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US 11,697,703 B2Granted
Manufacture of novolacs and resoles using lignin
AssigneeBakelite UK Holding Ltd.
InventorsAnthony Maiorana, Srirama N. Maddipatla Venkata, Stephen W. Arbuckle, Ganapathy Viswanathan
Life of this patent
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Abstract
Processes for manufacturing novolacs and resoles from lignin are disclosed. A phenol-aldehyde-lignin dispersion is formed which can then be used to make either a novolac or a resole, depending upon the catalysts used.
Claims20
A process comprising:
- a) heating a mixture of a phenol, lignin, and a first catalyst comprising an acidic compound to a temperature in the range of from 70° C. to 200° C. to form a dispersion;
- b) cooling the dispersion to a temperature in the range of from 60° C. to 99° C.;
- c) adding a first aldehyde to the dispersion;
- d) condensing the dispersion under reflux conditions to form a phenol-aldehyde-lignin dispersion having from 0.01 to 10 weight percent free aldehyde;
- e) cooling the phenol-aldehyde-lignin dispersion;
- f) adding a second aldehyde and a second catalyst comprising a basic compound to the phenol-aldehyde-lignin dispersion;
- and then
- g) condensing the phenol-aldehyde-lignin dispersion to form a resole having less than 1 weight percent free aldehyde.
5 more elements
A process for making a resole resin, comprising:
- a) heating a mixture of a phenol, lignin, and a first catalyst comprising an acidic compound to a temperature in the range of from 70° C. to 200° C. to form a dispersion;
- b) cooling the dispersion;
- c) adding a first aldehyde to the dispersion;
- d) condensing the dispersion under reflux conditions to form a phenol-aldehyde-lignin dispersion having from 0.01 to 10 weight percent free aldehyde;
- e) cooling the phenol-aldehyde-lignin dispersion;
- f) adding a second aldehyde and a second catalyst comprising a basic compound to the phenol-aldehyde-lignin dispersion;
- g) condensing the phenol-aldehyde-lignin dispersion to form a resole having from 0.01 to 10 weight percent free aldehyde;
- and then
- h) distilling the resole to produce a distilled resole having from 0.01 to 10 weight percent free aldehyde.
6 more elements
A process for making a resole resin, comprising:
- a) heating a mixture of a phenol, lignin, and a first catalyst comprising an acidic compound to a temperature in the range of from 70° C. to 200° C. to form a dispersion having a weight ratio of lignin to phenol ranging from 0.1:1 to 1:1;
- b) cooling the dispersion;
- c) adding a first aldehyde to the dispersion;
- d) condensing the dispersion under reflux conditions to form a phenol-aldehyde-lignin dispersion having from 0.01 to 10 weight percent free aldehyde;
- e) cooling the phenol-aldehyde-lignin dispersion;
- f) adding a second aldehyde and a second catalyst comprising a basic compound to the phenol-aldehyde-lignin dispersion;
- g) condensing the phenol-aldehyde-lignin dispersion to form a resole having less than 1 weight percent free aldehyde;
- and then
- h) distilling the resole to produce a distilled resole having from 0.01 to 10 weight percent free aldehyde, a glass transition temperature of 0° C. to 165° C. and a softening point of −10° C. to 180° C.
6 more elements
Dependencies are inferred from the claim text.