Preparation of intercondensation product of monohydric phenol-furfural resin and formaldehyde, and utilization thereof in the production of plywood

Claim 1

THE METHOD COMPRISING PRODUCING A THERMOSETTING PHENOL-FURFURAL-FORMALDEHYDE RESIN CONDENSATION PRODUCT IN WHICH RETARDATION IN THE RATE OF CURE OF THE RESIN CONDENSATION PRODUCT IS SUBSTANTIALLY INHIBITED, BY FORMING AN AQUEOUS MIXTURE OF A MONOHYDRIC PHENOL SELECTED FROM THE GROUP OF PHENOLS CONSISTING OF PHENOL PER SE, CRESOL AND XYLENOL; FURFURAL, AND AN ALKALINE CATALYST ACCELERATING THE FORMATION OF THE RESIN-REACTION PRODUCT ON HEATING, THERE BEING PRESENT BETWEEN ABOUT 0.1 AND ABOUT 0.5 MOL OF FURFURAL FOR EACH MOL OF PHENOL, HEATREACTING SAID MIXTURES AND PRODUCING A SOLUTION OF THE MONOHYDRIC PHENOL-FURFURAL RESIN IN AN EXCESS OF MONOHYDRIC PHENOL, THE LATTER BEING ADAPTED TO COMBINE WITH SUBSEQUENTLY ADDED FORMALDEHYDE, AND HEAT-REACTING AND INTERCONDENSING SAID SOLUTION WITH FORMALDEHYDE IN THE PRESENCE OF AN INORGANIC ALKALI METAL COMPOUND UNTIL THE FINAL INTERCONDENSED RESIN SOLUTION HAVING A SOLIDS CONTENT BETWEEN ABOUT 30% AND ABOUT 55% HAS A VISCOSITY BETWEEN THE LIMITS OF ABOUT 130 AND ABOUT 10,000 CENTIPOISES, THERE BEING PRESENT BETWEEN ABOUT 1.5 AND ABOUT 2.9 MOLS OF FORMALDEHYDE FOR EACH MOL OF PHENOL, THE TOTAL ALKALINE MATERIAL PRESENT DURING THE PRODUCTION OF THE MONOHYDRIC PHENOL-FURFURAL-FORMALDEHYDE INTERCONDENSED RESIN BEING EQUIVALENT TO BETWEEN ABOUT 0.1 AND ABOUT 1.0 MOL OF SODIUM HYDROXIDE PER MOL OF PHENOL.

Claim 2

THE METHOD COMPRISING PRODUCING A THERMOSETTING PHENOL-FURFURAL-FORMALDEHYDE RESIN CONDENSATION PRODUCT IN WHICH RETARDATION IN THE RATE OF CURE OF THE RESIN CONDENSATION PRODUCT IS SUBSTANTIALLY INHIBITED, BY FORMING AN AQUEOUS MIXTURE OF A MONOHYDRIC PHENOL SELECTED FROM THE GROUP OF PHENOLS CONSISTING OF PHENOL PER SE, CRESOL AND XYLENOL; FURFURAL, AND AN ALKALINE CATALYST ACCELERATING THE FORMATION OF THE RESIN-REACTION PRODUCT ON HEATING, THERE BEING PRESENT BETWEEN ABOUT 0.1 AND ABOUT 0.5 MOL OF FURFURAL FOR EACH MOL OF PHENOL, HEATREACTING SAID MIXTURES AND PRODUCING A SOLUTION OF THE MONOHYDRIC PHENOL-FURFURAL RESIN IN AN EXCESS OF MONOHYDRIC PHENOL, THE LATTER BEING ADAPTED TO COMBINE WITH SUBSEQUENTLY ADDED FORMALDEHYDE, AND HEAT-REACTING AND INTERCONDENSING SAID SOLUTION WITH FORMALDEHYDE IN THE PRESENCE OF AN INORGANIC ALKALI METAL COMPOUND UNTIL THE FINAL INTERCONDENSED RESIN SOLUTION HAVING A SOLIDS CONTENT BETWEEN ABOUT 30% AND ABOUT 55% HAS A VISCOSITY BETWEEN THE LIMITS OF ABOUT 130 AND ABOUT 10,000 CENTIPOISES, THERE BEING PRESENT BETWEEN ABOUT 1.5 AND ABOUT 2.9 MOLS OF FORMALDEHYDE FOR EACH MOL OF PHENOL, THE TOTAL ALKALINE MATERIAL PRESENT DURING THE PRODUCTION OF THE MONOHYDRIC PHENOL-FURFURAL-FORMALDEHYDE INTERCONDENSED RESIN BEING EQUIVALENT TO BETWEEN ABOUT 0.1 AND ABOUT 1.0 MOL OF SODIUM HYDROXIDE PER MOL OF PHENOL.