Preparation of phenol-formaldehyde resin beads using suspension or emulsion polymerization
AssigneeGeorgia-Pacific Chemicals LLC
InventorsShahid P. Qureshi, Xing Dong, Charles C. Chan, Joseph Frank Ludvik
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Abstract
Methods for making polymer particles in gel form via an emulsion and/or suspension polymerization are provided. In at least one specific embodiment, the method can include reacting a first reaction mixture comprising a phenolic monomer, an aldehyde monomer, and a first catalyst to produce a prepolymer. The method can also include combining the prepolymer with a carrier fluid and a second catalyst to produce a second reaction mixture. The second catalyst can include a dicarboxylic acid, an anhydride, a dihydroxybenzene, or any mixture thereof. The method can also include polymerizing the prepolymer to form polymer particles in gel form.
Claims20
A method for making polymer particles in gel form via emulsion or suspension polymerization, the method comprising:
- reacting a first reaction mixture comprising a phenolic monomer, an aldehyde monomer, and a first catalyst to produce a prepolymer;
- combining the prepolymer with a carrier fluid and a second catalyst to produce a second reaction mixture, wherein the second catalyst comprises a dicarboxylic acid, an anhydride, a dihydroxybenzene, or any mixture thereof;
- and
- polymerizing the prepolymer to form polymer particles in gel form.
A method for making polymer particles in gel form via emulsion or suspension polymerization, the method comprising:
- reacting a first reaction mixture comprising a phenolic monomer and formaldehyde in the presence of a first catalyst to produce a prepolymer, wherein the phenolic monomer comprises phenol, resorcinol, or a mixture thereof;
- combining a carrier fluid and a second catalyst with the prepolymer to form an emulsion or a suspension, wherein the second catalyst comprises an anhydride, a dihydroxybenzene, or a mixture thereof;
- and
- polymerizing the prepolymer in the emulsion or suspension to produce polymer particles in gel form.
A method for making an aerogel, comprising:
- making a prepolymer from a first reaction mixture comprising a phenolic monomer, formaldehyde, and a first catalyst, wherein the phenolic monomer comprises phenol, a first dihydroxybenzene, or a mixture thereof, and wherein the first catalyst comprises ammonia, dimethylethanolamine, ethylenediamine, triethylamine, trimethylamine, tripropylamine, diethylethanolamine, hexamethylenetetramine, lithium carbonate, or any mixture thereof;
- combining the prepolymer with a carrier fluid and a second catalyst comprising maleic anhydride, a second dihydroxybenzene, or a mixture a mixture thereof to form an emulsion or suspension;
- polymerizing the prepolymer in the emulsion or suspension to form polymer particles in gel form, wherein about 40% or more of the polymer particles in gel form have an average cross-sectional length greater than or equal to 1 mm;
- and
- drying the polymer particles in gel form to produce an aerogel.
Dependencies are inferred from the claim text.