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US 5,670,571 AGranted
Process for producing a dispersed novolac resin and use in a binder system for thermal insulation
AssigneeGeorgia-Pacific Resins, Inc.
InventorsKurt D. Gabrielson, Rodney R. Conner
Life of this patent
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Abstract
An aqueous dispersion of small particles of a phenol/formaldehyde novolac resin, referred to as a dispersed novolac resin, useful for example as a binder in preparing glass fiber insulation. The dispersed novolac resin is produced by preparing a molten novolac resin, cooling, adding water and optionally a surfactant and then adding a protective colloid. Additional water is added to provide the desired dispersion.
Claims11
A process for producing a dispersed particulate novolac resin comprising the steps in the following order of:
- (a) reacting a phenol with an aldehyde in the presence of a catalyst under acidic conditions to produce a novolac resin;
- (b) heating the novolac resin to remove water, unreacted phenol, and other volatile organic materials from the resulting novolac and to produce a molten novolac resin;
- (c) cooling the molten novolac resin to a point where water can be added;
- (d) adding about 10-30 wt % of water based on the total novolac resin solids and, optionally, a surfactant, to the molten resin, the water being added in an amount sufficient to produce a water-in-oil emulsion;
- (e) adding a protective colloid to the emulsion in an amount sufficient to stabilize the dispersed particulate novolac resin;
- and
- (f) adding additional water and agitating to produce the dispersed particulate novolac resin, wherein the particulate novolac resin has a particle size of 0.1.mu. to 20.mu..
4 more elements
Dependencies are inferred from the claim text.