Dry process resinified consolidated product of phenol formaldehyde and cellulose

Claim 1

THE PROCESS OF PRODUCING A CONSOLIDATED PRODUCT WHICH COMPRISES ADMIXING AN ALPHA-CELLULOSE CONTAINING FIBROUS BODY, FREE PHENOL, AND AN AQUEOUS SOLUTION OF A PREFORMED ALKALINE CONDENSED THERMOSETTING RESIN CONDENSATION PRODUCT OF PHENOL AND FORMALDEHYDE, WHICH AQUEOUS RESIN SOLUTION POSSESSES A PH ABOVE ABOUT 9.8 AND REQUIRES FROM ABOUT 1I TO ABOUT 28 SECONDS TO CHANGE FROM THE LIQUID TO THE DRY-RUBBERY STATE AS MEASURED BY THE DRY-RUBBER TEST AT 300*F. FOR SPEED OF SETTING, THE TOTAL AMOUNT OF WATER PRESENT IN THE MIXTURE SO PRODUCED BEING NO MORE THAN ABOUT 10% BY WEIGHT BASED UPON THE BONE-DRY FIBROUS CONTENT, AND CONSOLIDATING SAME BY SUBJECTING THER MIXTURE AT A TEMPERATURE OF 290-340*F. AT A PRESSURE OF FROM 500-1000 P.S.I. FOR FROM 30 SECONDS TO 2 MINUTES FOLLOWED BY FURTHER CONSOLIDATION AT A PRESSURE OF 5-500 P.S.I. FOR FROM 3-10 MINUTES AT 290-30*F., THE QUANTITY OF SAID FREE PHENOL BEING ABOUT 2-30 PARTS BY WEIGHT PER 100 PARTS THERMOSETTING RESIN SOLIDS, THE SAID THERMOSETTING RESIN BEING THE WATER-SOLUBLE CONDENSATION PRODUCT OBTAINED UPON REACTING PHENOL AND FORMALDEHYDE IN THE PRESENCE OF AN ALKALINE CATALYST IN A MOLAR RATIO OF ABOUT 1 MOL PRODUCT TO ABOUT 1.9-2.25 MOLS OF FORMALDEHYDE TO ABOUT 0.18-0.85 MOL ALKALINE CATALYST EXPRESSED AS SODIUM HYDROXIDE, THE THERMOSETTING RESIN AO PRODUCED BEING FURTHER CHARACTERIZED BY CONTAINING NOT MORE THAN ABOUT 1.5% BY WEIGHT BASED UPON THE THERMOSETTING RESIN SOLIDS OF UNREACTED PHENOL.