Adhesive composition

Claim 1

A METHOD FOR FORMING AN ALDEHYDE-PHENOLIC CONDENSATION COPOLYMER, WHICH COMPRISES: FORMING AN ESSENTIALLY LINEAR AND NON-CROSS-LINKABLE ALDEHYDE CONDENSATION PREPOLYMER HAVING A VISCOSITY OF 5 CPS TO 75 CPS AT 25*C BY REACTING AN ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE ACETALDEHYDE, BENZALKEHYDE, PROPIONALDEHYDE, BUTYRALDEHYDE, FURFURALDEHYDE, AND MIXTURES THEREOF WITH A PHENOLIC COMPOUND SELECTED FROM THE GROUP CONSISTING OF PHENOL, RESORCINOL, XYLENOL AND CRESOL IN A MOLE RATIO OF ALKEHYDE TO PHENOLIC COMPOUND OF 0.5 : 1 TO 5 : 1 IN WATER IN AMOUNTS OF 25% TO 75% BASED ON THE TOTAL WEIGHT OF MATERIALS IN THE PRESENCE OF A CATALYST OF THE HYDROXIDE OR CARBONATE COMPOUNDS OF ALKALI METAL OR ALKALINE EARTH METALS, AMMONIUM HYDROXIDE OR AMMONIUM CARBONATE; FORMING A HIGHLY THERMOSETTABLE AND CROSS-LINKABLE ALDEHYDE CONDENSATION ALDEHYDE CONDENSATION PREPOLYMER HAVING A VISCOSITY OF 5 CPS TO 75 CPS AT 25*C, BY REACTING SAID ALDEHYDE WITH SAID PHENOLIC COMPOUND IN A MOLE RATIO OF ALDEHYDE TO PHENOLIC COMPOUND OF 2.0 : 1 TO 3.0 : 1 IN WATER IN AMOUNTS OF 25% TO 75% BASED ON THE TOTAL WEIGHT OF MATERIAL IN THE PRESENCE OF SAID CATALYST; ADMIXING FROM 90% - 10% BY WEIGHT OF SAID LINEAR ALDEHYDE PREPOLYMER WITH 10% - 90% BY WEIGHT OF SAID HIGHLY THERMOSETTABLE PREPOLYMER; AND COPOLYMERIZING SAID ADMIXING AT A TEMPERATURE OF 60*C TO THE REFLUX TEMPERATURE IN THE PRESENCE OF SAID BASE IN AMOUNTS OF 0.05 TO 00.8 MOLES PER MOLE OF PHENOLIC COMPOUND WHICH RESULTS IN A COPOLYMER HAVING A VISCOSITY OF 30 TO 3,000 CPS AT 25*C.

Claim 2

A METHOD FOR FORMING AN ALDEHYDE-PHENOLIC CONDENSATION COPOLYMER, WHICH COMPRISES: FORMING AN ESSENTIALLY LINEAR AND NON-CROSS-LINKABLE ALDEHYDE CONDENSATION PREPOLYMER HAVING A VISCOSITY OF 5 CPS TO 75 CPS AT 25*C BY REACTING AN ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE ACETALDEHYDE, BENZALKEHYDE, PROPIONALDEHYDE, BUTYRALDEHYDE, FURFURALDEHYDE, AND MIXTURES THEREOF WITH A PHENOLIC COMPOUND SELECTED FROM THE GROUP CONSISTING OF PHENOL, RESORCINOL, XYLENOL AND CRESOL IN A MOLE RATIO OF ALKEHYDE TO PHENOLIC COMPOUND OF 0.5 : 1 TO 5 : 1 IN WATER IN AMOUNTS OF 25% TO 75% BASED ON THE TOTAL WEIGHT OF MATERIALS IN THE PRESENCE OF A CATALYST OF THE HYDROXIDE OR CARBONATE COMPOUNDS OF ALKALI METAL OR ALKALINE EARTH METALS, AMMONIUM HYDROXIDE OR AMMONIUM CARBONATE; FORMING A HIGHLY THERMOSETTABLE AND CROSS-LINKABLE ALDEHYDE CONDENSATION ALDEHYDE CONDENSATION PREPOLYMER HAVING A VISCOSITY OF 5 CPS TO 75 CPS AT 25*C, BY REACTING SAID ALDEHYDE WITH SAID PHENOLIC COMPOUND IN A MOLE RATIO OF ALDEHYDE TO PHENOLIC COMPOUND OF 2.0 : 1 TO 3.0 : 1 IN WATER IN AMOUNTS OF 25% TO 75% BASED ON THE TOTAL WEIGHT OF MATERIAL IN THE PRESENCE OF SAID CATALYST; ADMIXING FROM 90% - 10% BY WEIGHT OF SAID LINEAR ALDEHYDE PREPOLYMER WITH 10% - 90% BY WEIGHT OF SAID HIGHLY THERMOSETTABLE PREPOLYMER; AND COPOLYMERIZING SAID ADMIXING AT A TEMPERATURE OF 60*C TO THE REFLUX TEMPERATURE IN THE PRESENCE OF SAID BASE IN AMOUNTS OF 0.05 TO 00.8 MOLES PER MOLE OF PHENOLIC COMPOUND WHICH RESULTS IN A COPOLYMER HAVING A VISCOSITY OF 30 TO 3,000 CPS AT 25*C.

Claim 5

A method for forming an aldehyde-phenolic condensation copolymer, which comprises the steps of: forming an essentially linear and non-cross-linkable aldehyde condensation prepolymer having a viscosity of 5 cps to 75 cps at 25*C by reacting an aldehyde selected from the group consisting of formaldehyde, acetaldehyde, benzaldehyde, propionaldehyde, butyraldehyde, furfuraldehyde, and mixtures thereof with a phenolic compound selected from the group consisting of phenol, resorcinol, xylenol and cresol in a mole ratio of aldehyde to phenolic compound of 0.5 : 1 to 1.5 : 1 in water in amounts of 25% to 75% based on the total weight of materials in the presence of a catalyst of the hydroxide or carbonate compounds of alkali metals or alkaline earth metals, ammonium hydroxide or ammonium carbonate; condensing from 90% - 10% by weight of said linear and non-cross-linkable aldehyde condensation prepolymer with 10% - 90% by weight of the components of a highly thermosettable and cross-linkable aldehyde condensation prepolymer of an aldehyde and a phenolic compound in the presence of said catalyst in 25% to 75% water based on the total weight of materials at a temperature less than 70*C until all of said aldehyde has reacted, wherein the mole ratio of said aldehyde and phenolic compound is 2.0 : 1 to 3.0 : 1; and continuing said condensation reaction until a copolymer is obtained having a viscosity of 30 to 3,000 cps at 25*C.

Claim 6

A method for forming an aldehyde-phenolic condensation copolymer, which comprises the steps of: forming an essentially linear and non-cross-linkable aldehyde condensation prepolymer having a viscosity of 5 cps to 75 cps at 25*C by reacting an aldehyde selected from the group consisting of formaldehyde, acetaldehyde, benzaldehyde, propionaldehyde, butyraldehyde, furfuraldehyde, and mixtures thereof with a phenolic compound selected from the group consisting of phenol, resorcinol, xylenol and cresol in a mole ratio of aldehyde to phenolic compound of 0.5 : 1 to 1.5 : 1 in water in amounts of 25% to 75% based on the total weight of materials in the presence of a catalyst of the hydroxide or carbonate compounds of alkali metals or alkaline earth metals, ammonium hydroxide or ammonium carbonate; condensing from 90% - 10% by weight of said linear and non-cross-linkable aldehyde condensation prepolymer with 10% - 90% by weight of the components of a highly thermosettable and cross-linkable aldehyde condensation prepolymer of an aldehyde and a phenolic compound in the presence of said catalyst in 25% to 75% water based on the total weight of materials at a temperature less than 70*C until all of said aldehyde has reacted, wherein the mole ratio of said aldehyde and phenolic compound is 2.0 : 1 to 3.0 : 1; and continuing said condensation reaction until a copolymer is obtained having a viscosity of 30 to 3,000 cps at 25*C.

Claim 7

A method of forming an aldehyde-phenolic condensation copolymer, which comprises tHe steps of: forming a highly thermosettable and cross-linkable aldehyde condensation prepolymer having a viscosity of 5 cps to 75 cps at 25*C by reacting an aldehyde selected from the group consisting of formaldehyde, acetaldehyde, benzaldehyde, propionaldehyde, butyraldehyde, furfuraldehyde and mixtures thereof with a phenolic compound selected from the group consisting of phenol, resorcinol, xylenol and cresol in a mole ratio of aldehyde to phenolic compound of 2.0 : 1 to 3.0 : 1 in water in amounts of 25% to 75% based on the total weight of materials in the presence of a catalyst of the hydroxide or carbonate compounds of alkali metals or alkaline earth metals, ammonium hydroxide or ammonium carbonate; condensing from 10% - 90% by weight of said highly thermosettable prepolymer with 90% - 10% by weight of the components of an essentially linear and non-cross-linkable aldehyde condensation prepolymer of an aldehyde and a phenolic compound in the presence of said catalyst in 25% to 75% water based on the total weight of materials at a temperature less than 70*C until all of said aldehyde has reacted, wherein the mole ratio of said aldehyde and phenolic compound is 0.5 to 1.5 : 1; and continuing said condensation reaction until a copolymer is obtained having a viscosity of 30 to 3,000 cps at 25*C.

Claim 8

A method of forming an aldehyde-phenolic condensation copolymer, which comprises tHe steps of: forming a highly thermosettable and cross-linkable aldehyde condensation prepolymer having a viscosity of 5 cps to 75 cps at 25*C by reacting an aldehyde selected from the group consisting of formaldehyde, acetaldehyde, benzaldehyde, propionaldehyde, butyraldehyde, furfuraldehyde and mixtures thereof with a phenolic compound selected from the group consisting of phenol, resorcinol, xylenol and cresol in a mole ratio of aldehyde to phenolic compound of 2.0 : 1 to 3.0 : 1 in water in amounts of 25% to 75% based on the total weight of materials in the presence of a catalyst of the hydroxide or carbonate compounds of alkali metals or alkaline earth metals, ammonium hydroxide or ammonium carbonate; condensing from 10% - 90% by weight of said highly thermosettable prepolymer with 90% - 10% by weight of the components of an essentially linear and non-cross-linkable aldehyde condensation prepolymer of an aldehyde and a phenolic compound in the presence of said catalyst in 25% to 75% water based on the total weight of materials at a temperature less than 70*C until all of said aldehyde has reacted, wherein the mole ratio of said aldehyde and phenolic compound is 0.5 to 1.5 : 1; and continuing said condensation reaction until a copolymer is obtained having a viscosity of 30 to 3,000 cps at 25*C.