# US 2020/0399461 A1 · Phenolic epoxy system

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- Number: US 2020/0399461 A1
- Document ID: US20200399461A1
- Status: Published application
- Kind: A1
- Application number: 16/445,043
- Filed: 2019-06-18
- Published: 2020-12-24
- Earliest claimed: 2019-06-18
- Assignees: Hexion Inc.
- Applicants: Hexion Inc.
- Inventors: Kimberly GOODWIN; Ganapathy S. VISWANATHAN; Scott PEACE; Anthony MAIORANA; Vishal PATIL
- Web page: https://patentgrep.com/patent/US20200399461A1

## CPC

- C08L 63/04: Epoxynovolacs
- C08G 59/5073: {having two nitrogen atoms in the ring}
- C08G 59/621: {Phenols}
- C08G 59/686: {containing nitrogen}
- C08G 65/2612: {containing aromatic or arylaliphatic hydroxyl groups}
- C08L 61/12: with polyhydric phenols
- C09D 5/03: Powdery paints
- C09D 161/12: with polyhydric phenols
- C09D 163/04: Epoxynovolacs
- C09J 5/06: involving heating of the applied adhesive
- C09J 161/12: with polyhydric phenols
- C09J 163/04: Epoxynovolacs
- C09J 2461/00: Presence of condensation polymers of aldehydes or ketones
- C09J 2463/00: Presence of epoxy resin
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)

## Abstract

The embodiments described herein generally relate to methods and chemical compositions of phenolic epoxy systems. In one embodiment, a composition comprising a phenolic epoxy resin system includes an epoxy resin component and an alkoxylated phenol-aldehyde novolac resin.

## Claims

### Claim 1

A composition comprising a phenolic epoxy resin system, comprising:
an epoxy resin component; and
an alkoxylated phenol-aldehyde novolac resin, and
an optional curing agent.

### Claim 2 (depends on 1)

The composition of claim 1, wherein the alkoxylated phenol-aldehyde novolac resin comprises a reaction product from at least:
a phenol-aldehyde novolac resin; and
an alkoxylation agent selected from the group consisting of an alkylene oxide, an alkylene carbonate, and combinations thereof; and
an optional alkoxylation catalyst.

### Claim 3 (depends on 1)

The composition of claim 1, wherein the composition is a powder.

### Claim 4 (depends on 1)

The composition of claim 1, wherein the epoxy resin component comprises a functionality equal or greater than 2.

### Claim 5 (depends on 1)

The composition of claim 1, wherein the reaction product comprises 10% to 50% alkoxylated reactive sites of the phenol-aldehyde novolac resin and comprises a functionality equal or greater than 2.

### Claim 6 (depends on 1)

The composition of claim 1, wherein the composition comprises:
from 20 wt. % to 70 wt. % of the epoxy resin component; and
from 30 wt. % to 80 wt. % of the alkoxylated phenol-aldehyde novolac resin; and
from 0 wt. % to 5 wt. % of the optional catalyst, wherein the total weight percent is 100 weight percent.

### Claim 7 (depends on 1)

The composition of claim 1, wherein the optional curing agent is selected from the group consisting of hexamethylenetetramine, oxazolidine, paraformaldehyde, trioxane, 2-methyl imidazole, imidazole, melamine, triethanol amine, tributyl amine, and combinations thereof.

### Claim 8 (depends on 1)

The composition of claim 1, wherein the optional curing agent is present in the composition and comprises from 0.1 wt. % to 5 wt. % of the composition.

### Claim 9 (depends on 1)

The composition of claim 1, wherein the reaction product components comprise:
from 59 wt. % to 90 wt. % of the phenol-aldehyde novolac resin; and
from 10 wt. % to 41 wt. % of the alkoxylation agent selected from the group consisting of an alkylene oxide, an alkylene carbonate, and combinations thereof; and
from 0 wt. % to 5 wt. % optional catalyst, wherein the total amount of all weight percent is 100 wt. %.

### Claim 10 (depends on 9)

The composition of claim 9, wherein the optional catalyst is present in the composition and comprises from 0.05 wt. % to 5 wt. % of the reaction product components.

### Claim 11 (depends on 1)

The composition of claim 1, wherein the at least one alkylene oxide comprises a compound selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, and combinations thereof.

### Claim 12 (depends on 1)

The composition of claim 1, wherein the alkylene carbonate comprises a compound selected from the group consisting of ethylene carbonate, propylene carbonate, butylene carbonate, and combinations thereof.

### Claim 13

A process comprising:
reacting a phenol-aldehyde resin and an alkoxylation agent selected from the group consisting of an alkylene oxide, an alkylene carbonate, and combinations thereof, to form an alkoxylated phenol-aldehyde resin; and
reacting the alkoxylated phenol-aldehyde resin and an epoxy resin component.

### Claim 14 (depends on 13)

The process of claim 13, wherein the reacting the alkoxylated phenol-aldehyde resin and the epoxy resin component under processing conditions involving applied heat from an external source forms a binder.

### Claim 15 (depends on 13)

The process of claim 13, wherein the applied heat comprises a temperature from about 50° C. to about 270° C.

### Claim 16 (depends on 13)

The process of claim 13, wherein the reacting the alkoxylated phenol-aldehyde resin and the epoxy resin component is performed in the presence of a curing agent.

### Claim 17 (depends on 13)

The process of claim 13, wherein the alkoxylated phenol-aldehyde resin comprises 10% to 50% alkoxylated reactive sites of the phenol-aldehyde novolac resin and comprises a functionality equal or greater than 2.

### Claim 18 (depends on 13)

The process of claim 13, wherein the reacting the phenol-aldehyde resin and the alkoxylation agent is performed in the presence of a catalyst.

### Claim 19 (depends on 13)

The process of claim 13, wherein the reacting the alkoxylated phenol-aldehyde resin and the epoxy resin component forms a composition in liquid or solid form.

### Claim 20 (depends on 13)

The process of claim 13, further comprising applying the composition as a composite, liquid coatings, hot melt adhesive, molding powder, powder coating, and combinations thereof.