Effect of Lignosulphonates on the Moisture Resistance of Phenol–Formaldehyde Resins for Exterior Plywood

Abstract

Phenol–formaldehyde (PF) resins remain the preferred adhesive for exterior plywood, as they confer these boards their extreme weather resistance. However, their high price and toxicity has made phenol alternatives, such as technical lignins, increasingly more attractive. While many works report the use of kraft lignin, the most commercially available form are lignosulphonates (LS). However, these lack industrial success and are associated with low moisture resistance. In the current study, lignosulphonate–phenol–formaldehyde (LPF) resoles were synthesized considering a phenol replacement of 30% (w/w). Two LS samples of softwood (SLS) and hardwood (HLS) origin were compared. These samples were previously methylolated to increase their reactivity. The effectiveness of the treatment was confirmed through the Automated Bonding Evaluation System. Plywood was manufactured and tested according to EN 314 class 3 for exterior conditions, which is seldom found in the literature. Although a 35% increase in shear strength is still necessary to comply with the standard, methylolated SLS was the most promising substitute, as it resulted in the highest board performance. Notably, when this sample was used without previous methylolation, the plywood boards suffered delamination during immersion in boiling water prior to shear testing. These results reinforce the need for the methylolation of LS to increase the weather resistance of plywood.