US3839251A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Phenolic resin and process for making same
Assignee: GP Chemicals Equity LLC
•
Filing: 1972-06-28
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Granted: 1974-10-01
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Expires: 1992-06-28
Abstract
Abstract A resin suitable for use in the caulless system of composition board manufacture is prepared by a controlled reaction of phenol with formaldehyde in the presence of small amounts of sodium hydroxide catalyst. One mole of phenol is reacted with from about 2.5 to 3.5 moles of formaldehyde in the presence of caustic soda catalyst to form a first stage resin having a viscosity of 150 300 cps at 77*F. Additional phenol in the range of 0.25 moles to 0.5 moles per mole of phenol in the initial reaction is then added as a second stage and the resin is again reacted to a viscosity of 150 to 750 centipoises. The amount of phenol added is that amount necessary to impart to particles of wood coated with the resin sufficient tack to cause them to adhere to each other and form a sheet of sufficient structural integrity and firmness to normal transfer operations in the caulless system of particle board manufacture. The resin has a pH of about 8.5 to about 10. Its cure may be accelerated by adding about 2 - 4 percent resorcinol formaldehyde resin.
Inventors
- 👤 L Bornstein
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 05:39
CPC Classifications
C; C08; C08G; C08G8/00; C08G8/04; C08G8/08; C08G8/10
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
39 words
A METHOD OF PREPARING A PHENOLIC RESIN HAVING IMPROVED CURRING SPEED, WETTING PROPERTIES, FLOW CHARACTERISTICS AND TACK IMPARTING PROPERTIES UNDER HOT PRESS PARTICLE BOARD MOLDINNG CONDITIONS SUITABLE FOR USE IN THE CAULLESS PRODUCTION OF PARTICLE BOARD, SAID METHOD COMPRISING:
Claim 2
Independent Claim
39 words
A METHOD OF PREPARING A PHENOLIC RESIN HAVING IMPROVED CURRING SPEED, WETTING PROPERTIES, FLOW CHARACTERISTICS AND TACK IMPARTING PROPERTIES UNDER HOT PRESS PARTICLE BOARD MOLDINNG CONDITIONS SUITABLE FOR USE IN THE CAULLESS PRODUCTION OF PARTICLE BOARD, SAID METHOD COMPRISING:
Claim 3
Dependent Claim
56 words
REACTING PHENOL WITH A MOLAR EXCESS OF FORMALDEHYDE IN THE RANGE OF ABOUT 2.5 TO 3.5 MOLES OF FORMALDEHYDE PER MOLE OF PHENOL IN AN AQUEOUS MEDIUM UTILIZING AN ALKALINE CATALYST UNTIL THE RESULTING AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY AT 77*F WITHIN THE RANGE 150 CPS TO 300 CPS TO FORM A FIRST STAGE RESIN,
Claim 4
Dependent Claim
56 words
REACTING PHENOL WITH A MOLAR EXCESS OF FORMALDEHYDE IN THE RANGE OF ABOUT 2.5 TO 3.5 MOLES OF FORMALDEHYDE PER MOLE OF PHENOL IN AN AQUEOUS MEDIUM UTILIZING AN ALKALINE CATALYST UNTIL THE RESULTING AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY AT 77*F WITHIN THE RANGE 150 CPS TO 300 CPS TO FORM A FIRST STAGE RESIN,
Claim 5
Dependent Claim
36 words
ADDING FROM ABOUT 0.25 TO ABOUT 0.50 MOLES OF PHENOL PER MOLE OF PHENOL IN THE REACTION OF STEP (1), SAID ADDED PHENOL BEING SUFFICIENT TO IMPART TACK CHARACTERISTICS TO WOOD PARTICLES COATED WITH THE RESIN,
Claim 6
Dependent Claim
36 words
ADDING FROM ABOUT 0.25 TO ABOUT 0.50 MOLES OF PHENOL PER MOLE OF PHENOL IN THE REACTION OF STEP (1), SAID ADDED PHENOL BEING SUFFICIENT TO IMPART TACK CHARACTERISTICS TO WOOD PARTICLES COATED WITH THE RESIN,
Claim 7
Dependent Claim
36 words
adding from about 0.25 to about 0.50 moles of phenol per mole of phenol in the reaction of step (1), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin,
Claim 8
Dependent Claim
36 words
adding from about 0.25 to about 0.50 moles of phenol per mole of phenol in the reaction of step (1), said added phenol being sufficient to impart tack characteristics to wood particles coated with the resin,
Claim 9
Dependent Claim
12 words
The process of claim 1 wherein the alkaline catalyst is sodium hydroxide.
Claim 10
Dependent Claim
45 words
The process of claim 2 wherein the molar proportion of catalyst is in the range 0.2 to 0.3 based upon the number of moles of phenol initially reacted and the pH of the final resin is in the range of about 8.5 to about 10.
Claim 11
Dependent Claim
20 words
continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and
Claim 12
Dependent Claim
20 words
continuing the reaction until the aqueous resin has a Brookfield viscosity within the range 150 cps to 750 cps, and
Claim 13
Dependent Claim
20 words
CONTINUING THE REACTION UNTIL THE AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY WITHIN THE RANGE 150 CPS TO 750 CPS, AND
Claim 14
Dependent Claim
20 words
CONTINUING THE REACTION UNTIL THE AQUEOUS RESIN HAS A BROOKFIELD VISCOSITY WITHIN THE RANGE 150 CPS TO 750 CPS, AND
Claim 15
Dependent Claim
11 words
RAPIDLY COOLING THE AQUEOUS RESIN TO A TEMPERATURE LESS THAN 80*F.
Claim 16
Dependent Claim
11 words
RAPIDLY COOLING THE AQUEOUS RESIN TO A TEMPERATURE LESS THAN 80*F.
Claim 17
Dependent Claim
11 words
rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 18
Dependent Claim
11 words
rapidly cooling the aqueous resin to a temperature less than 80*F.
Claim 19
Dependent Claim
19 words
The process of claim 3 wherein the catalyst is added incrementally to prevent excessive heat build-up in the reactor.
Claim 20
Dependent Claim
28 words
The process of claim 1 wherein the molar ratio of formaldehyde to phenol in the final resin is from about 1.8 to 1 to about 3.0 to 1.
Claim 21
Dependent Claim
33 words
The process of claim 4 wherein the second stage resin is kept at a temperature from about 160*F - 180*F until the Brookfield viscosity within the range 250 to 275 cps is reached.
Claim 22
Dependent Claim
22 words
A process as recited in claim 1 wherein the viscosity range in step (1) is about 175 cps to about 225 cps.
Claim 23
Dependent Claim
36 words
A process as recited in claim 1 wherein the amount of phenol added in step (2) is in the range of about 0.30 moles to about .40 moles per mole of phenol in the initial reaction.
Claim 24
Dependent Claim
31 words
A process as recited in claim 1 wherein the molar ratio of formaldehyde to phenol in the reaction of step (1) is in the range of about 3.0 to about 3.5.
Claim 25
Dependent Claim
10 words
A phenolic resin prepared by the process of claim 1.
Claim 26
Dependent Claim
10 words
A phenolic resin prepared by the process of claim 4.
Claim 27
Dependent Claim
10 words
A phenolic resin prepared by the process of claim 6.
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US2557826A
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US2457493A
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US3422068A
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-09-30 | 1978-04-01 | 1978-10-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-09-30 | 1982-04-01 | 1982-10-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-09-30 | 1986-04-01 | 1986-10-01 | $7700.00 | Window Closed / Lapsed |