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US 5,096,983 AGranted
Method for making a phenolic resole resin composition having extended work life
AssigneeBorden, Inc.
InventorArthur H. Gerber
Life of this patent
Estimating the term…
Abstract
There are disclosed methods and compositions for retarding the room temperature gelation and eventual hardening of phenolic resole resins when such resins are mixed with lightburned magnesium oxide or magnesium hydroxide hardening agents with or without an ester functional hardening agent. Retardation of gelation and hardening is achieved by incorporating into said mixture a compound which decreases the solubility of magnesium in said mixture. Additionally, hardening at higher temperatures, thermal curing, as well as refractories, coated abrasives, polymer concrete, and other methods and compositions of this invention are disclosed.
Claims34
A method for preparing a phenolic resole resin composition having an extended work life which comprises mixing:
- a. a hardenable phenolic resole resin having a pH of from about 5 to 8.5;
- b. a magnesium hardening agent in an amount sufficient to increase the rate of hardening of said resin and selected from the group consisting of lightburned magnesium oxide having a surface area of at least 10 square meters per gram and magnesium hydroxide;
- c. an ester functional hardening agent in an amount sufficient to increase the rate of hardening of said composition;
- and
- d. a compound which decreases the solubility of magnesium in the composition, said compound being one which increases the time required to gel the composition at 25.degree. C. by at least 35% when mixed therein at a concentration of 2% based on the weight of resin.
2 more elements
A method for preparing a phenolic resole resin composition which comprises mixing:
- a. a hardenable phenolic resole resin having a pH of from about 4.5 to 9.5;
- b. a lightburned magnesium oxide hardening agent having a surface area of at least 10 square meters per gram, the quantity of said magnesium oxide being sufficient to increase the rate of hardening of said resin;
- c. an ester functional hardening agent in an amount sufficient to increase the rate of hardening of said composition;
- and
- d. from about 0.05% to 5% based on the weight of resin of a retarder compound selected from the group consisting of:
- a compound which provides a fluoride, bifluoride, citrate, tartrate, aspartate, oxalate, phosphate, glutamate, malate, iminodiacetate, iminodipropionate, aminoacetate, aminopropionate, aminobenzoate anion;
- or a tetraalkoxy silane having from 1 to 3 carbon atoms in each alkoxy group;
- and a partially hydrolyzed tetraalkoxy silane having from 1 to 3 carbon atoms in each alkoxy group.
5 more elements
A method for retarding the hardening of a binder composition which comprises mixing:
- a. a phenolic resole resin having a pH of about 5 to 8.5, a solids content of about 50% to 80% by weight of said resin, a viscosity of about 200 to 3,000 cps at 25.degree. C., and wherein the molar ratio of phenol to aldehyde is in the range or 1:1 to 1:2.2, and a water content of from about 5% to 20% by weight of the resin;
- b. from about 2% to 35% by weight of the resin of lightburned magnesium oxide having a surface area of at least 10 square meters per gram;
- c. from about 5% to 40% based on the weight of resin of an ester functional hardening agent selected from the group consisting of a lactone, a cyclic organic carbonate, a carboxylic acid ester, and mixtures thereof;
- and
- d. from about 0.1% to 5% based on the weight of resin of a retarder compound which decreases the solubility of magnesium in the composition, said retarder compound being one which increases the time required to gel the composition at 25.degree. C. by at least 60% when mixed therein at a concentration of 2% based on the weight of resin.
2 more elements
A method for retarding the hardening of a binder composition at ambient temperature which comprises mixing:
- a. a phenolic resole resin having a pH of about 5 to 8.5, a solids content of about 50% to 80% by weight of said resin, a viscosity of about 200 to 3,000 cps at 25.degree. C., and wherein the molar ratio of phenol to aldehyde is in the range or 1:1 to 1:2.2, and a water content of from about 5% to 20% by weight of the resin;
- b. from about 2% to 35% by weight of the resin of lightburned magnesium oxide having a surface area of at least 10 square meters per gram;
- c. from about 5% to 40% based on the weight of resin of an ester functional hardening agent selected from the group consisting of a lactone, a cyclic organic carbonate, a carboxylic acid ester, and mixtures thereof;
- and
- d. from about 0.1% to 5% based on the weight of resin of a retarder compound selected from the group consisting of:
- a compound which provides a fluoride, bifluoride, citrate, tartrate, aspartate, oxalate, phosphate, glutamate, malate, iminodiacetate, iminodipropionate, aminoacetate, aminopropionate, aminobenzoate anion;
- or a tetraalkoxy silane having from 1 to 3 carbon atoms in each alkoxy group;
- a partially hydrolyzed tetraalkoxy silane having from 1 to 3 carbon atoms in each alkoxy group;
- and mixtures thereof.
6 more elements
A method for preparing a phenolic resole resin composition having an extended work life which comprises mixing:
- a. a phenolic resole resin having a pH of from about 4.5 to 9.5, a solids content of about 50% to 90% by weight of the resin, and a viscosity of about 100 to 4,000 cps at 25.degree. C.;
- b. from about 5% to 50% by weight of resin of lightburned magnesium oxide having different surface areas in a ratio of one part of said magnesium oxide by weight thereof having a surface area of at least 50 square meters per gram and 0.5 to 4 parts of said magnesium oxide having a surface area of from about 10 to 25 square meters per gram;
- c. from about 0.05% to about 5% by weight based on the weight of resin of a compound which decreases the solubility of magnesium in the composition, said compound being one which increases the time required to gel the composition at 25.degree. C. by at least 35% when mixed therein at a concentration of 2% based on the weight of resin;
- and
- d. from about 5% to 40% by weight of the resin of an ester functional hardening agent.
2 more elements
A method for retarding the hardening of a phenolic resole resin composition at ambient temperature which comprises mixing:
- a. a hardenable phenolic resole resin having a pH of from about 4.5 to 9.5;
- b. a magnesium hardening agent in an amount sufficient to increase the rate of hardening of said resin and selected from the group consisting of lightburned magnesium oxide having a surface area of at least 10 square meters per gram and magnesium hydroxide;
- c. an ester functional hardening agent in an amount sufficient to increase the rate of hardening of said composition;
- and
- d. a compound which decreases the solubility of magnesium in the composition, said compound being one which increases the time required to gel the composition at 25.degree. C. by at least 35% when mixed therein at a concentration of 2% based on the weight of resin.
2 more elements
Dependencies are inferred from the claim text.