Process for the production of phenol silicoformate compounds and their condensation products

Claim 2

The process for the production of phenol silicoformate compounds by the following steps: (a) mixing silicoformic acid and a phenol compound, (b) adding an alkali catalyst equal to 1 to 10% by weight of silicoformic acid and phenol compound, (c) heating said mixture to just below the boiling point of the phenol compound for 20 to 80 minutes while agitating at ambient pressure, thereby (d) producing a granular phenol silicate compound.

Claim 3

The method of claim 1 wherein the phenol compound is selected from the group consisting of phenol, p-cresol, o-cresol, m-cresol, cresylic acid, xylenols, resorcinol, cashew nut shell liquids, anacordol, p-tert-butyl pheol, anacardic acid, Bisphenol A, creosote oil, 2,6-dimethylphenol, and mixtures thereof.

Claim 4

The method of claim 1 wherein the alkali catalyst is an alkali metal carbonate, selected from the group consisting of sodium carbonate and potassium carbonate.

Claim 5

The method of claim 1 wherein the alkali catalyst is as alkali metal hydroxide, selected from the group consisting of sodium hydroxide and potassium hydroxide.

Claim 6

The method of claim 1, including the further steps, following step (d), of: (a) adding an aldehyde in the ratio of 1 to 3 mols to each mol of the phenol compound, (b) heating said mixture at 50° to 120° C for 20 to 90 minutes while agitating, thereby (c) producing a resinous product.

Claim 7

The method of claim 5 wherein the aldehyde is selected from the group consisting of formaldehyde, acetaldehyde, butylaldehyde, chloral, acrolein, paraformaldehyde, furfural and mixtures thereof.

Claim 8

The method of claim 5 including the further step of adding an acid catalyst until the pH is 3 to 6 following step (a) and before step (b) of Claim 5.

Claim 9

The method of claim 7 wherein the acid catalyst is selected from the group consisting of sulfuric acid, hydrochloric acid, acetic acid, formic acid, oxalic acid, tartaric acid, aromatic sulfonic acid, sodium hydrogen sulfate and mixtures thereof.

Claim 10

The method of claim 1 wherein the phenol compound is phenol.

Claim 11

The method of claim 5 wherein the aldehyde is formaldehyde in an aqueous solution.

Claim 12

The method of claim 7 wherein the acid catalyst is added until the pH is about 7.

Claim 13

The product, phenol silicate compounds, produced by the method of claim 1.

Claim 14

The product, resinous products, produced by the method of claim 5.

Claim 15

The method of claim 1 wherein the silicoformic acid is produced by the following steps: (a) adding about one mol of dry granular alkali metal metasilicate slowly to 1 to 2 mols of concentrated sulfuric acid; (b) agitating said mixture to keep the temperature below 100° C and oxygen evolves from the mixture, thereby (c) producing a white granular mixture of alkali metal sulfate and silicon acid compounds consisting of silicoformic acid and hydrated silica; (d) washing said mixture with water, filtering the mixture to remove the alkali sulfate and then air drying at 25° to 75° C, leaving a fine white granular mixture of silicoformic acid and hydrated silica.

Claim 16

The method of claim 1 wherein the silicoformic acid is mixed with the phenol compound in the ratio of 1:1 to 1:2 mols; the mols of silicoformic acid are calculated on the basis of the silicon dioxide content.