Cold set phenol-formaldehyde resin

Claim 2

A resin prepolymer obtained by a process comprising the steps of reacting a phenol and an aldehyde in a mole ratio of from 1 to 1-2.3 at a temperature of from 100° C. to 130° C. in the presence of catalytic amounts of organic derivatives of titanium, ziconium or alkyl and alkoxide derivatives of aluminum.

Claim 3

The resin of claim 1 wherein the catalyst is present in amount of about 100 to 5000 ppm of metal ion based on the phenol content.

Claim 4

The resin of claim 2 wherein the catalyst is a tetra-substituted alkyl titanate, each alkyl group having from 1 to 10 carbon atoms.

Claim 5

The resin of claim 3 wherein the alkyl titanate is tetrakis-ethylhexyl titanate.

Claim 6

The resin of claim 3 wherein the alkyl titanate is tetra-isopropyl titanate.

Claim 7

The resin of claim 3 wherein the alkyl titanate is tetrabutyl titanate.

Claim 8

The resin of claim 2 wherein the catalyst is a trialkyl-aluminum compound, each alkyl having from 1 to 10 carbon atoms, or a trialkoxide aluminum compound, each alkoxide group having from 1 to 10 carbon atoms.

Claim 9

The resin of claim 7 wherein the catalyst is aluminum isopropoxide.

Claim 10

The resin of claim 2 wherein the catalyst is a tetraalkyl substituted organo zirconium compounds, each alkyl group having from 1 to 10 carbon atoms.

Claim 11

The resin of claim 9 wherein the catalyst is zirconium isopropoxide.

Claim 12

The resin of claim 2 wherein the catalyst is a titanium salt of an alkyl or aryl carboxylic acid of from 1 to 20 carbon atoms.

Claim 13

The resin of claim 1 wherein the phenol is an unsubstituted phenol and the aldehyde is formaldehyde.

Claim 14

The resin of claim 1 wherein the phenol is an unsubstituted phenol and the aldehyde is salicylaldehyde.

Claim 15

The resin of claim 1 modified by conducting the reaction of phenol and formaldehyde in the presence of a modifier selected from the group consisting of natural polymers, polyols, amines, amides, or monohydric alcohols.

Claim 16

The resin of claim 14 wherein the modifier is present in an amount of from 1 to 20%.

Claim 17

The resin of claim 14 wherein the modifier is urea.

Claim 18

The resin of claim 14 wherein the natural polymer modifier is an alkaline treated soy protein.

Claim 19

The resin of claim 14 wherein the amine modifier is aniline.

Claim 20

The resin of claim 14 wherein the monohydric alcohol modifier is furfuryl alcohol.

Claim 21

An organic solvent soluble resin prepolymer characterized by a cloud point of 45 to 50%, and a neat viscosity of 200-1000 cps at 75° C. in which a prepolymer wherein the benzylic ether and methylene bridges are present in a ratio of about 1:5 obtained by the process comprising the steps of reacting phenol and formaldehyde in a mole ratio of about 1 to 1-2.3 in the presence of catalytic amounts of organic derivatives of titanium or zirconium or alkyl and alkoxide derivatives of aluminum at a temperature of up to about 120° C., for a period of time sufficient to provide a cloud point of 40 to 60% thereby forming water and methanol, separating a major portion of the water and methanol by distillation at 115°-120° C. for a period of time sufficient to provide a cloud point of 47-50% and viscosity of 100-130 centipoise at 75° C. and separating residual water and methanol at reduced pressure at about 80° C. or less thereby producing a prepolymer having a cloud point of about 45-50% and a neat viscosity of 200-1000 centipoise at 75° C.

Claim 22

An organic solvent soluble resin prepolymer characterized by a cloud point of 45 to 50%, and a neat viscosity of 200-1000 cps at 75° C. in which a prepolymer wherein the benzylic ether and methylene bridges are present in a ratio of about 1:5 obtained by the process comprising the steps of reacting phenol and formaldehyde in a mole ratio of about 1 to 1-2.3 in the presence of catalytic amounts of organic derivatives of titanium or zirconium or alkyl and alkoxide derivatives of aluminum at a temperature of up to about 120° C., for a period of time sufficient to provide a cloud point of 40 to 60% thereby forming water and methanol, separating a major portion of the water and methanol by distillation at 115°-120° C. for a period of time sufficient to provide a cloud point of 47-50% and viscosity of 100-130 centipoise at 75° C. and separating residual water and methanol at reduced pressure at about 80° C. or less thereby producing a prepolymer having a cloud point of about 45-50% and a neat viscosity of 200-1000 centipoise at 75° C.

Claim 23

The resin of claim 1 modified by reacting the resin with an alkanol of 1-5 carbon atoms or an acylating agent.

Claim 24

The resin of claim 14 wherein the amine modifier further includes substituted derivatives of aniline.

Claim 25

The resin of claim 14 wherein the polyol modifier includes polyhydric compounds.