Recent Advances in Soyad ® Adhesives Don Saylor & Dr. Jim Wescott HPVA Meeting Scottsdale, AZ May 25, 2010
2 Outline Soyad Program Development Emissions Durability Summary / Path Forward
3 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
4 Soyad Timeline
5 Soy Flour + Curing Resin Process and Performance Additives Soyad ® Adhesive Technology CROSSLINKED ADHESIVE
6 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
7 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
8 Commitment to Excellence 600 Technical Service Chemical Engineers in NA available to support Soyad!
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
10 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
11 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
12 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
13 Estimated CARB P2 level < 10 ULEF Continues to generate additional CH2O ULEF at 96 hrs = 33X Soyad
14 Soyad panels emit very little additional formaldehyde after the first 24 hours ULEF rate is actually increasing exponentially (scavenger is consumed?)
15 Similar Trend at 25 C
Durability in EWF
17 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”)
18 Day #Condition Time (hr) Temperature (°F) Relative Humidity Theoretical MC Pre-TestConditioning727050%9.2% 1Hot/Wet248090%20.2% 2Cold/Moist241570%13.5% 3Hot/Dry249020%4.3% 4Cool/Wet243690%21.0% 5Hot/Dry249020%4.3% Post-TestConditioning727050%9.2% 3X Temperature/Humidity Cycling Protocol Stability Testing of EWF
19 Length (in) Height (in) Width (in) Control Samples Cycled Samples Dimensional Stability of Shear Test Samples Panel Testing 3-Cycle SoakShear Strength Testing DryStd.%WetStd.% %ShearDev.DryShearDev.Wet TypeScorePass(psi) WF(psi) WF Control % Cycled % Shear and 3-Cycle Soak Test Results Bond lines 1 & 2 tested in shear tests (oak-gum-gum) Stability Testing of EWF
20 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
21 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 !