US4626569A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing a molded product and the molded product produced thereby
Assignee: Plastics Engineering Co
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Filing: 1985-10-01
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Granted: 1986-12-02
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Expires: 2005-10-01
Abstract
Abstract The process and product derived therefrom use the moldable composition derived from intimate co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties. This composition is particularly useful in admixture with a carbonaceous filler, preferably graphite in a proportion as high as 76% by weight based on the total composition. Generally in such admixtures the graphite may comprise 30-76%, advantageously 35-65% and preferably 40-60% of the molding composition. The vitreous carbon is improved in electrical properties and in the capability of being suitably molded, carbonized and graphitized into large shapes, particularly thin plates which are much more stress-free and crack or pore-free than otherwise produced.
Inventors
- 👤 Phillip A. Waitkus
- 👤 Louis L. Korb
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 12:49
CPC Classifications
C; C08; C08G; C08G8/00; C08G8/38; C04; C04B; C04B35/00; C04B35/515; C04B35/52; C04B35/524; C04B35/528; C04B35/532; C08G8/04; C08G8/08
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
244 words
The process for producing from a moldable composition a moldable product substantially free of pits and holes and much less subject to cracking and failure during formation and use comprising the step of molding the said composition at a temperature of 100°-180° C. and at a pressure between 500 pounds per square inch and 20 tons per square inch, said moldable composition being prepared by the addition of a phenolic-aldehyde Novolac resin in which at least 50 molar percent of said aldehyde is furfuraldehyde to an aqueous solution or suspension of a phenolic-aldehyde resol resin prior to the removal of 90 percent of the removable water from said resol resin solution or suspension, the proportions of said resins comprising 20-80 parts by weight of said Novolac resin and 20-80 parts by weight of said resol resin with the combined weight of said two resins comprising 100 parts by weight, thereafter effecting co-reaction of said resins together with an amine selected from the group consisting of hexamethylenetetramine and amines in which there is at least one hydrogen connected to a nitrogen atom, the amount of said amine being equivalent to 1-15 percent by weight of hexamethylenetetramine based on the total weight of phenolic component, and removal of water from the resulting reaction mass while maintaining the resin in a moldable condition, the Novolac resin having been prepared with the removal of at least 25 percent by weight of the water removable during the Novolac preparation.
Claim 2
Dependent Claim
244 words
The process for producing from a moldable composition a moldable product substantially free of pits and holes and much less subject to cracking and failure during formation and use comprising the step of molding the said composition at a temperature of 100°-180° C. and at a pressure between 500 pounds per square inch and 20 tons per square inch, said moldable composition being prepared by the addition of a phenolic-aldehyde Novolac resin in which at least 50 molar percent of said aldehyde is furfuraldehyde to an aqueous solution or suspension of a phenolic-aldehyde resol resin prior to the removal of 90 percent of the removable water from said resol resin solution or suspension, the proportions of said resins comprising 20-80 parts by weight of said Novolac resin and 20-80 parts by weight of said resol resin with the combined weight of said two resins comprising 100 parts by weight, thereafter effecting co-reaction of said resins together with an amine selected from the group consisting of hexamethylenetetramine and amines in which there is at least one hydrogen connected to a nitrogen atom, the amount of said amine being equivalent to 1-15 percent by weight of hexamethylenetetramine based on the total weight of phenolic component, and removal of water from the resulting reaction mass while maintaining the resin in a moldable condition, the Novolac resin having been prepared with the removal of at least 25 percent by weight of the water removable during the Novolac preparation.
Claim 3
Dependent Claim
11 words
The process of claim 1 in which said amine is hexamethylenetetramine.
Claim 4
Dependent Claim
29 words
The process of claim 1 in which the amount of said amine is equivalent to 1-10 percent of weight of hexamethylenetetramine based on the total weight of phenolic component.
Claim 5
Dependent Claim
11 words
The process of claim 3 in which said amine is hexamethylenetetramine.
Claim 6
Dependent Claim
15 words
The process of claim 2 in which the phenolic component in the Novolac is phenol.
Claim 7
Dependent Claim
23 words
The process of claim 5 in which the phenolic component in the resol is phenol and the aldehyde in the resol is formaldehyde.
Claim 8
Dependent Claim
23 words
The process of claim 6 in which the furfuraldehyde content in said Novolac is at least 75 molar percent of the aldehyde component.
Claim 9
Dependent Claim
21 words
The process of claim 6 in which the furfuraldehyde in said Novolac is approximately 100 molar percent of the aldehyde component.
Claim 10
Dependent Claim
36 words
The process of any one of claims 1, 2, 3, 4, 5, 6, 7 or 8 in which said Novolac addition is performed after sufficient refluxing is effected for substantially complete reaction of the resol aldehyde.
Claim 11
Dependent Claim
25 words
The process of claim 8 in which said Novolac is added prior to initiation of said water removal from said resol resin solution or suspension.
Claim 12
Dependent Claim
27 words
The process of claim 8 in which said Novolac is added prior to removal of 25 percent of the water from said resol resin solution or suspension.
Claim 13
Dependent Claim
19 words
The process of claim 8 in which said Novolac is substantially completely free of water prior to said addition.
Claim 14
Dependent Claim
27 words
The process of claim 8 in which at least 35 percent by weight of the water present in said Novolac preparation is removed prior to said addition.
Claim 15
Dependent Claim
27 words
The process of claim 8 in which at least 50 percent by weight of the water present in said Novolac preparation is removed prior to said addition.
Claim 16
Dependent Claim
26 words
The process of claim 8 in which at least 75 percent by weight of water present in said Novolac preparation is removed prior to said addition.
Claim 17
Dependent Claim
21 words
The process of claim 4 in which said composition contains 40-316 parts of finely divided carbonaceous filler per 100 parts resin.
Claim 18
Dependent Claim
18 words
The process of claim 4 which contains 40-150 parts of finely divided graphite per 100 parts of resin.
Claim 19
Dependent Claim
18 words
The process of claim 8 which contains 40-150 parts of finely divided graphite per 100 parts of resin.
Claim 20
Dependent Claim
18 words
The process of claim 12 which contains 40-150 parts of finely divided graphite per 100 parts of resin.
Claim 21
Dependent Claim
18 words
The process of claim 14 which contains 40-150 parts of finely divided graphite per 100 parts of resin.
Claim 22
Dependent Claim
18 words
The process of claim 15 which contains 40-150 parts of finely divided graphite per 100 parts of resin.
Claim 23
Dependent Claim
45 words
The process of any one of claims 1, 2, 3, 4, 5, 8, 12, 17 or 20 in which the ratio of parts by weight of said resol resin to parts by weight of said Novolac resin is in the range of 70/30 to 50/50.
Claim 24
Dependent Claim
33 words
The process of any one of claims 1, 2, 3, 4, 6, 8, 12 or 17 in which the said amine is added prior to or simultaneously with the addition of said Novolac.
Claim 25
Dependent Claim
28 words
The process of claim 4 in which said hexamethylenetetramine is used in a proportion of 1 to 5 percent by weight based on the weight of resin product.
Claim 26
Dependent Claim
45 words
The process of any one of claims 1, 2, 3, 4, 12, 16 or 22 in which said Novolac resin is added to said resol aqueous solution or suspension prior to the removal of 75 percent of the water from said resol solution or suspension.
Claim 27
Dependent Claim
19 words
The process of claim 1, in which said molded product is a plate having a thickness of 0.04-0.05 inch.
Claim 28
Dependent Claim
22 words
The process of claim 26, in which said molding is effected at a pressure of 800 to 1500 pounds per square inch.
Claim 29
Dependent Claim
11 words
A molded product produced according to the process of claim 1.
Claim 30
Dependent Claim
54 words
A molded product produced according to the process of claim 1 wherein said resol resin solution or suspension is the reaction mixture in which said resol resin is prepared by the reaction of phenol with an aldehyde, and said addition is performed after sufficient refluxing is effected for substantially complete reaction of the aldehyde.
Claim 31
Dependent Claim
21 words
A molded product produced according to claim 29 wherein said Novolac is substantially completely free of water prior to said addition.
Claim 32
Dependent Claim
22 words
A molded product produced according to claim 29 wherein the Novolac aldehyde is substantially all furfuraldehyde and the phenolic component is phenol.
Claim 33
Dependent Claim
28 words
The process of claim 8 in which said hexamethylenetetramine is used in a proportion of 1 to 5 percent by weight based on the weight of resin product.
References Cited (Backward Citations)
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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) | 1989-12-01 | 1990-06-02 | 1990-12-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-12-01 | 1994-06-02 | 1994-12-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-12-01 | 1998-06-02 | 1998-12-02 | $7700.00 | Window Closed / Lapsed |