Melamine-containing resole resitol and resite compositions
AssigneeBorden, Inc.
InventorWayne R. Walisser
Life of this patent
Estimating the term…
Abstract
The titled compositions are useful binding adhesives, especially, for example, with engineered glass fiber-containing products, and the like. In the A-stage, the compositions are typically exceptionally water soluble and low temperature storage stable. Such compositions can be prepared initially by a procedure in which a resole or the like is copolymerized with free melamine(s) and is conditioned to include acidic stage conditioning. For example, phenol per se, formaldehyde and sodium hydroxide followed by melamine per se and aqueous sulfamic acid solution, with subsequent neutralization, can yield the exceptionally water soluble low temperature storage stable A-stage composition. The C-stage composition is non-punking and can be structurally hard and sound.
Claims32
A composition of matter comprising a res(ole)(itol)(ite)-melamine composition, including an essentially aqueous A-stage form of said resolemelamine composition containing residues of free melamine(s) to aldehyde(s) to phenolic compounds(s) in a molar equivalent ratio ranging from about 0.2:1.5:1 to 0.8:3.5:1, which A-stage form is low temperature safe-storage stable, has a cloud point temperature of about 5.degree. C. or less at the time of formation and is essentially infinitely water soluble.
A composition of matter comprising a res(ole)(itol)(ite)-melamine composition prepared by a process which comprises steps of serially contacting at least one fundamental alkaline resole which comprises residues of at least one phenolic compound and at least one aldehyde in a molar equivalent ratio of residues of aldehyde(s) to phenolic compound(s) from about 1.5:1 to 6:1 with at least one free melamine, wherein sufficient free melamine is contacted therewith to at least initially provide an essentially aqueous A-stage form of said composition having a molar equivalent ratio of residues of the free melamine(s) to the aldehyde(s) to the phenolic compound(s) ranging from about 0.04:1.5:1 to 2:6:1;
- conditioning so as to dissolve at least a substantial portion of said free melamine, and providing acidic conditions of at least pH 5.5 therefor with further conditioning for a time ranging from about 10 minutes to 2 hours at temperatures ranging from about 10.degree. to 50.degree. C., under conditions aqueous to at least the A-stage such that said composition is prepared.
A process for preparing a res(ole)(itol)(ite)-melamine composition comprising serially contacting at least one fundamental alkaline resole which comprises residues of at least one phenolic compound and at least one aldehyde in a molar equivalent ratio of residues of aldehyde(s) to phenolic compound(s) from about 1.5:1 to 6:1 with a sufficient quantity of at least one free melamine to at least initially provide an essentially aqueous A-stage form of said composition having a molar equivalent ratio of residues of the free melamine to the aldehyde to the phenolic compound of from about 0.04:1.5:1 to 2:6:1, conditioning so as to dissolve at least a substantial portion of said free melamine, and providing acidic conditions of at least pH 5.5 therefor with further conditioning at temperatures ranging from about 10.degree. to 50.degree. C. for a time ranging from about minutes to 2 hours, under conditions aqueous to at least the A-stage such that said composition is prepared.
A composition of matter comprising a res(ole)(itol)(ite)-melamine composition prepared by a process comprising the steps of serially contacting at least one fundamental alkaline resole which comprises residues of hydroxybenzene and formaldehyde in molar equivalent ratios of residues of formaldehyde to hydroxybenzene ranging from about 1.5:1 to 3.5:1 with cyanurotriamide in an amount effective to provide an essentially aqueous A-stage form of said composition having a molar equivalent ratio of residues of the cyanurotriamide to the formaldehyde to the hydroxybenzene ranging from about 0.2:2.5:1 to 0.8:3.5:1, conditioning so as to dissolve at least a substantial portion of said cyanurotriamide, and providing acidic conditions of pH 5.5 to 6.5 therefor with further conditioning at temperatures ranging from about 10.degree. to 50.degree. C. for a time ranging from about 10 minutes to 2 hours under conditions aqueous to at least the A-stage such that a composition is prepared in which the A-stage composition has a cloud point temperature of about 5.degree. C. or less and at the time of formation and is essentially infinitely water soluble.
An essentially aqueous A-stage form of a resole-melamine composition in which the resole is prepared from aldehyde(s) to phenolic compound(s) in a molar equivalent ratio ranging from about 2.5:1 to 3.5:1 and a free melamine is added to said resole in quantities such that the molar equivalent ratio of said free melamine to said phenolic compound(s) ranges from greater than 0.2:1 to 0.8:1, said composition being low temperature safe-storage stable, having a cloud point temperature of about 5.degree. C. or less at the time of formation and being essentially infinitely water soluble.
Dependencies are inferred from the claim text.