Emulsifiable resoles having dispersed inert salts
AssigneeMonsanto Company
InventorHarold P. Higginbottom
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Abstract
This invention relates to high efficiency stable aqueous emulsifiable resoles which contain low concentrations of free phenol and free aldehyde causing less pollution than prior art resoles. Said resoles are catalyzed with alkaline earth metal hydroxides and neutralized with oxalic acid or its acid salts providing colloidal inert insoluble oxalate salts dispersed in said resoles. Said resole and said salts being emulsifiable with protein type emulsifiers providing stable emulsions when water in excess of the water tolerance of the resole is added.
Claims18
An improved stable aqueous solution of an emulsifiable resole wherein the solution has a pH in the range 6 to 8.5 and contains less than 2 percent of free phenol, less than 2 percent of free formaldehyde, said resole has a number average molecular weight of less than 300, a water tolerance between about 100 and 800 percent, a combined formaldehyde to phenol molar ratio in the range of 2.0:1 to 2.9:1, and contains sufficient methylolated 2,2'-and 2,4'-dihydroxydiphenylmethanes to inhibit crystallization of the resole solution, said resole being prepared with a catalyst comprising alkaline earth metal hydroxides selected from the group consisting of calcium, barium, strontium and mixtures thereof wherein said improvement comprises:
- said pH being adjusted with a compound selected from the group consisting of oxalic acid, ammonium oxalate and mixtures thereof providing a stable colloidal dispersion of insoluble oxalate salts of said alkaline earth metal ions in said solution, said resole and said salts being emulsifiable by about 1 to 12 percent by weight of an emulsifier based on the weight of said resole, said emulsifier being selected to provide a stable emulsion of the resole and salt when water in excess of the water tolerance is added to said solution.
A process for preparing an aqueous storage stable emulsifiable resole solution which comprises:
- a. reacting 1.0 mole phenol with from 0.05 to 0.30 moles formaldehyde under acid conditions for formation of novolac resin,
- b. adding from 1.75 to 3.5 moles formaldehyde and reacting under basic conditions to produce a resole of molecular weight less than 300, and containing less than 2 weight percent free phenol, said basic conditions being provided by a catalyst comprising alkaline earth hydroxides selected from the group consisting of calcium, barium, strontium and mixtures thereof,
- c. adjusting the pH of the aqueous resole to between about 6 and 8.5 with a compound selected from the group consisting of oxalic acid, ammonium oxalate and mixtures thereof providing a stable colloidal dispersion of insoluble oxalate salts of said alkaline earth metal ions in said solution said resole and said salts being emulsifiable in from about 1 to 12 percent by weight of an emulsifier based on the weight of said resole, selected to provide a stable emulsion when water in excess of the water tolerance of said resole is added to the resole solution.
Dependencies are inferred from the claim text.