Bisphenol-containing resin coating articles and methods of using same
AssigneeBorden Chemical, Inc.
InventorsCalvin K. Johnson, Kwok-tuen Tse
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Abstract
Proppants comprising a particle coated with a composition comprising bisphenol-aldehyde novolak resin, a bisphenol homopolymer or mixtures including such polymers are disclosed. Foundry sands comprising a particle coated with a composition comprising bisphenol-aldehyde novolak resin, a bisphenol homopolymer or mixtures including such polymers are disclosed. Methods of making and using these proppant particles in subterranean formations or making and using these foundry sands in foundries are also disclosed.
Claims28
A coated particle useful in production of foundry shell molds and foundry cores, comprising:
- a granular refractory substrate;
- a curable coating composition coated on the substrate, the composition comprising:
- (i) a resin selected from the group of a bisphenol-aldehyde novolak polymer and a bisphenol homopolymer, the bisphenol component of the novolak polymer and homopolymer having a Formula I:
- ##STR11## wherein R and R.sup.1 are independently selected from the group of alkyl, aryl, arylalkyl and H, and are located meta to the respective OH group of the respective aromatic ring of Formula I;
- X is a bond, sulfonyl, alkylidene unsubstituted or substituted with halogen, cycloalkylidene, and halogenated cycloalkylidene, with the proviso that alkylidene is defined by Formula II:
- ##STR12## wherein R.sup.2 and R.sup.3 are independently selected from H, alkyl, aryl, arylalkyl, halogenated alkyl, halogenated aryl and halogenated arylalkyl;
- with an absence of bisphenol F for the novolak polymer;
- and
- (ii) a crosslinking agent, wherein the composition comprises at least about 10 weight % of the novolak polymer and R.sup.2 and R.sup.3 of the novolak polymer are independently selected so there is an absence of bisphenol E.
- wherein the novolak polymer has a bisphenol:aldehyde molar ratio from about 1:0.85 to 1:0.4.
A coated particle useful in production of foundry shell molds and foundry cores, comprising:
- a granular refractory substrate;
- a curable coating composition coated on the substrate, the composition comprising:
- (i) a resin selected from the group of a bisphenol-aldehyde novolak polymer and a bisphenol homopolymer, the bisphenol component of the novolak polymer and homopolymer having a Formula I:
- ##STR13## wherein R and R.sup.1 are independently selected from the group of alkyl, aryl, arylalkyl and H, and are located meta to the respective OH group of the respective aromatic ring of Formula I;
- X is a bond, sulfonyl, alkylidene unsubstituted or substituted with halogen, cycloalkylidene, and halogenated cycloalkylidene, with the proviso that alkylidene is defined by Formula II:
- ##STR14## wherein R.sup.2 and R.sup.3 are independently selected from H, alkyl, aryl, arylalkyl, halogenated alkyl, halogenated aryl and halogenated arylalkyl;
- with an absence of bisphenol F for the novolak polymer;
- and
- (ii) a crosslinking agent,
- wherein the composition comprises at least about 10 weight % of the bisphenol homopolymer.
A method for making an aldehyde-modified polymer consisting of the steps of:
- making a member of the group consisting of a bisphenol-aldehyde novolak polymer, a bisphenol homopolymer and mixtures thereof;
- and
- reacting the member with an aldehyde under alkaline conditions.
A process for making a bisphenol-aldehyde novolak polymer comprising the sequential steps of:
- mixing, to form a mixture at elevated temperature, a solvent with at least one bisphenol of Formula I:
- ##STR15## wherein R and R.sup.1 are independently selected from the group of alkyl, aryl, arylalkyl and H, and are located meta to the respective OH group of the respective aromatic ring of Formula I;
- X is a bond, sulfonyl, alkylidene unsubstituted or substituted with halogen, cycloalkylidene, and halogenated cycloalkylidene, with the proviso that alkylidene is defined by Formula II:
- ##STR16## wherein R.sup.2 and R.sup.3 are independently selected from H, alkyl, aryl, arylalkyl, halogenated alkyl, halogenated aryl and halogenated arylalkyl, wherein there is an absence of bisphenol F;
- adding a catalyst selected from the group consisting of acid catalyst and divalent metal catalyst to said mixture;
- adding an aldehyde to said mixture;
- and
- refluxing the mixture.
Dependencies are inferred from the claim text.