Pollution free method of making 2,6-bis(2,4-dihydroxy phenylmethyl)-4-chlorophenol tire cord dips and products

A process for making a cord dip which comprises:

• a. reacting in the presence of from about 0.05 to 0.8 moles of a base catalyst
• 1. one mole of p-chlorophenol with
• 2. from about 2 to 2.2 moles of formaldehyde to form a reaction mixture containing 2,6-bis-hydroxymethyl-4-chlorophenol;
• b. then without separating the 2,6-bis-dihydroxy-methyl-4-chlorophenol from the reaction mixture, adding
• 1. from 1 to 3 moles of resorcinol and
• 2. sufficient acid to neutralize the base catalyst and to lower the pH of the reaction mixture to a value of from 1 to 6;
• c. heating the mixture to form a reaction product containing 2,6-bis (2,4-dihydroxy phenylmethyl)-4-chlorophenol;
• d. adding base to the mixture to dissolve the 2,6-bis(2,4-dihydroxy phenylmethyl)-4-chlorophenol and to increase the pH to a value above 7;
• e. then without separating the 2,6-bis(2,4-dihydroxy phenylmethyl)-4-chlorophenol from the reaction mixture, adding a major amount of weight on a solid basis of an alkaline dispersion of a rubbery vinyl pyridine copolymer to a minor amount by weight on a solids basis of the reaction product containing 2,6-bis(2,4-dihydroxy phenylmethyl)-4-chlorophenol.