Phenolic resin compositions with improved impact resistance

A phenolic siloxane composition prepared by combining:

• a phenolic compound selected from the group consisting of phenol and substituted phenol;
• with
• a silicone intermediate;
• an aldehyde;
• and
• an acid or base;
• wherein the silicone intermediate is combined with at least one of the phenolic compound and the aldehyde, and the other one of the phenolic compound and the aldehyde is thereafter added to form a phenolic polymer having Si--O groups in its backbone.

A phenolic siloxane composition prepared by combining:

• a phenolic compound selected from the group consisting of phenol and substituted phenol, with a silicone intermediate and thereafter adding;
• an aldehyde;
• an acid or base;
• and
• a sufficient amount of catalyst to form a phenolic polymer having Si--O groups in its backbone, and a siloxane polymer, the phenolic polymer and siloxane polymer forming a thermoset IPN, the catalyst being selected from the group consisting of organometallic compounds, amine compounds, acids, bases, and mixtures thereof.

A phenolic siloxane composition prepared by combining:

• a phenolic resole resin;
• a silicone intermediate;
• and
• a sufficient amount of catalyst to facilitate forming a thermoset IPN of phenolic polymer and siloxane polymer, the phenolic polymer having Si--O groups in its backbone.

A phenolic siloxane thermoset composition prepared by combining:

• in the range of from 65 to 99.5 percent by weight of phenolic resole resin based on the total composition;
• with
• a silicone intermediate in the absence of a solvent to form a phenolic polymer having Si--O groups in its backbone;
• and adding
• a sufficient amount of catalyst to the silicone intermediate and phenolic resole resin combination facilitate processing and curing the composition at temperatures below 100.degree. C., wherein the catalyst comprises an organometallic compound and an amine compound.

A phenolic siloxane composition prepared by combining:

• a phenolic novolac resin;
• a formaldehyde donor that reacts with the phenolic novolac resin to form a phenolic polymer;
• a silicone intermediate that forms a siloxane polymer and that introduces siloxane groups into the phenolic polymer;
• and
• a sufficient amount of catylist to facilitate forming a thermostat IPN of the phenolic polymer and siloxane polymer.

A method for forming a phenolic siloxane composition comprising the steps of:

• combining a phenol ingredient, an aldehyde ingredient, and a silicone intermediate ingredient in a predetermined sequence;
• reacting the ingredients to form phenolic prepolymers, siloxane prepolymers, and to introduce Si--O groups into the backbone of the phenolic prepolymers;
• and
• curing the reacted ingredients.

A method for forming a phenolic siloxane composition comprising the steps of:

• combining a phenolic resole resin and a silicone intermediate to form a mixture;
• reacting the mixture in the absence of a solvent to form a mixture including a phenolic polymer having siloxane groups in its backbone;
• and
• adding a sufficient amount of catalyst comprising an organometallic compound and an amine compound to the mixture to facilitate cure.

A method for forming a phenolic siloxane composition comprising the steps of:

• combining a phenolic novolac resin, a formaldehyde donor, and a silicone intermediate to form a mixture;
• reacting the mixture in the absence of a solvent to form a phenolic polymer having siloxane groups in the polymer backbone;
• and
• adding a sufficient amount of catalyst to the mixture to facilitate cure.

A phenolic siloxane composition prepared by combining:

• a phenolic compound selected from the group consisting of phenol and substituted phenol;
• with an aldehyde;
• an acid or base;
• and
• a silicone intermediate;
• wherein at least one of the phenolic compound and the aldehyde is combined with the silicone intermediate to form a mixture, and the other of the phenolic compound and the aldehyde is added to the mixture to form a siloxane polymer and a phenolic polymer that has Si--O groups in its backbone, the phenolic polymer and siloxane polymer forming an IPN.

A phenolic siloxane thermoset composition prepared by combining:

• a formaldehyde donor;
• in the range of from 50 to 95 percent by weight of phenolic novolac resin based on the total composition, the phenolic novolac resin reacting with the formaldehyde donor to form a phenolic polymer;
• a silicone intermediate that forms a siloxane polymer and that introduces siloxane groups into the phenolic polymer;
• and
• a sufficient amount of catalyst to facilitate curing the composition at temperatures below 100.degree. C. to form an IPN of siloxane polymer and phenolic polymer.

A phenolic siloxane thermoset composition prepared by combining:

• in the range of from 65 to 99.5 percent by weight of phenolic resole resin based on the total composition, the phenolic resole resin forming a phenolic polymer;
• a silicone intermediate that forms a siloxane polymer and that introduces siloxane groups into the phenolic polymer;
• and
• a sufficient amount of catalyst to facilitate processing and curing the composition at temperatures below 100.degree. C. to form an IPN of siloxane polymer and phenolic polymer.

A method for forming a phenolic siloxane composition comprising the steps of:

• combining a phenolic resole resin and a silicone intermediate to form a mixture;
• reacting the mixture in the absence of a solvent to form an IPN of siloxane polymer and phenolic polymer characterized in that the phenolic polymer has siloxane groups in its backbone;
• and
• adding a sufficient amount of catalyst to the mixture to facilitate cure.