US4182696A
Expired / Lapsed
US
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Process for producing particulate filler-containing resole molding compositions from aqueous dispersion
Assignee: Union Carbide Corp
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Filing: 1977-12-14
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Granted: 1980-01-08
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Expires: 1997-12-14
Abstract
Abstract Particulate, solid, heat-reactive, filler-containing resole molding compositions are directly produced by reacting a phenol, formaldehyde, and an amine in an aqueous medium containing a water-insoluble filler material having reactive sites on the surface thereof which chemically bond with a phenolic resin and protective colloid to produce an aqueous suspension of a particulate filler-containing resole, and recovering the filler-containing resole from said suspension.
Inventors
- 👤 John Wynstra
- 👤 Sidney J. Schultz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 02:22
CPC Classifications
C; C08; C08L; C08L61/00; C08L61/34; C08G; C08G14/00; C08G14/02; C08G14/04; C08G14/06; C08G8/00
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
145 words
A process for producing particulate solid, heat-reactive, substantially water-insoluble resole molding compositions which process comprises the steps of: (a) reacting formaldehyde, a phenol, and an effective amount of an amine compound selected from the group consisting of hexamethylenetetramine, a compound containing amino hydrogen, and mixtures thereof, in an aqueous medium containing a substantially water-insoluble filler material having reactive sites on the surface thereof which chemically bond with a phenolic resin in an amount sufficient to provide a molding composition with at least about 5 weight percent of said filler and an effective amount of a protective colloid that exhibits protective colloid properties, for a period of time and at a temperature sufficient to produce an aqueous dispersion of a particulate solid, heat-reactive, substantially water-insoluble, thermosetting resole molding composition which has been advanced to the desired stage; and (b) recovering said resole from said aqueous dispersion.
Claim 2
Dependent Claim
145 words
A process for producing particulate solid, heat-reactive, substantially water-insoluble resole molding compositions which process comprises the steps of: (a) reacting formaldehyde, a phenol, and an effective amount of an amine compound selected from the group consisting of hexamethylenetetramine, a compound containing amino hydrogen, and mixtures thereof, in an aqueous medium containing a substantially water-insoluble filler material having reactive sites on the surface thereof which chemically bond with a phenolic resin in an amount sufficient to provide a molding composition with at least about 5 weight percent of said filler and an effective amount of a protective colloid that exhibits protective colloid properties, for a period of time and at a temperature sufficient to produce an aqueous dispersion of a particulate solid, heat-reactive, substantially water-insoluble, thermosetting resole molding composition which has been advanced to the desired stage; and (b) recovering said resole from said aqueous dispersion.
Claim 3
Dependent Claim
13 words
The process of claim 1 wherein the amine compound is hexamethylenetetramine or ammonia.
Claim 4
Dependent Claim
16 words
The process of claim 1 wherein the phenol is monohydroxybenzene, 2,2-bis(4-hydroxyphenyl)propane, m-cresol, resorcinol, or mixtures thereof.
Claim 5
Dependent Claim
15 words
The process of claim 1 wherein the phenol is monohydroxybenzene, 2,2-bis(4-hydroxyphenyl)propane, or a mixture thereof.
Claim 6
Dependent Claim
15 words
The process of claim 2 wherein the phenol is monohydroxybenzene, 2,2-bis(4-hydroxyphenyl)propane, or a mixture thereof.
Claim 7
Dependent Claim
32 words
The process of claim 1 wherein the protective colloid is selected from the group consisting of gum arabic, gum ghatti, hydroxyalkyl guar gum, partially hydrolyzed polyvinyl alcohol, carboxymethyl cellulose and hydroxyethyl cellulose.
Claim 8
Dependent Claim
32 words
The process of claim 2 wherein the protective colloid is selected from the group consisting of gum arabic, gum ghatti, hydroxyalkyl guar gum, partially hydrolyzed polyvinyl alcohol, carboxymethyl cellulose and hydroxyethyl cellulose.
Claim 9
Dependent Claim
32 words
The process of claim 4 wherein the protective colloid is selected from the group consisting of gum arabic, gum ghatti, hydroxyalkyl guar gum, partially hydrolyzed polyvinyl alcohol, carboxymethyl cellulose, and hydroxyethyl cellulose.
Claim 10
Dependent Claim
32 words
The process of claim 5 wherein the protective colloid is selected from the group consisting of gum arabic, gum ghatti, hydroxyalkyl guar gum, partially hydrolyzed polyvinyl alcohol, carboxymethyl cellulose, and hydroxyethyl cellulose.
Claim 11
Dependent Claim
38 words
The process of claim 1 wherein step (a) is carried out at a temperature of at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 12
Dependent Claim
39 words
The process of claim 2 wherein step (a) is carried out at a temperature of from at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 13
Dependent Claim
38 words
The process of claim 4 wherein step (a) is carried out at a temperature of at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 14
Dependent Claim
37 words
The process of claim 5 wherein step (a) is carried out at a temperature at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 15
Dependent Claim
38 words
The process of claim 6 wherein step (a) is carried out at a temperature of at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 16
Dependent Claim
38 words
The process of claim 7 wherein step (a) is carried out at a temperature of at least 55° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 17
Dependent Claim
44 words
The process of claim 1 wherein step (a) is carried out at a temperature within the range of from about 70° to about 100° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 18
Dependent Claim
45 words
The process of claim 9 wherein step (a) is carried out at a temperature within the range of from about 70° C. to about 100° C. to a predetermined end point, whereupon the aqueous dispersion is rapidly cooled to a temperature below about 40° C.
Claim 19
Dependent Claim
32 words
The process of claim 1 wherein the amount of said filler in said aqueous medium is sufficient to provide a resole molding composition with up to about 75 weight percent of filler.
Claim 20
Dependent Claim
28 words
The process of claim 1 wherein said filler material is selected from the group consisting of cellulose fibers, asbestos fiber, wood flour, talc and mixtures of the same.
Claim 21
Dependent Claim
32 words
The process of claim 9 wherein the amount of said filler in said aqueous medium is sufficient to provide a resole molding composition with up to about 75 weight percent of filler.
Claim 22
Dependent Claim
28 words
The process of claim 20 wherein said filler material is selected from the group consisting of cellulose fibers, asbestos fibers, wood flour, talc and mixtures of the same.
Claim 23
Dependent Claim
21 words
The process of claim 1 wherein at least about 3 parts of amine compound per 100 parts of phenol is used.
Claim 24
Dependent Claim
21 words
The process of claim 4 wherein at least about 3 parts of amine compound per 100 parts of phenol is used.
Claim 25
Dependent Claim
21 words
The process of claim 5 wherein at least about 3 parts of amine compound per 100 parts of phenol is used.
Claim 26
Dependent Claim
20 words
A sinter-resistant, particulate solid, heat-reactive, substantially water-insoluble resole, which consists essentially of the product of the process of claim 1.
Claim 27
Dependent Claim
19 words
The resole of claim 25, wherein said resole consists essentially of the product of the process of claim 2.
Claim 28
Dependent Claim
19 words
The resole of claim 25, wherein said resole consists essentially of the product of the process of claim 3.
Claim 29
Dependent Claim
19 words
The resole of claim 25, wherein said resole consists essentially of the product of the process of claim 4.
Claim 30
Dependent Claim
19 words
The resole of claim 25 wherein said resole consists essentially of the product of the process of claim 5.
Claim 31
Dependent Claim
19 words
The resole of claim 25, wherein said resole consists essentially of the product of the process of claim 6.
Claim 32
Dependent Claim
19 words
The resole of claim 25, wherein said resole consists essentially of the product of the process of claim 10.
Claim 33
Dependent Claim
29 words
The process of claim 1 wherein the phenol is a mixture of trifunctional or tetrafunctional phenol and less than about 50 mole % of a difunctional or monofunctional phenol.
Claim 34
Dependent Claim
17 words
The process of claim 32, wherein the trifunctional phenol is monohydroxybenzene and the difunctional phenol is p-t-butylphenol.
Claim 35
Dependent Claim
18 words
The process of claim 32, wherein the trifunctional phenol is monohydroxybenzene and the difunctional phenol is para-or ortho-cresol.
Claim 36
Dependent Claim
12 words
The process of claim 32, wherein the tetrafunctional phenol is 2,2-bis(4-hydroxyphenyl) propane.
Claim 37
Dependent Claim
19 words
The process of claim 1 wherein the aqueous dispersion contains about 30 to about 50% by weight of water.
References Cited (Backward Citations)
US1343575A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-01-07 | 1983-07-09 | 1984-01-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-01-07 | 1987-07-09 | 1988-01-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-01-07 | 1991-07-09 | 1992-01-08 | $7700.00 | Window Closed / Lapsed |