Enhancing adhesion of thermosetting urea-formaldehyde resins by preventing the formation of H-bonds with multi-reactive melamine

Contemporary urea-formaldehyde (UF) resins with low-molar-ratio contain highly crystalline domains induced by the hydrogen (H) bonds between their linear molecules, which inhibits cross-linking, and results in poor adhesion. In this study, a novel way of controlling the crystallinity of such resins by preventing the formation of H-bonds using multi-reactive melamine during synthesis was reported. FTIR and 1H-NMR spectroscopy confirmed the shifting of the carbonyl (C = O) peak, and N-H signal. XRD patterns revealed the conversion of crystalline to amorphous domains by adding 20% melamine, resulting in a decrease in crystallinity from 52 to 22%. The amorphous UF resins cured faster, have higher molecular weight and cross-linking density, and also followed the autocatalytic reaction model with excellent theoretical fitting. In addition, a 33% increase in adhesion strength, and a 62% reduction in formaldehyde emission was recorded. Hence, the addition of 20% melamine into the UF resins leads to better adhesion and less formaldehyde emission.