Resol beads, methods of making them, and methods of using them

A process for producing cured resol beads, the process comprising:

• a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
• b) recovering water-insoluble resol beads above a minimum particle size from the aqueous dispersion;
• c) retaining or recycling beads below the minimum particle size in the aqueous dispersion of resol beads and further reacting to obtain fully-formed resol beads above the minimum particle size;
• and
• d) thermally curing the fully-formed resol beads in a heated fluid, with agitation, to obtain cured resol beads.

A process for producing cured resol beads, the process comprising:

• a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
• b) recovering water-insoluble resol beads above a minimum particle size from the aqueous dispersion;
• c) retaining or recycling beads within a desired particle size range in or to the aqueous dispersion of resol beads and further reacting to obtain fully-formed resol beads above the minimum particle size;
• and
• d) thermally curing the fully-formed resol beads in a heated fluid, with agitation, to obtain cured resol beads.

Cured resol beads made by a process comprising:

• a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
• b) recovering water-insoluble resol beads above a minimum particle size from the aqueous dispersion;
• c) retaining or recycling beads below the minimum particle size in the aqueous dispersion of resol beads and further reacting to obtain fully-formed resol beads above the minimum particle size;
• and
• d) thermally curing the fully-formed resol beads in a heated fluid, with agitation, to obtain cured resol beads.

Cured resol beads made by a process comprising:

• a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
• b) recovering water-insoluble resol beads above a minimum particle size from the aqueous dispersion;
• c) retaining or recycling beads within a desired particle size range in or to the aqueous dispersion of resol beads and further reacting to obtain fully-formed resol beads above the minimum particle size;
• and
• d) thermally curing the fully-formed resol beads in a heated fluid, with agitation, to obtain cured resol beads.