US4839445A
Expired / Lapsed
US
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Spherical particles of thermosetting phenolic resin and process for producing the same
Assignee: Unitika Ltd
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Filing: 1988-01-06
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Granted: 1989-06-13
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Expires: 2008-01-06
Abstract
Abstract The present invention relates to a process for producing spherical thermosetting phenolic resin particles having a size of no larger than about 1,000 microns, and the spherical thermosetting phenolic resin particles produced by this process. In accordance with the process of the present invention, a novolak resin, and a nitrogenous basic compound, and, optionally, an aldehyde, are reacted while they are suspended in an aqueous medium in the presence of a suspension stabilizer. The thermosetting phenolic resin produced by the process of the present invention not only displays superior thermal curing characteristics during molding; the cured product fabricated by molding this resin also exhibits good physical properties such as improved mechanical strength and heat resistance. Therefore, the spherical thermosetting phenolic resin particles produced by the process of the present invention can be extensively used as molding materials, binders, adhesives, and in many other applications.
Inventors
- 👤 Yoshiaki Echigo
- 👤 Kenichi Sugawara
- 👤 Mutsunori Yamao
- 👤 Yoshiyuki Suematu
- 👤 Keiichi Asami
- 👤 Tuneyuki Ohsawa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 17:26
CPC Classifications
C; C08; C08G; C08G8/00; C08G8/04; C08G8/08; C08G8/10; C08J; C08J3/00; C08J3/12; C08J3/16; C08J2361/00; C08J2361/04; C08J2361/06
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
67 words
A process for producing spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which comprises reacting a novolak resin with a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 2
Dependent Claim
67 words
A process for producing spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which comprises reacting a novolak resin with a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 3
Dependent Claim
13 words
A process according to claim 1, wherein said nitrogenous basic compound is hexamethylenetetramine.
Claim 4
Dependent Claim
35 words
A process according to claim 1, wherein said nitrogenous basic compound is used in an amount of from about 0.1 to about 50 parts by weight per 100 parts by weight of the novolak resin.
Claim 5
Dependent Claim
33 words
A process according to claim 2, wherein said hexamethylenetetramine is used in an amount of from about 0.1 to about 50 parts by weight per 100 parts by weight of the novolak resin.
Claim 6
Dependent Claim
33 words
A process according to claim 1, wherein said nitrogenous basic compound is used in an amount of from 0.5 to 20 parts by weight per 100 parts by weight of the novolak resin.
Claim 7
Dependent Claim
31 words
A process according to claim 2, wherein said hexamethylenetetramine is used in an amount of from 0.5 to 20 parts by weight per 100 parts by weight of the novolak resin.
Claim 8
Dependent Claim
69 words
A process for producing spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which comprises reacting a novolak resin, an aldehyde, and a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 9
Dependent Claim
69 words
A process for producing spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which comprises reacting a novolak resin, an aldehyde, and a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 10
Dependent Claim
13 words
A process according to claim 7, wherein said nitrogenous basic compound is hexamethylenetetramine.
Claim 11
Dependent Claim
51 words
A process according to claim 7, wherein said nitrogenous basic compound is used in an amount of from about 0.1 to about 50 parts by weight, and said aldehyde is used in an amount of about 50 parts by weight or less, per 100 parts by weight of the novolak resin.
Claim 12
Dependent Claim
49 words
A process according to claim 8, wherein said hexamethylenetetramine is used in an amount of from about 0.1 to about 50 parts by weight, and said aldehyde is used in an amount of about 50 parts by weight or less, per 100 parts by weight of the novolak resin.
Claim 13
Dependent Claim
65 words
Spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which are produced by reacting a novolak resin with a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 14
Dependent Claim
65 words
Spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which are produced by reacting a novolak resin with a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 15
Dependent Claim
16 words
Spherical thermosetting phenolic resin particles according to claim 11, wherein said nitrogenous basic compound is hexamethylenetetramine.
Claim 16
Dependent Claim
38 words
Spherical thermosetting phenolic resin particles according to claim 11, wherein said nitrogenous basic compound is used in an amount of from about 0.1 to about 50 parts by weight per 100 parts by weight of the novolak resin.
Claim 17
Dependent Claim
36 words
Spherical thermosetting phenolic resin particles according to claim 12, wherein said hexamethylenetetramine is used in an amount of from about 0.1 to about 50 parts by weight per 100 parts by weight of the novolak resin.
Claim 18
Dependent Claim
36 words
Spherical thermosetting phenolic resin particles according to claim 11, wherein said nitrogenous basic compound is used in an amount of from 0.5 to 20 parts by weight per 100 parts by weight of the novolak resin.
Claim 19
Dependent Claim
34 words
Spherical thermosetting phenolic resin particles according to claim 12, wherein said hexamethylenetetramine is used in an amount of from 0.5 to 20 parts by weight per 100 parts by weight of the novolak resin.
Claim 20
Dependent Claim
67 words
Spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which are produced by reacting a novolak resin, an aldehyde, and a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 21
Dependent Claim
67 words
Spherical thermosetting phenolic resin particles with a size of no larger than about 1,000 microns which are produced by reacting a novolak resin, an aldehyde, and a nitrogenous basic compound at a temperature sufficient to produce said phenolic resin particles for a period of time sufficient to produce said phenolic resin particles while they are suspended in an aqueous medium in the presence of a suspension stabilizer.
Claim 22
Dependent Claim
16 words
Spherical thermosetting phenolic resin particles according to claim 17, wherein said nitrogenous basic compound is hexamethylenetetramine.
Claim 23
Dependent Claim
54 words
Spherical thermosetting phenolic resin particles according to claim 17, wherein said nitrogenous basic compound is used in an amount of from about 0.1 to about 50 parts by weight, and said aldehyde is used in an amount of about 50 parts by weight or less, per 100 parts by weight of the novolak resin.
Claim 24
Dependent Claim
53 words
Spherical thermosetting phenolic resin particles according to claim 18, wherein said hexamethylenetetramine is used in an amount of from about 0.1 to about 50 l parts by weight, and said aldehyde is used in an amount of about 50 parts by weight or less, per 100 parts by weight of the novolak resin.
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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) | 1992-06-12 | 1992-12-12 | 1993-06-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-06-12 | 1996-12-12 | 1997-06-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-06-12 | 2000-12-12 | 2001-06-13 | $7700.00 | Window Closed / Lapsed |