e d b y the addition o f U F resin i n the f o r m o f a suspension. R u b b e r being t h e r m o plastic, a t ' p l y w o o d b o n d i n g temperature it softens a n d u n d e r the applied pressure grips i n t o the interstices o f w o o d surfaces, allowing a close contact f o r mechanical a n d specific adhesion. T h e use o f mineral filler (kaolin) has opposite functions i n the t w o components o f the blend. W i t h urea formaldehyde it prevents excessive penetration o f the synthetic resin i n t o the w o o d . W i t h rubber it embeds itself into the rubber latices p r o v i d i n g a n imperfect surface f o r mechanical adhesion. F o r economical curing time o f the adhesive blend it is necessary t o have a m i n i m u m o f 55 % solid content.

THE USE OF NATURAL RUBBER LATEXRESIN BLENDS AS AN ADHESIVE FOR PLYWOOD

47

Present pressing conditions are : Temperature 120C Pressure f o r tea chest panels 150 psi Pressing time 5 to 7 min I n order t o m a k e the blend applicable o n a commercial scale it is necessary t o use centrifuged latex, or centrifuged-field latex blends, because the extra water needed t o keep the total solid content a t 5 5 % could be m a d e use o f t o disperse the urea formaldehyde p o w d e r a n d the kaolin filler. U F resin is used i n the unextended f o r m i n chipboard manufacture. H e n c e N R l a t e x - U F resin blends, without extender, should be a promising material f o r investigation in its use as the binder in the manufacture o f chipboard. Economics of NR usage T h e total annual consumption o f urea formaldehyde resin i n Sri L a n k a p l y w o o d manufacture is approximately 1,400 tons. I f 65 % o f this is t o be substituted b y N R , 910 tons o f d r y rubber are needed. A t 3 l b o f d r y rubber p e r gal o f field latex approximately 760,000 gal are needed. I t is proposed that this latex be collected f r o m small estates a n d f r o m small holders at collecting centres. I t is estimated that each collecting centre could collect approximately 200 gal p e r day. O n the assumption that the annual n u m b e r o f tapping days is 250, fifteen such collecting centres will be required. C e y l o n P l y w o o d s C o r p o r a t i o n m a y p a y such collecting centers the R S S N o . 1 outstation price less -/08 cts. ( N a d a r a j a h el al., 1972). T h e price t o be p a i d b y collecting centres t o rubber producers is suggested at R S S N o . 1 outstation price less - / 1 6 cts. T h e collecting centre could hence incur a n expense o f u p t o -/08 cts p e r l b i n collecting latex. C e y l o n P l y w o o d s C o r p o r a t i o n could arrange transport o f the collected stabilized latex t o the P l y w o o d factories. Concentration o f field latex t o a higher d r y rubber content is advantageous. T h e quantity needed per a n n u m will be only 410,000 gal, i f the d r y rubber content is maintained at 5 5 % . C e y l o n P l y w o o d s C o r p o r a t i o n could either contract w i t h the Plantations M i n i s t r y f o r t h e supply o f stabilized centrifuged latex o r be a share holder i n a central centrifuging factory ( N a d a r a j a h , Perera, Balasingham, & F e r n a n d o , 1972), t o obtain a regular supply o f centrifuged latex. C u r r e n t C I F prices o f urea formaldehyde a n d hardener p e r 1,000 kilos are R s . 1,820/- a n d R s . 2,820/-, respectively. T o t a l foreign exchange expenditure o n glue components is 4 million rupees. C o s t p e r p o u n d o f urea formaldehyde is R s . 1.47 local. N a t u r a l rubber at R S S 1 average price f o r 1 9 7 1 being -/80 cts per l b , the cost o f the rubber w o u l d approximately be - / 7 4 cts per l b t o the C e y l o n P l y w o o d s C o r poration. Centrifuging will raise the cost b y 2 0 % a n d will bring the price o f rubber to approximately -/96 cts p e r lb. N e w uses o f N R should be f o u n d a n d implemented t o keep N R prices at attractive levels. I n this context the substitution o f urea formaldehyde resin i n part w i t h rubber i n p l y w o o d manufacture should be deserving o f implementation n o t o n l y in Sri L a n k a b u t in all natural rubber producing countries. T h e replacement o f U F resin b y rubber t o the extent o f 9 1 0 tons w o u l d result i n a saving o f a b o u t 8 lakhs t o the C e y l o n P l y w o o d s C o r p o r a t i o n a n d a foreign exchange involvement o f approximately l | million rupees. T h e local cost p e r l b o f P F resin is R s . 2 . 1 8 a n d the cost o f N R is -/96 cts per l b o f d r y rubber in the f o r m o f formaldehyde stabilized centrifuged latex. T h e replacement o f 5 0 % o f the imported P F resin which a m o u n t s t o approximately 50 toris, b y N R w o u l d result i n a saving o f approximately o n e l a k h o f rupees t o the C e y l o n P l y w o o d s C o r p o r a t i o n a n d o f a foreign exchange involvement o f a p p r o ximately one l a k h o f rupees.

48

W. G. WEERARATNE,

M. NADARAJAH

D. A. R. ELIATAMBY, U. P. P. AMARAS1NGHE AND N. LIYANAGE W i t h the expansion o f cashew n u t production i n S r i L a n k a , it is expected that cashew n u t shell liquor ( C N S L ) should be available i n S r i L a n k a i n the near future. C a r d a n o l is the active constituent o f C N S L a n d is present in C N S L as anacardic acid. C a r d a n o l is a meta substituted phenol, a n d i s m o n o - h y d r o x y with the C H h y d r o carbon chain substituted i n the meta position. Since this phenol is reactive at the ortho and para positions, and is ^ f u n c t i o n a l w i t h respect t o the reaction with formaldehyde, it is suitable f o r investigations regarding t h e condensation w i t h formaldehyde t o f o r m P F resins. W e are investigating the preparation o f this type o f P F resin and its properties in blends w i t h N R latex.
1 5 a 7

ACKNOWLEDGEMENT

W e are grateful t o D r . O . S. Peries, D i r e c t o r , R . R . I. G , f o r his encouragement o f this project.

REFERENCES BUTTREY, D . N . (1964). Plastics In the furniture industry, ch. 3 p p . 38-41. L o n d o n :

Macdonald.
ELIATAMBY, D . A ; R . , NADARAJAH, M . , AMARASINGHE, U . P . P . AND LIYANAGE,

N . (1972). T h e use o f natural rubber-resin blends as an adhesive f o r p l y w o o d . Sri Lanka Patent application No. 6911.
HOUWINK, R . AND VAN ALPHEN, J . 16,121-129. KNIGHT, R . A . G . (1952). Adhesive for wood. p. 5. L o n d o n : C h a p m a n & H a l l L t d , L E BRAS, J . AND PICCINI, I. (1951). D i r e c t reinforcement o f latex b y m i x i n g (1955). R e i n f o r c i n g effect o f condensation

polymers o n rubber i n connection w i t h their particle size. J. Polym. Sci.,

resin dispersions, Ind. Engng. Chem. 43, 381-386. MCGAVACK, J . (1959). Preservation a n d concentration o f latex. Technol, 32, 1660-1674.
NADARAJAH, M . , PERERA, K . A . , BALASINGHAM, K .

Rubb. Chem.

AND FERNANDO, W . S . E . Pro-

(1972).

Proposals f o r a central factory f o r latex i n Sri L a n k a . (Internal report.)

NADARAJAH, M . , BARTHOLOMEUSZ, P . A . AND MUTHUKUDA, D . S . (1971).

posals t o i m p r o v e a n d increase quality production o f pale crepe i n C e y l o n . RRIC Bulletin, 6, 62-76.

NADARAJAH, M . , COOMARASAMY, A . , KASINATHAN, S . AND TIRIMANNE, A . S . L . (1972). S o m e naturally occurring anti-oxidants i n Hevea brasiliensis latex, J . I.R.I., 6, 26-29.

Synthetic organic adhesives. I n Adhesion and Adhesives, e d . . H o u w i n k , R . a n d S a l o m o n , G . p p . 186-337, A m s t e r d a m : Elesvier Publishing C o m p a n y . SALZBERG, H . K . (1962). Casein glues a n d adhesives. la Handbook of Adhesives ed. Skeist, I. p p . 129-147. N e w Y o r k : R e i n h o l d Publishing C o r p o r a t i o n . SCOTT, J . R . (1962). F u n d a m e n t a l s o f processing. In Applied Science of Rubber ed. W . J . S . N a u n t o n , p p . 324-325. L o n d o n : E d w a r d A r n o l d . SKEIST, I. (1962). I n t r o d u c t i o n t o adhesives. I n Handbook of Adhesives e d . Skeist, I. p p . 3-13, N e w Y o r k : R e i n h o l d Publishing C o r p o r a t i o n . STERN, H . J . (1967). Rubber: Natural and Synthetic p. 2 3 9 , L o n d o n : M a c l a r e n & Sons L t d . VAN ALPHEN, J . ( 1 9 5 4 ) . R u b b e r Reinforcement b y resins f o r m e d i n latex. Proc. 3rd Rubb. Technol. Conf, 670-683. VAN ALPHEN, J . (1957). R u b b e r A m i n o p l a s t s . Rubb. Plast. Age., 237-240. WAKE, W . G . ( 1 9 6 5 ) . R u b b e r s . I n Adhesion and Adhesives ed. H o u w i n k , R . a n d S a l o m o n , G . C h . 6, p p . 375-418. A m s t e r d a m : Elsevier Publishing C o m p a n y .

RAYNER, C . A . A . (1956).