Resole resin binder composition

Claim 2

A binder composition comprising a low viscosity resole resin and a metal salt curing accelerator, said salt being soluble in said resole resin, having a metal ion selected from the group consisting of barium (Ba++), magnesium (Mg++), manganese (Mn++), chromium (Cr+++), zinc (Zn++), aluminum (Al+++), dibasic aluminum Al(OH) + 2 , cobalt (Co++) and mixtures thereof and having an organic acid salt radical selected from the group consisting of formate, acetate, propionate, benzoate, lactate and mixtures thereof said metal salt being present in from about 0.5 to 5 parts based on 100 parts of resole resin solids.

Claim 3

A binder composition of claim 1, said resole resin comprising the reaction product of formaldehyde and a phenol, said phenol selected from the group of phenol, substituted phenols, substituted phenol mixture and mixtures thereof in a mol ratio 1.0 to 3.0, reacted in the presence of a basic catalyst.

Claim 4

A binder composition of claim 2, wherein said substituted phenol mixture has been prepared by alkylation of phenol with a mixture of carbocyclic compounds under acid conditions at a temperature in the range of 25° to 200° C., whereby 10 to 80 parts by weight of the mixture of carbocyclic compounds reacts with 100 parts by weight of phenol, said mixture of carbocyclic compounds comprising: A. from 10 to 40 parts by weight of compounds each molecule of which has: 1. the indene nucleus, 2. from 9 to 13 carbon atoms, 3. as nuclear substituents from 0 to 4 methyl groups; B. from 5 to 70 parts by weight of compounds each molecule of which has: 1. the dicyclopentadiene nucleus, 2. from 10 to 13 carbon atoms, 3. as nuclear substituents from 0 to 3 methyl groups, C. from 15 to 65 parts by weight of compounds each molecule of which has: 1. a phenyl group substituted by a vinylidene group, 2. from 8 to 13 carbon atoms, 3. as substituents from 0 to 3 groups selected from the class consisting of methyl and ethyl; and D. from 0 5 parts by weight of divinyl benzene.

Claim 5

A binder composition of claim 2, wherein said phenol is phenol.

Claim 6

A binder composition of claim 2, wherein said phenol is a substituted phenol having at least one radical selected from the group consisting of alkyl, aryl, cycloalkyl, alkenyl, cycloalkenyl, alkaryl, aralkyl, carbocyclic, halogen and mixtures thereof.

Claim 7

A binder composition of claim 1, wherein said resole resin comprises a solids content of from about 20 to 85 percent, a water content of from about 2 to 35 percent by weight based on said resole resin, a viscosity of from about 5 to 5000 cps, said metal salt being present in from about 0.5 to 5 parts based on 100 parts of resole resin solids.

Claim 8

A binder composition of claim 2, wherein said basic catalyst is selected from the group consisting of ammonium hydroxide, hexamethylene tetramine and triethylamine.

Claim 9

A binder composition of claim 2, wherein said metal salt is zinc acetate.

Claim 10

A binder composition of claim 2, wherein said metal salt is cobalt acetate.

Claim 11

A binder composition of claim 1, wherein said metal salt is aluminum dihydroxy acetate.

Claim 12

A binder composition of claim 1, wherein said resole resin and accelerator are contained in a solution comprising about 20 to 98 percent by weight resole resin solids, about 2 to 80 percent by weight water and about 0.5 to 5 parts by weight accelerator per 100 parts of resole resin solids.

Claim 13

A binder composition of claim 1, wherein said resole resin and accelerator are contained in a solution comprising: A. about 20 to 85 percent by weight of resole resin solids, B. about 0.5 to 15 percent by weight of water, C. about 0.5 to 5 parts by weight accelerator per 100 parts of resole resin solids, and D. the balance up to 100 percent by weight of said solution being an organic liquid which 1. is substantially inert to said resin and water, 2. evaporates below about 150° C., at atmospheric pressures, 3. is a mutual solvent for said resin, said water and said accelerator, being present in an amount sufficient to maintain a solution.