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US 5,847,058 AGranted
Alkylresorcinol modified phenol-aldehyde resol resin and binder system, and method of making same
AssigneeMasonite Corporation
InventorZygmunt Teodorczyk
Life of this patent
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Abstract
A process for the production of a storage-stable, modified phenol-aldehyde resol resin includes the use of an alkylresorcinol modifier and preferably a readily-available mixture of alkylresorcinols. A binder system includes the modified phenol-aldehyde resin combined with a curing agent that includes an additional source of an aldehyde, e.g., a phenol-formaldehyde resin. The resin and binder system are useful in the production of a wood composite (such as plywood, oriented strandboard, or fiberboard).
Claims29
A method of preparing a modified phenol-aldehyde resole resin, comprising:
- (a) reacting a phenolic compound and an aldehyde at a molar ratio of aldehyde to phenolic compound in a range of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- and
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) wherein the molar ratio of said aldehyde to the total of said phenolic compound and said alkylresorcinol compound is greater than about 1:1, to produce said resole resin.
A method of producing a modified phenol-formaldehyde resin, comprising:
- (a) reacting a phenolic compound comprising a phenol or a phenol derivative and an aldehyde at a molar ratio of aldehyde to phenolic compound of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- and
- (b) reacting a modifier comprising an alkyl resorcinol compound with the product of step (a) wherein (1) the molar ratio of said phenolic compound to said modifier is about 1:1 to about 10:1 and (2) the molar ratio of said aldehyde to the total of said phenolic compound and said modifier is greater than about 1:1.
A method of preparing a binder system useful in the production of a cellulosic composite, comprising:
- (a) reacting a phenolic compound and an aldehyde at a molar ratio of aldehyde to phenolic compound in a range of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) at a molar ratio of aldehyde to total phenolics of greater than about 1:1, to form a modified phenol-aldehyde resole resin;
- and
- (c) combining said modified phenol-aldehyde resin with a curing agent which comprises an organic resin comprising an aldehyde, to form said binder system.
1 more element
A method of producing a cellulosic composite, comprising:
- (a) reacting a phenolic compound comprising phenol or a phenol derivative and an aldehyde at a molar ratio of aldehyde to phenolic compound in a range of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) at a molar ratio of aldehyde to total phenolics of greater than about 1:1, to form a modified phenol-aldehyde resole resin;
- (c) combining said modified phenol-aldehyde resin with a curing agent which comprises an organic resin comprising an aldehyde to form a binder system;
- (d) combining said binder system with a cellulosic filler;
- (e) forming the product of step (d) into a mat;
- and
- (f) consolidating said mat under heat to form said cellulosic composite.
4 more elements
A method of producing a cellulosic composite, comprising:
- (a) reacting a phenolic compound comprising phenol or a phenol derivative and an aldehyde at a molar ratio of aldehyde to phenolic compound of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- and
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) wherein (1) the molar ratio of said phenolic compound to said modifier is about 1:1 to about 10:1 and (2) the molar ratio of said aldehyde to the total of said phenolic compound and said modifier is greater than about 1:1;
- (c) combining the product of step (b) with a phenol-aldehyde resin and a cellulosic filler;
- (d) forming the product of step (c) into a mat;
- and
- (e) pressing said mat under heat to form said cellulosic composite.
4 more elements
A method for the production of plywood, comprising:
- (a) reacting a phenolic compound comprising phenol or a phenol derivative and an aldehyde at a molar ratio of aldehyde to phenolic compound in a range of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst present in an amount of about 0.1 to about 0.2 moles catalyst per mole of said phenolic compound;
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) to form a modified phenol-aldehyde resole resin;
- (c) combining said modified phenol-aldehyde resin with a curing agent which comprises a phenolic resin to form a binder system;
- (d) placing said binder system on a wood panel;
- (e) curing the product of step (d) under heat and pressure.
2 more elements
A method of preparing a modified phenol-aldehyde resole resin, comprising:
- (a) reacting a phenolic compound comprising phenol or a phenol derivative and an aldehyde at a molar ratio of aldehyde to phenolic compound in a range of about 1.2:1 to about 2.0:1, said reaction taking place in the presence of an alkaline catalyst;
- and
- (b) reacting a modifier comprising an alkylresorcinol compound with the product of step (a) wherein the molar ratio of said aldehyde to the total of said phenolic compound and said alkylresorcinol compound is greater than about 1:1, to produce said resole resin.
Dependencies are inferred from the claim text.