C - Chemistry – Metallurgy – 08 – L
Patent
C - Chemistry, Metallurgy
08
L
400/7313
C08L 61/10 (2006.01) C08G 8/10 (2006.01) C03C 25/00 (2006.01)
Patent
CA 1092741
ABSTRACT OF THE DISCLOSURE This specification discloses ecologically desirable, improved binder compositions suitable for bonding fibers. These binders exhibit low pollutant characteristics and improved properties, due to a combination into the binder of aminoplast resins or non phenolic monomeric materials capable of co- condensing with formaldehyde, together with a substantially phenol-free, low mono methylolphenol, high 2,4,6-trimethylol phenols content, water soluble thermosetting phenyl formaldehyde resole solution. Other binder ingredients such as water, mineral oil, emulsifiers, stabilizers, water soluble dye and silane type coupling agents are also included as needed. The non phenolic components may be selected from the group comprising urea, dicyandiamide, urea formaldehyde resins, melamine formaldehyde resin and the like. The phenolic resole resin is made to conform to the desired composition by mixing together a high mole ratio of formaldehyde with phenol and calcium hydroxide with cooling so that very little reaction takes place. The reaction is then allowed to proceed according to a carefully controlled temperature-time cycle without external heat input until substantially all the phenol has reacted to form condensation products and yet the mixture is still infinitely dilutable with water. Such binder compositions may be applied at solids levels of 1% to 80% and contain much lower phenolic resin component than binders of prior art with similar bonding characteristics. A very satisfactory resole which conforms to this composition is produced by reacting U.S.P. phenol and formaldehyde in a high mole ratio of 2.8 to 4.5 or preferably 3.2 to 4.4 moles formaldehyde per mole of phenol in the presence of from 6 to 10 moles of water per mole of reactants using calcium oxide or calciumhydroxide as an alkaline catalyst, said catalyst being employed at a level of 0.08 to 0.16 moles calcium (Ca) per mole of phenol (3.5% to 7.0% Ca metal on wt. of phenol) and carrying out the condensation under closely programmed conditions. Suitable conditions are for example: 1. Blending phenol and formaldehyde at a temperature of about 85°F. 2. Introducing calcium oxide or hydroxide at such a rate and with cooling of the mixture so that the reactants so not heat above 125°F during the first hour of the reaction. 3. Continuing the reaction without heat input at a temperature which does not exceed 155°F until analyses indicates that all the phenol has reacted to form condensation products, yet the resinous mass has not advanced to a stage at which it is no longer infinitely dilutable with water. This "end point" for the reaction depends on the mole ration of formaldehyde to phenol and is in the range 4.5 wt.% for mole ratio 2.8:1 to 14% for mole ratio 4.5:1, the precise value depending on the reaction temperatures and the operating characteristics of the reaction equipment.
222679
Deuzeman Hendrik H.j.
Lumley Norman
Santos Ruben A.
Fiberglas Canada Limited
Gowling Lafleur Henderson Llp
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