Background of the Invention Due to recent changes in the species, size and quality of standing timber available for harvest throughout the world, composites of lignocellulosic materials have replaced traditional solid sawn lumber for use in many structural applications. Many of these composites are used in applications, which require resistance to wood-destroying organisms such as fungi and various insects. Accordingly, this requires treatment with a wood preservative.

Traditionally, solid wood products are dipped or pressure treated with solutions of preservative chemicals. However, the nature of a composite material makes it possible to incorporate a preservative into the product during its manufacture. This decreases total production costs and yields a superior product in which the composite has a constant loading of preservative throughout its thickness.

Borates have been used as broad-spectrum wood preservatives for over 50 years.

Their benefits include efficacy against most wood destroying organisms such as fungi, termites and wood-boring beetles. Coupled with their low acute mammalian toxicity and low environmental impact, their fungicidal and insecticidal properties have resulted in them being considered the wood preservative of choice for most structural or construction applications. Borates such as boric acid, borax, disodium octaborate tetrahydrate (commercially available as Tim-bor (E) Industrial Wood Preservative from

U. S. Borax Inc.) and, more recently, zinc borate are well accepted as wood preservatives.

Generally, boric acid, borax and disodium octaborate are used for treating solid wood products by dip or pressure treatment. However, these preservatives are readily soluble in water and can be incompatible with many resin systems used in producing composite products, resulting in an adverse effect on the internal bond strength of the resultant composites and poor mechanical strength. Anhydrous borax and zinc borate have been used successfully at relatively low levels with some resin systems, such as the phenol- formaldehyde resins, to produce composites with acceptable internal bond strength. See Knudson et al., U. S. Patent No. 4,879,083. Zinc borate is also particularly preferred because its inherent low solubility reduces leaching and loss of the active ingredients in laboratory tests and in high moisture hazard environments in service. Although the low solubility borates of Knudson et al., especially zinc borate, have been used successfully to treat wood composites such as oriented strand board (OSB), waferboard, fiberboard and particleboard, they suffer from several specific problems related to their low solubility.

For example, while they perform very well in laboratory decay tests in high humidity situations, or after leaching, if the tests are carried out without leaching and at lower ambient relative humidities (20-30 % moisture content in the wood) a limited amount of fungal decay can occur.

This invention provides composites made from wood and other lignocellulosic materials which are resistant to attack by wood destroying organisms such as fungi and insects, have excellent internal bonding strength, low inherent leaching and yet still provide both rapid and long-lasting performance against decay fungi and insects at low as well as high moisture content.

Summary of the Invention According to this invention, a pesticidal amount of a lower solubility borate and a higher solubility borate, in combination, are incorporated into lignocellulosic-based composites, thereby producing composites which have rapid, yet long-lasting, resistance against insect and fungal attack in low moisture and high moisture environments.

Detailed Description of the Invention The mixed solubility borate formulations of this invention can be prepared by well known blending or mixing of the two or more variably soluble borates. Generally, a larger proportion of the lower solubility borate component is used in combination with a smaller proportion of the higher solubility borate component. Weight ratios of the lower solubility component to the higher solubility component as low as 0.1: 1 or as high as 9: 1 can give improvement over using a single borate, but the preferred ratio is in the range of between about 1: 1 and 3: 1 for low soluble component to high soluble component.

Blending of the two or more components if carried out prior to addition to the lignocellulosic matrix or resin binder may be done using batch or continuous methods.

Any suitable means of blending may be used, such as a V-blender, rotary blender, zig zag blender, pin blender, paddle or ribbon blender, fluidized bed blender, conical screw blender, or air flow blender. In addition to using a simple blend, the mixed borate formulation can be prepared by coating the low soluble borate component with the high soluble borate component or by intimately combining them both with a binder (e. g. water) such as by using a pan granulator. Such coated or granulated combinations are beneficial in preventing segregation of the two components during transport etc. and prior to incorporation into the composite. They also improve product distribution and reduce segregation within the composite.

The low solubility and high solubility borates which are combined to be used in the method of this invention may be any one or more of the high soluble borate compounds such as boric acid and boric oxide, ammonium borate or alkali metal borates such as the sodium borates borax pentahydrate, borax decahydrate, sodium pentaborate, disodium octaborate, and sodium metaborate; and any one or more of the low solubility borate compounds such as transition metal borates (e. g. copper borates, zinc borates), or barium metaborate. Some alkaline earth metal borates, including calcium borates, calcium magnesium borates, magnesium borates and calcium sodium borates are of intermediate

solubility and can be used effectively as either a low soluble or high soluble borate depending on the combination used. For example, a formulation comprising an intermediate solubility borate, such as calcium borate, and a high solubility borate, such as sodium borate, would provide an effective mixed solubility borate formulation according to this invention, and such would be the preferred for use in a low moisture environment such as in interior sheathing. Similarly, a formulation comprising an intermediate solubility borate, such as calcium borate, and a low solubility borate, such as zinc borate, would provide an effective mixed solubility borate formulation, and such would be preferred for use in a high moisture hazard environment such as in exterior siding.

The preferred sodium borates are the sodium tetraborates, the sodium octaborates and the sodium pentaborates. Such sodium borates may be synthetically produced or may be a naturally occurring borate, such as tincal, tincalconite or kernite.

The preferred zinc borates are the zinc polytriborates, having a ZnO: B2 03 ratio of 2: 3. A number of polytriborates are known and these metal oxide formulations can be described using the metal oxide to boron oxide to water ratios. Suitable polytriborates as examples include the 2: 3: 3.5 (sometimes referred to as 4: 6: 7), the 2: 3: 7 and the 2: 3: 7.5, or with the full formulae 2ZnO 3B203-3. 5H20, 2ZnO 3B203-7H20, and 2ZnO-3B203-7. 5H20, respectively. Other suitable hydrated zinc borates include the 3: 5: 14, the 1: 1: 2 (where the 2 is probably actually 1.67) and the 4: 1: 1 or with the full formulae 3ZnO 5B203 14H20 (also referred to incorrectly as 2ZnO 3B203-9H20), ZnO-B203-xH20, where x is about 1.67 (this compound is typically referred to as either ZnO-B203 2H20 or 2ZnO-2B203-3H20) and 4ZnO-B203 H20, respectively. Such zinc borates are synthetically produced.

Suitable copper borates include a number of known compounds, but also amorphous mixtures of borate and copper. Examples include [Cu (NH3) 4] 0'2B203-6H20 (cuprammine borate hexahydrate). This compound is typically the first crop of crystals one obtains upon concentrating ammoniacal"copper borate"solutions, i. e., borax and copper sulfate dissolved in ammonia solution. It is metastable and decomposes to other

copper and cuprammine borates upon standing in solution. Known or reported suitable copper borate compounds include the mixed metal oxide 3Na202CuO8B203 17Ha0 as well as the 4: 1: 5,3: 2: 3,2: 1: 1 and 1: 1: 2 copper borates or, with the full formulae, 4CuO B203-5H20, 3Cu0-2B203-3H20, 2CuO-B203-H20, and CuO#B2O3#2H2O, respectively. Such suitable copper borates are synthetically produced.

The preferred calcium borates are the calcium polytriborates, having a CaO : B203 ratio of 2: 3, and calcium hexaborates, having a CaO : B2 03 ratio of 1: 3, with the most preferred being the calcium polytriborates. Such calcium polytriborates may be synthetically produced or may be a naturally occurring borate, such as inyonite, meyerhofferite and colemanite. Examples of suitable calcium hexaborates include nobleite and gowerite. Calcium-sodium borates and calcium-magnesium borates include probertite, ulexite and hydroboracite.

The particle size of the combined borates is not critical, but should be of a size that can be readily dispersed throughout the composite product. Generally, a mean particle size of as large as about 500 microns and as small as about 1 micron may be used, but for best results, it is preferred that the particle size be in the range of from about 150 microns to about 10 microns. It is also generally advantages for the two borates being mixed to have similar particle sizes to aid in the blending operation.

The effective amount of mixed borate formulation incorporated in the composite is a pesticidal amount; that is, an amount sufficient to control or kill fungi (e. g. mold and decay fungi) and/or insects that destroy wood and similar cellulosic-based composite products. Generally, a range of from about 0.1 to about 4 percent by weight of the formulation, based on the composite product is used to control pests. The amount used will depend on the target pests, desired performance longevity and the expected level of precipitation exposure. Preferably, from about 0.5 to about 2 percent is used for optimum performance against both decay fungi and termites. Loadings as low as 0.05 percent by weight can have a favorable effect against some mold organisms.

The mixed borate formulations are considered to have a low impact on the environment, with low mammalian toxicity, resulting in relatively safe use and disposal.

They are effective fungicidal and insecticidal compounds that are relatively inexpensive, easy to store, handle and use. Further, the borate formulations have some immediate water solubility, providing rapid and continuing pesticidal activity in composites subject to exposure to low moisture environments in uses such as interior sheathing, but also a reservoir of more slowly released active ingredients to provide very long term performance and performance under high moisture hazard environments such as exterior siding.

The lignocellulosic-based composites of this invention are produced by well known procedures by combining particles of the lignocellulosic material with an adhesive binder and forming the composite, generally with heat and pressure. The mixed solubility borate formulations of this invention may be pre-mixed and incorporated by adding to the lignocellulosic particles and/or binder, prior to forming the composite. Alternatively, the higher solubility borate and lower solubility borate may be introduced separately from one another, for example sequentially or simultaneously, e. g. from separate hoppers and feeders, during manufacture of the composite, to form a mixed preservative in situ. In cases where a composite is manufactured in multiple layers, the borate preservative of this invention may be implemented by incorporating a high solubility borate in one or more layers and a low solubility borate into a different layer or layers. Preferably, a more soluble borate is incorporated into an inner layer or layers and a less soluble borate is incorporated into one or more outer layers. Incorporation of the two different borates into different layers of a multi-layer composite may also provide a particular advantage in cases where one type of resin or lignocellulose particle is used in a core or inner layer and a different resin or particle system is used in the outer layers since, for example, some resin systems may be adversely effected by the use of a high solubility borate, while others may not be effected.

Lignocellulosic-based composites are formed from small fractions of cellulosic material, which are bonded with an adhesive binder, generally with heat and under

pressure. The method of forming cellulosic-based composites is well known and has resulted in many products, including particleboard, oriented strand board (OSB), waferboard, fiberboard (including medium-density and high-density fiberboard), parallel strand lumber (PSL), laminated strand lumber (LSL), laminated veneer lumber (LVL), and similar products. Examples of suitable cellulosic materials include wood, straw (including rice, wheat and barley), flax, hemp and bagasse. The small fractions of cellulosic material can be in any processed form such as chips, flakes, fibers, strands, wafers, trim, shavings, sawdust, straw, stalks and shives.

The methods for manufacturing composites are well known and the specific procedure will be dependent on the cellulosic raw material and the type of composite desired. However, generally the cellulosic material is processed into fractions or particles of appropriate size, which may be called a furnish, mixed with an adhesive binder and the resultant mixture is formed into the desired configuration such as a mat, and then formed, usually under pressure and with heat, into the final product. The process could be considered an essentially dry process; that is, generally, no water is added to form a slurry of the materials (other than any water that may be used as a carrier for liquid resins).

The binder is preferably an adhesive resin that is cured with heat to give a strong bond between the cellulosic particles or fractions and provide structural composites with high mechanical strength. Such heat-cured adhesive resins are well known and include the formaldehyde-and isocyanate-based resins. Phenol-formaldehyde, phenol-resorcinol- formaldehyde, urea-formaldehyde, melamine-urea-formaldehyde and diphenylmethanediisocyanate (pMDI) are examples of suitable heat-cured resins in current use. The preferred levels of binder can typically range from about 1.5% to about 15% by weight of the finished wood composite, but may be as low as 0.5% or as high as 25% for some composites, depending on a variety of constraints such as the particle size of the furnish and the strength and durability required of the finished wood composite. For example, structural quality OSB would typically contain between about 1.5% and 7% binder, whereas structural quality particle board may require up to 15 to 20% binder or more and medium density fiberboard (MDF) with low strength and durability

requirements, such as pegboard, may contain less than 1%. Unlike many borates that have been used in the past to preserve cellulosic-based composites, the mixed borate formulation of the present invention may be used successfully, without adverse effect on the binder or on the mechanical strength of the composite product. Another application for the mixed solubility preservatives of this invention is in the emerging area of woodfiber-plastic composites where wood is mixed with thermoplastic binders such as high density polyethylene, polypropylene or polyvinyl chloride. In this application the mixed solubility preservative compositions may be incorporated into woodfiber-plastic composites containing thermoplastic binder levels up to about 30-50% by weight of the finished wood composite.

The mixed borate formulation may be incorporated in the composite in any manner that will result in dispersion throughout the final product. In the case of wood- based composites, it may be mixed with the wood particles, or furnish, prior to mixing with the resin or it may be added to the resin or wood-resin mixture and then formed into a mat for pressing, heating and curing to produce the final composite. Preferably, the mixed borate formulation is evenly distributed on wood particles such as chips or strands, in order to maximize contact between the wood particles and the preservative, then the resin is applied and the wood furnish is spread evenly onto plates or an endless belt (conveyor belt), forming a mat to be pressed into its final thickness. Heat is applied to cure the resin and form the final composite product. The wood furnish may contain optional amounts of additives, such as slack wax or flow agents, if desired, to aid in processing or performance, but are not essential.

EXAMPLES The following examples illustrate the novel preservative compositions and. methods of this invention.

Example 1 Wood composite samples were made having a phenol-formaldehyde (PF) resin face and a diphenylmethanediisocyanate (pMDI) resin core. Some of the samples included a combination of the zinc borate, 2ZnO-3B203-3. 5H20, (ZB) and disodium octaborate tetrahydrate (DOT) and others contained ZB alone, while still others contained no wood preservative. The ZB/DOT combination formulations contained 60% ZB by weight and 40% DOT. The preservative compositions were added to the wood composite samples at a loading of 0.1% by weight of the wood composite. The samples were cut to 50mm x 25mm x 20mm before testing. A total of eight samples from each treatment set were subjected to decay testing.

A total of eight samples from each treatment set were tested according to a standard European decay test protocol known as EN113. The samples were first sealed in plastic bags and gamma irradiated at a level of at a level of 2.0 Mrad using a 60Co source to ensure sterilization prior to mono-culture decay testing.

Aqueous solutions of 2.0% malt and 2.0% agar were prepared and then autoclaved at 120°C for 30 minutes. The solutions were allowed to cool to between 50°C and 80°C and were then poured into pre-autoclaved animal jars (dimensions: height=7cm, diameter=9cm) with approximately 100ml per jar. The jars were placed into a container, kept in a temperature-controlled room at 22°C (2°C) and observed for two days. After the jars were ensured to be free of contamination, they were inoculated with a mature culture of Coniophora puteana (brown rot-Basidimycotina). Inoculated jars were incubated at 22°C (2°C) until the mycelium covered between 2/3 and 9/10 of the solid agar substrate.

All specimens were placed on sterilized plastic mesh to prevent agar contact and water logging. The gamma-irradiated wood composites were then placed onto the fungal cultures. The jar lids were loosely screwed on to allow for air exchange. Following introduction of the samples to the cultures, the animal jars were again incubated at 22°C (t2°C) for a period of twelve weeks. The composites were then oven dried at 80°C

overnight and then weighed to determine the percent weight loss resulting from the fungal decay.

The decay results are shown in Table 1, expressed as average percent weight loss of the wood composite samples after 12 weeks of fungal decay exposure. These results show that the mixed solubility product is better at inhibiting fungal decay than the zinc borate alone.

Table 1 Average Wood Composites % Wt. Loss % error control 23. 05 0.53 ZB only 15. 98 0.81 ZB (60)/DOT (40) 12. 02 0. 74 Example 2 The effectiveness of the mixed solubility wood preservatives of this invention against mold growth was tested on samples of aspen oriented strand board (OSB). Two OSB formulations were evaluated. One type was bonded with pMDI resin at a 6% loading. The other type was bonded with a PF resin face and a pMDI resin core. The OSB samples contained either a mixed solubility borate preservative formulation or a low solubility borate alone, or no preservative in the case of the control samples. The low solubility borate in all cases was zinc borate 2: 3: 3.5. The two different high solubility borates were tested-disodium octaborate tetrahydrate (DOT) and boric oxide (B203), also known as anhydrous boric acid (ABA). The weight ratio of low solubility borate to high solubility borate in the mixed solubility samples was either 80/20 or 60/40. Two different target loadings of preservative in the OSB samples were tested-0.18% and 0.88% by weight.

Mold exposure testing was carried out using a modified version of the ASTM: D 3273-94 procedure. Exposure of the OSB samples to mold was done in an experimental chamber consisting of a 597mm x 3 11 mm x 413mm plastic container tilted on its side to give a 45° roof angle to prevent condensate dripping on the samples and

filled with 2-3 inches of water. The water was heated to 32.5°C (i1°C), using a thermostatically controlled heating coil. A 292mm x 394mm x 133mm plastic bowl was filled to within 3 inches from the top with a mixture of damp potting soil and unsterile soil collected from outdoors to provide an inoculum source for mold. The bowl was floated in the plastic container. The boards were placed on a plastic mesh above the inoculum source. The blocks were inverted at one week intervals. The test ran for a duration of 4 weeks.

After the four week mold exposure, the samples were examined visually and rated for mold formation on a scale of 0 to 4, with 0 representing no mold formation (i. e. complete control) and 4 representing complete coverage or overgrowth of the sample by mold. The results are presented in Table 2. The borate loading (i. e. 0.18% v. 0.88%) had a significant effect, with the higher loading providing better control, as expected. With regard to the ratio of high solubility borate to low solubility borate, the samples containing 40% soluble borate (i. e. 60% zinc borate) provided a significant improvement over the samples containing 0% soluble borate (i. e. 100% zinc borate), on average.

Furthermore, significantly greater mold growth was observed at the faces of the OSB board samples compared to the edges.

Table 2 Target Mold Borate Formation Rating at x% Loading Soluble Measured Hi h Solubili Borate % BAE Borate Board at x=0 x=20 x=40 0.18 ABA pMDI-6% Edges 2.00 2.00 2.00 0.18 ABA PF-pMDI Edges 2.00 1.50 1.75 0. 18 DOT pMDI-6% Edges 2.00 1. 75 2.00 0.18 DOT PF-pMDI Edges 2. 00 2.25 1.75 Average 2.00 1. 88 1.88 0.88 ABA pMDI-6% Edges 0.75 1.50 0.25 0.88 ABA PF-pMDI Edges 1.50 2.00 0.75 0. 88 DOT pMDI-6% Edges 0.75 0. 75 1.25 0. 88 DOT PF-pMDI Edges 1.50 1. 25 1.50 Average 1. 13 1. 38 0.94 0.18 ABA pMDI-6% Faces 0. 75 1. 00 0. 50 0. 18 ABA PF-pMDI Faces 1.25 0. 88 0.25 0. 18 DOT pMDI-6% Faces 0.75 0. 75 1.25 0.18 DOT PF-pNml Faces 1. 25 1.88 0.38 Average 1.00 1.13 0.59 0.88 ABA pMDI-6% Faces 0.00 0.63 0.00 0. 88 ABA PF-pMDI Faces 0.75 0. 75 0. 25 0. 88 DOT pMDI-6% Faces 0.00 0. 63 0.00 0. 88 DOT PF-pMDI Faces 0.75 0.75 0. 25 Average 0.38 0.69 0.13

Example 3 Another set of mold tests similar to Example 2 was carried out. Test samples consisted of Aspen OSB bonded with pMDI resin at a 6% loading. The OSB samples were treated with a hydrophobic resin 1% EW-58S, manufactured by Borden, which served as a water repellant. The preservative treated OSB samples contained either zinc borate alone or a mixture of zinc borate and DOT, at a 60/40 weight ratio. Target loadings of preservative were 0.05,0.10 and 0.20% by weight in the OSB samples. The OSB test samples were cut into 76mm x 102mm panels for use in the mold testing. Mold

exposure testing was carried out using essentially the same method described in Example 2, except that the water was heated to 30.5°C (1°C). The relative humidity within the environmental chamber was monitored and maintained at 95 to 99% with an average temperature of 27 to 30°C.

After the four week mold exposure, the samples were examined visually and rated for mold growth on a scale of 0 to 4, as in Example 2. The results are presented in Table 3. These results show consistently better control of mold growth for the samples containing a mixture of 40% by weight DOT (60% zinc borate) compared with samples containing 100% by weight zinc borate and no high solubility borate.

Table 3 Target Borate Mold Formation Rating at x% DOT Loading% BAE Measured at x=0 x=40 0.05 Faces 1. 00 0.33 0.05 Edges 1. 00 0.67 0.10 Faces 2. 67 0.67 0.10 Edges 3. 33 0.67 0.20 Faces 1. 00 1.00 0.20 Edges 2 1_ Average 1. 89 0. 84 Example 4 The performance of mixed solubility borate preservatives against termites was investigated in a study using aspen waferboards bonded with either 100% pMDI (in both face and core) or with Phenol Formaldehyde (PF) in the face and pMDI in the core. The boards were made with a target loading of 0.88% preservative utilizing the formulations (blends) described in Table 4. The borates were incorporated into the board by mixing the preservative formulations with the aspen wafers in a blender before addition of the adhesive and wax. Composite board specimens were exposed to the Formosan

subterranean termite (Coptotermes formosanus Shiraki) at a field test site in Hilo, Hawaii.

The specimens, along with untreated aspen'feeder'stakes, are placed in a horizontal array on hollow core concrete blocks approximately 10 cm thick. In addition to surrounding the test specimens, the untreated feeder stakes are also driven into the ground in an effort to increase the termite pressure on the test specimens. The assembly is then covered with a wooden box to prevent direct contact with rain. This is a severe test format conducted using a very termite susceptible wood species (aspen).

After 3,9 and 15 months exposure the boards were rated visually on a scale of 0 to 10. A rating of 10 indicates the sample was in perfect condition, while a 0 rating means the sample was essentially destroyed. Each result consisted of an average rating from the inspection of 10 separate samples (10 replicates).

The results are summarized in Table 4. In the boards made with the PF/pMDI resin system, the 80/20 and 60/40 mixed solubility preservative blends outperformed low solubility preservative alone (100% ZB) after 9 and 15 months exposure in this rigorous, accelerated termite test.

Table 4 Borate Preservative Com osition wt. % Termites Ratin s Board ZB DOT ABA 3 mos. 9 mos. 15 mos. PMDI 100 0 0 10 9. 8 9. 9 MDI 80 20 0 10 9.9 9. 9 MDI 60 40 0 10 9.9 9. 9 pMDI800 20109. 89. 9 MDI 60 0 40 10 9. 6 10 PF/pMDI 100 0 0 10 9.5 9. 7 PF/pMDI 80 20 0 10 9.9 9. 9 PF/uMDI 60 40 O 10 9. 8 10 PF/pMDI 80 0 20 10 9. 7 10 PF/pMDI 60 O 40 10 9. 9 9. 9 Various changes and modifications of the invention can be made and, to the extent that such variations incorporate the spirit of this invention, they are intended to be included within the scope of the appended claims.