Process for the manufacture of dispersions of thermosetting phenolic reaction products

Claim 2

PROCESS FOR THE MANUFACTURE OF A WATER-DILUTABLE, SELFEMULSIFIED, AQUEOUS DISPERSION OF A THERMOSETTING REACTION PRODUCT WHICH COMPRISES A. WARMING AN AQUEOUS MIXTURE OF

Claim 3

PHENOL,

Claim 4

PHENOL,

Claim 5

A SUBSTITUTED PHENOL HAVING FROM 1 TO 14 SUBSTITUENTS ON THE PHENOL NUCLEUS AND HAVING AT LEAST ONE RING CARBON ATOM AVAILABLE FOR REACTION WITH FORMALDEHYDE, AND WHICH SUBSTITUTED PHENOL HAS A SPEED OF REACTION OF UNSUBIS 40 TO 150 PERCENT OF THE SPEED OF REACTION OF UNSUBSTITUTED PHENOL,

Claim 6

A SUBSTITUTED PHENOL HAVING FROM 1 TO 14 SUBSTITUENTS ON THE PHENOL NUCLEUS AND HAVING AT LEAST ONE RING CARBON ATOM AVAILABLE FOR REACTION WITH FORMALDEHYDE, AND WHICH SUBSTITUTED PHENOL HAS A SPEED OF REACTION OF UNSUBIS 40 TO 150 PERCENT OF THE SPEED OF REACTION OF UNSUBSTITUTED PHENOL,

Claim 7

a substituted phenol having from 1 to 4 substituents on the phenol nucleus and having at least one ring carbon atom available for reaction with formaldehyde, and which substituted phenol has a speed of reaction which is 40 to 150 percent of the speed of reaction of unsubstituted phenol,

Claim 8

a substituted phenol having from 1 to 4 substituents on the phenol nucleus and having at least one ring carbon atom available for reaction with formaldehyde, and which substituted phenol has a speed of reaction which is 40 to 150 percent of the speed of reaction of unsubstituted phenol,

Claim 9

Process of claim 1 wherein the substituted phenol component (2) is made by heating to about 150* to 160*C a mixture of phenol and a styrene compound in excess phenol as the solvent in the presence of from about 1 to 5 percent by weight of oxalic acid, relative to the total amount of phenol and the styrene compound, until the reaction mixture contains at least 95 percent by weight of an equimolar phenol-styrene reaction product.

Claim 10

Process of claim 1 wherein the substituted phenol (2) is selected from the group consisting of p-tert-butyl phenol o- Alpha -phenylethylphenol o- Beta -phenylethylphenol p- Alpha -phenylethylphenol p- Beta -phenylethylphenol o- Alpha -phenylisopropylphenol o- Beta -phenylisopropylphenol p- Alpha -phenylisopropylphenol p- Beta -phenylisopropylphenol o- Alpha -methylphenylethylphenol o- Beta -methylphenylethylphenol p- Alpha -methylphenylethylphenol p- Beta -methylphenylethylphenol, and mixtures thereof.

Claim 11

formaldehyde or a formaldehyde donor,

Claim 12

formaldehyde or a formaldehyde donor,

Claim 13

FORMALDEHYDE OR A FORMALDEHYDE DONOR,

Claim 14

FORMALDEHYDE OR A FORMALDEHYDE DONOR,

Claim 15

A SECONDARY AMINE, AND

Claim 16

A SECONDARY AMINE, AND

Claim 17

a secondary amine, and

Claim 18

a secondary amine, and

Claim 19

Process of claim 1 wherein as phenol (1) and substituted phenol (2) there is used a mixture of phenol and Alpha - and Beta -phenylethylphenol.

Claim 20

Process of claim 1 wherein a member of the group consisting of water, a protective colloid, and mixtures of water and a protective colloid are added to the mixture during the stirring and cooling step (b).

Claim 21

AN acid until a sample of the dispersion reaction mixture has a B-time of 30 seconds to 10 minutes at 160*C, and b. while stirring, cooling the mixture from step (a), said process being further characterized in the mixture of substituted phenol and phenol is employed in a ratio such that the average functionality of the sum of the phenolic compounds (1) and (2) relative to the formaldehyde component (3) is between 2.1 and 2.8, and the amount of formaldehyde in the mixture being so chosen that the molar ratio of the total sum of formaldehyde (3) to the sum of the phenolic compounds (1) and (2) ranges from about 0.9 to 1.5 to 1, and the secondary amine content (4) in the mixture ranges from about 50 to about 200 mol percent, relative to the total weight of the phenols (1) and (2), the amount of acid (5) in the mixture being equivalent to the secondary amine (4), the amount of water in the mixture, including added water and water of reaction, ranging from 30 to 60 percent by weight, relative to the weight of the total mixture.

Claim 22

AN acid until a sample of the dispersion reaction mixture has a B-time of 30 seconds to 10 minutes at 160*C, and b. while stirring, cooling the mixture from step (a), said process being further characterized in the mixture of substituted phenol and phenol is employed in a ratio such that the average functionality of the sum of the phenolic compounds (1) and (2) relative to the formaldehyde component (3) is between 2.1 and 2.8, and the amount of formaldehyde in the mixture being so chosen that the molar ratio of the total sum of formaldehyde (3) to the sum of the phenolic compounds (1) and (2) ranges from about 0.9 to 1.5 to 1, and the secondary amine content (4) in the mixture ranges from about 50 to about 200 mol percent, relative to the total weight of the phenols (1) and (2), the amount of acid (5) in the mixture being equivalent to the secondary amine (4), the amount of water in the mixture, including added water and water of reaction, ranging from 30 to 60 percent by weight, relative to the weight of the total mixture.

Claim 23

AN ACID UNTIL A SAMPLE OF THE DISPERSION REACTION MIXTURE HAS A B-TIME OF 30 SECONDS TO 10 MINUTES AT 160*C, AND B. WHILE STIRRING, COOLING THE MIXTURE FROM STEP (A), SAID PROCESS BEING FURTHER CHARACTERIZED IN THE MIXTURE OF SUBSTITUTED PHENOL AND PHENOL IS EMPLOYED IN A RATIO SUCH THAT THE AVERAGE FUNCTIONALITY OF THE SUM OF THE PHENOLIC COMPOUNDS (1) AND (2) RELATIVE TO THE FORMALDEHYDE COMPONENT (3) IS BETWEEN 2.1 AND 2.8, AND THE AMOUNT OF FORMALDEHYDE IN THE MIXTURE BEING SO CHOSEN THAT THE MOLAR RATIO OF THE TOTAL SUM OF FORMALDEHYDE (3) TO THE SUM OF THE PHENOLIC COMPOUNDS (1) AND (2) RANGES FROM ABOUT 0.9 TO 1.5 TO 1, FAND THE SECONDARY AMINE CONTENT (4), IN THE MIXTURE RANGES FROM ABOUT 50 TO ABOUT 200 MOL PERCENT, RELATIVE TO THE TOTAL WEIGHT OF THE PHENOLS (1) AND (2), THE AMOUNT OF ACID (5) IN THE MIXTURE BEING EQUIVALENT TO THE SECONDARY AMINE (4), THE AMOUNT OF WATER IN THE MIXTURE, INCLUDING ADDED WATER AND WATER OF REACTION, RANGING FROM 30 TO 60 PERCENT BY WEIGHT, RELATIVE TO THE WEIGHT OF THE TOTAL MIXTURE.

Claim 24

AN ACID UNTIL A SAMPLE OF THE DISPERSION REACTION MIXTURE HAS A B-TIME OF 30 SECONDS TO 10 MINUTES AT 160*C, AND B. WHILE STIRRING, COOLING THE MIXTURE FROM STEP (A), SAID PROCESS BEING FURTHER CHARACTERIZED IN THE MIXTURE OF SUBSTITUTED PHENOL AND PHENOL IS EMPLOYED IN A RATIO SUCH THAT THE AVERAGE FUNCTIONALITY OF THE SUM OF THE PHENOLIC COMPOUNDS (1) AND (2) RELATIVE TO THE FORMALDEHYDE COMPONENT (3) IS BETWEEN 2.1 AND 2.8, AND THE AMOUNT OF FORMALDEHYDE IN THE MIXTURE BEING SO CHOSEN THAT THE MOLAR RATIO OF THE TOTAL SUM OF FORMALDEHYDE (3) TO THE SUM OF THE PHENOLIC COMPOUNDS (1) AND (2) RANGES FROM ABOUT 0.9 TO 1.5 TO 1, FAND THE SECONDARY AMINE CONTENT (4), IN THE MIXTURE RANGES FROM ABOUT 50 TO ABOUT 200 MOL PERCENT, RELATIVE TO THE TOTAL WEIGHT OF THE PHENOLS (1) AND (2), THE AMOUNT OF ACID (5) IN THE MIXTURE BEING EQUIVALENT TO THE SECONDARY AMINE (4), THE AMOUNT OF WATER IN THE MIXTURE, INCLUDING ADDED WATER AND WATER OF REACTION, RANGING FROM 30 TO 60 PERCENT BY WEIGHT, RELATIVE TO THE WEIGHT OF THE TOTAL MIXTURE.

Claim 25

Product produced by the process of claim 1.

Claim 26

Product produced by the process of claim 2.