Mechanical Properties, Thermal Stability, and Formaldehyde Emission Analysis of Nanocellulose-Reinforced Urea–Formaldehyde Resin and Its Mechanism

In this research, a urea–formaldehyde (UF) resin was modified with nanocrystalline cellulose (NCC) and nanofibrillated cellulose (CNF), and the properties of the modified resin were comprehensively evaluated by combining the techniques of infrared spectroscopy (FTIR), X-ray diffraction (XRD), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM). The results showed that (1) the introduction of NCC and CNF significantly changed the hydrogen bonding network of the UF resin, in which CNF enhanced the internal hydrogen bonding of the resin through its long-chain structure and elevated the cross-linking density. NCC increased the crystallinity of the resin, while CNF enhanced the overall performance of the resin by improving its dispersion. (2) The composite curing agent system significantly reduced the curing temperature of the resin, resulting in a more homogeneous and efficient curing reaction, and the CNF-modified UF exhibited better thermal stability. (3) The addition of NCC and CNF significantly improved the dry and water-resistant bonding strengths of the resins. In addition, the use of complex curing agent further enhanced the bonding strength, especially in the CNF-modified system; the addition of complex curing agent increased the dry bonding strength to 1.60 MPa, and the water-resistant bonding strength reached 1.13 MPa, which showed a stronger cross-linking network and structural stability. (4) The addition of NCC and CNF led to a significant reduction in the free formaldehyde content of UF resins, resulting in respective levels of 0.17% and 0.14%. For plywood bonded with the CNF-modified UF resin, formaldehyde emissions were measured at 0.35 mg/L, which were markedly lower than the 0.54 mg/L of the unmodified sample. This further highlights CNF’s effectiveness in minimizing formaldehyde release. (5) Overall, CNF is superior to NCC in improving the thermal stability, bonding strength, water resistance, formaldehyde release, and overall performance of the resin. The use of complex curing agents not only optimizes the curing process of the resin but also further enhances the modification effect, especially for CNF-modified resins, which show more significant performance advantages.