US3931386A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing drawn or undrawn flame-resistant, anti-fusing cured phenolic continuous filaments
Assignee: Gun Ei Chemical Industry Co Ltd
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Filing: 1972-10-30
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Granted: 1976-01-06
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Expires: 1992-10-30
Abstract
Abstract A process for producing a drawn or undrawn flame-resistant and anti-fusing cured phenolic continuous filament which comprises melt-spining an uncured novolak resin which may contain a fiber-forming thermoplastic synthetic resin and then curing the melt-spun filament with a curing agent in the presence of a catalyst; characterized by pre-curing the melt-spun filament with an aldehyde as a curing agent in the presence of an acid catalyst, and then curing the pre-cured filament with an aldehyde in the presence of a basic catalyst.
Inventors
- 👤 Isao Kimura
- 👤 Hiroaki Koyama
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 08:33
CPC Classifications
D; D01; D01F; D01F6/00; D01F6/58; D01F6/76; C; C08; C08G; C08G8/00; C08G8/04; C08L; C08L61/00; C08L61/04; C08L61/06
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
167 words
A process for producing a drawn or undrawn flame-resistant and anti-fusing cured phenolic continuous filament which comprises melt-spinning an uncured novolak resin which may contain up to 40% by weight based on the total weight of a fiber-foaming thermoplastic synthetic resin selected from the group consisting of nylon resin and polyurethane resin and then curing the melt-spun filament with a curing agent in the presence of a catalyst; said novolak resin produced by the reaction of a phenol selected from the group consisting of phenol, o-cresol, m-cresol, p-cresol, 2,3-xylenol, 2,5-xylenol, 2,4-xylenol, 2,6-xylenol, 3,4-xylenol 3,5-xylenol o-ethylphenol, m-ethylphenol, p-ethylphenol, p-phenylphenol, p-tertiary butyl phenol, p-tertiary amylphenol, bisphenol A, resorcinol and mixtures thereof and an aldehyde selected from the group consisting of formaldehyde, paraformaldehyde, benzaldehyde hexamethylenetetramine, furfural and mixtures thereof; characterized by pre-curing the melt-spun filament with an aldehyde as a curing agent in the presence of an acid catalyst in a single pre-curing bath, and then curing the pre-cured filament with an aldehyde in the presence of a basic catalyst.
Claim 2
Dependent Claim
167 words
A process for producing a drawn or undrawn flame-resistant and anti-fusing cured phenolic continuous filament which comprises melt-spinning an uncured novolak resin which may contain up to 40% by weight based on the total weight of a fiber-foaming thermoplastic synthetic resin selected from the group consisting of nylon resin and polyurethane resin and then curing the melt-spun filament with a curing agent in the presence of a catalyst; said novolak resin produced by the reaction of a phenol selected from the group consisting of phenol, o-cresol, m-cresol, p-cresol, 2,3-xylenol, 2,5-xylenol, 2,4-xylenol, 2,6-xylenol, 3,4-xylenol 3,5-xylenol o-ethylphenol, m-ethylphenol, p-ethylphenol, p-phenylphenol, p-tertiary butyl phenol, p-tertiary amylphenol, bisphenol A, resorcinol and mixtures thereof and an aldehyde selected from the group consisting of formaldehyde, paraformaldehyde, benzaldehyde hexamethylenetetramine, furfural and mixtures thereof; characterized by pre-curing the melt-spun filament with an aldehyde as a curing agent in the presence of an acid catalyst in a single pre-curing bath, and then curing the pre-cured filament with an aldehyde in the presence of a basic catalyst.
Claim 3
Dependent Claim
40 words
The process according to claim 1, wherein the pre-curing is carried out at a temperature ranging from about 15°to about 105°C with the concentration each of the aldehyde and the acid catalyst being kept at 6.0 to 40% by weight.
Claim 4
Dependent Claim
48 words
The process according to claim 1, wherein the curing is carried out at a temperature ranging from about 40° to about 105°C with the concentration of the aldehyde being kept at 1 to 60% by weight and that of the basic catalyst, at 0.2 to 20% by weight.
Claim 5
Dependent Claim
44 words
The process according to claim 1, wherein the acid catalyst is selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, acetic acid, oxalic acid, formic acid, orthophosphoric acid, butyric acid, lactic acid, benzenesulfonic acid, p-toluensulfonic acid, boric acid and mixtures thereof.
Claim 6
Dependent Claim
42 words
The process according to claim 1, wherein the basic catalyst is selected from the group consisting of ammonia, ammonium hydroxide, amines, hydroxides of alkali metals, hydroxides of alkaline earth metals, carbonates of alkali metals, carbonates of alkaline earth metals and mixtures thereof.
Claim 7
Dependent Claim
25 words
The process according to claim 1, wherein the curing agent is selected from the group consisting of formaldehyde, paraformaldehyde, benzaldehyde, hexamethylenetetramine, furfural and mixtures thereof.
Claim 8
Dependent Claim
32 words
The process according to claim 1, wherein the melt-spun filament is drawn before and/or after curing and the draw ratio is up to 2.5 based on the length of the undrawn filament.
Claim 9
Dependent Claim
35 words
The process of claim 1 wherein the precuring is carried out for about 0.5 - 5 hours and the concentration each of the aldehyde and the acid catalyst is kept at 15 -25% by weight.
Claim 10
Dependent Claim
84 words
The process of claim 1 wherein the curing of the precured filament is carried out by first placing the precured filament in a bath containing the aldehyde and basic catalyst at a temperature of about 15° to 40°C. after which the temperature is gradually raised from about 40° to about 105°C. at a rate of less than 50°C./hr. with the concentration of the aldehyde being kept at 1 - 60% by weight and that of the basic catalyst of 0.2 - 20% by weight.
Claim 11
Dependent Claim
20 words
The process of claim 3 wherein the curing of the precured filament is carried out for 15 - 90 minutes.
Claim 12
Dependent Claim
72 words
The process of claim 1 wherein the curing treatment of the precured filament is carried out in an aqueous solution of formaldehyde and ammonia at 60°- 80°C. for 30 - 60 minutes, the concentration of the ammonia in the aqueous solution being within the range of 0.2 - 20% by weight and the concentration of the formaldehyde in the aqueous solution being in the range of from 1 - 60% by weight.
Claim 13
Dependent Claim
32 words
The process of claim 11 wherein the concentration of the ammonia is from 1 - 10% by weight and the concentration of the formaldehyde is from about 12 - 45% by weight.
Claim 14
Dependent Claim
34 words
The process of claim 1 wherein said nylon resin is selected from the group consisting of polycaproamide, poly-ω-aminoheptanoic acid, poly-ω-aminononanoic acid, polyundecaneamide, polydodecaneamide, polyhexamethylene adipamide, polyhexamethylene sebacamide, polyhexamethylene undecaneamide, polyhexamethylene dodecaneamide and copolyamides thereof.
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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) | 1979-01-05 | 1979-07-07 | 1980-01-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1983-01-05 | 1983-07-07 | 1984-01-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1987-01-05 | 1987-07-07 | 1988-01-06 | $7700.00 | Window Closed / Lapsed |