Bio-Based Impregnated Resin Preparation for Aldehyde-Free Decorative Paper Production

With the growing concern for environmental protection and personal health, utilizing bio-based impregnated resin has become a sustainable approach for producing aldehyde-free decorative paper and in-house decorations. Our current work focuses on the preparation of an aldehyde-free resin (AFR) by formulating quaternized cellulose nanofibrils (QCNFs, Ave. width 10 ± 3 nm, Ave. length of and >500 nm) with aqueous acrylate emulsion. We analyzed the synthesized QCNFs, acrylate emulsion, and AFR by using various methods, including FTIR, XPS, XRD, TGA/DTG, and rheometer, to evaluate their applicability for impregnated paper processing. At a low coating weight of 4.0 g/m2, a 30.8% increase and 4.9-times increase in tensile strength and contact angle were detected, respectively. Meanwhile, the free aldehyde emission from the AFR-coated paper was found to be 0.1 mg/L even at a high coating weight of 18.8 g/m2, which is far below the E0 level requirement in the JAS 234:2003 criteria. Therefore, the surface coating of the decorative base paper was found to be competitive in covering the porous structure of the paper, reinforcing its mechanical strength, and providing high water resistance. Moreover, the lower free aldehyde emission from the AFR-coated paper ensures its safety and potential application in house decoration products.