Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – From phenol – phenol ether – or inorganic phenolate
Patent
1998-10-07
2000-10-17
Truong, Duc
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
From phenol, phenol ether, or inorganic phenolate
528 86, 528119, 528176, 528193, 528486, 528494, 528495, 525219, 525534, 525538, 524128, 524736, C08G 6538
Patent
active
061334030
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
(a) Field of the Invention
This invention relates to employing reactive diluents, such as substituted or unsubstituted benzylic alcohol, preferably alkoxy benzyl alcohol or dibenzyl ether, together with resole resin and/or novolac resin hardening under acid catalysis.
(b) Description of the Prior Art
The hardening of phenolic resoles by the addition of strong acids is well known. Typical strong acids include the following: hydrochloric, sulphuric, phosphoric, trichloroacetic and sulphonic acids either alone or as mixtures thereof. Most often these acids are employed as aqueous solutions at concentrations varying from 20 to 85%. These hardeners normally cause the resoles to harden rapidly even at ambient temperatures of about 16.degree. C. to about 30.degree. C. As discussed below, hardening with strong acids has major limitations, i.e., they are difficult to control, they cannot easily afford extensive ambient temperature stability prior to hardening, they create corrosion problems, and they are very unstable when furfuryl alcohol, a desirable additive for phenolic resins, is employed with the phenolic resin.
According to U.S. Pat. No. 5,317,050 to Gerber, incorporated herein by reference in its entirety, it is known to employ aryl phosphite latent acid catalysts as an alternative to the strong acids. These latent acids provide controlled work time for hardening phenolic resins at ambient temperature and can provide extended work times at ambient temperatures. The phenolic resins are those which are hardenable by strong acids at ambient temperatures. Aryl phosphites are particularly effective hardening agents for both ambient temperature hardening or rapid hardening at relatively modest elevated temperatures, such as those of from about 50.degree. C. to 100.degree. C., or less, such as from 50.degree. C. to 80.degree. C.
U.S. Pat. No. 5,243,015 to Hutchings et al, incorporated herein by reference in its entirety, discloses a thermosetting phenolic resole resin composition, and process for its use, containing a latent catalyst in an amount adequate to cure the resole resin, upon application of heat, at a rate comparable to a rate of cure obtained with the resin using a conventional strong acid under comparable cure conditions. The latent catalyst comprises a salt of an amine selected from a primary amine, a secondary amine, or mixtures thereof, and a strong acid. Typically, the primary or secondary amine is selected from the group consisting of primary and secondary aliphatic, alicyclic, aromatic and heterocyclic amines. The strong acid is selected from the group consisting of sulfonic acids, organic acids and mineral acids. Typically, the sulfonic acid is selected from toluenesulfonic acid, xylenesulfonic acid, phenolsulfonic acid, methanesulfonic acid and mixtures thereof. Preferably, the strong acid has a pKa measured in an aqueous environment of less than about 3.0. Typical primary and secondary aliphatic amines include methylamine, ethylamine, propylamine, butylamine, dimethylamine and diethylamine, 1,3-diaminopropane, 1,2-diaminopropane, ethanolamine, ethylene diamine, butylene diamine, diethylene triamine, 1,2-diaminocyclohexane, cyclohexylamine, piperidine, pyrrolidine or piperazine.
In an alternate embodiment, the composition includes latent acid plus, as an additional ingredient, some strong acid catalyst typically in an amount which is insufficient by itself to cure resole resin at a commercially useful rate. Use of this lower amount of additional strong acid catalyst permits the composition to retain the extended pot life benefits associated with the latent catalyst, but allows the strong acid to act synergistically in combination with the latent catalyst to accelerate the cure rate of the resole resin dramatically.
U.S. Pat. No. 5,378,793 to Orpin, incorporated herein by reference in its entirety, discloses a hardener for producing phenolic resins from phenolic resoles which comprises a partial phosphate ester which is a latent acid. By partial phosphate ester is me
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Borden Chemical, Inc.
Truong Duc
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