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US 5,708,121 AGranted
Storage stable melamine-modified phenolic resole resins using an alkaline condensation and polyhydroxyl compound stabilization
AssigneeGeorgia-Pacific Resins, Inc.
InventorsClaude Phillip Parks, Kurt Forrest Anderson
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Abstract
This invention relates to an emulsifiable melamine-modified phenolic resole resin composition useful as a binder for glass fibers. The invention is more particularly directed to the process of preparing the resole resin composition using an alkaline condensation in the presence of a polyhydroxyl compound.
Claims27
A method of preparing a storage stable emulsifiable melamine-modified phenolic resole resin comprising:
- (a) preparing an alkaline resole resin by reacting formaldehyde and a phenol at a formaldehyde to phenol mole ratio between about 1:1 to 6:1 at a pH between about 8 and 10 in the presence of an effective catalytic amount of a monovalent basic catalyst;
- followed by
- (b) adding a polyhydroxy compound and reacting formaldehyde remaining unreacted after the formaldehyde and phenol reaction, with melamine at a pH between about 8 and 10, at an unreacted formaldehyde to melamine mole ratio between about 3:1 to 1:1, wherein the polyhydroxy compound is added in an amount sufficient to prevent premature crystallization of methylolated melamine species;
- (c) neutralizing the melamine modified, phenolic resole resin to a pH between about 6.5 and 8.5;
- and
- (d) adding a protective colloid to the neutralized melamine modified phenolic resole resin.
3 more elements
A storage stable emulsifiable melamine-modified phenolic resole resin comprising:
- a melamine-modified alkaline resole resin prepared by first reacting formaldehyde and a phenol at a formaldehyde to phenol mole ratio between about 1:1 to 6:1 at a pH of between about 8 and 10 in the presence of an effective catalytic amount of a monovalent basic catalyst;
- then adding a polyhydroxy compound and reacting formaldehyde remaining unreacted after the formaldehyde and phenol reaction with melamine at a pH between about 8 and 10, at an unreacted formaldehyde to melamine mole ratio between about 3:1 to 1:1, wherein the polyhydroxy compound is added in an amount sufficient to prevent premature crystallization of methylolated melamine species;
- adding a neutralizing agent to the melamine-modified phenolic resole resin to a pH between about 6.5 and 8.5;
- and adding a protective colloid to the neutralized melamine modified phenolic resole resin.
1 more element
Dependencies are inferred from the claim text.