Base-catalyzed phenol-formaldehyde

Base-catalyzed phenol-formaldehyde reactions exhibit second-order kinetics [Eq. (5)]. Several alkylphenols such as cresols also follow this rate equation ... 

TABLE 7.5 Relative Positional Reaction Rates in Base-Catalyzed Phenol-Formaldehyde Reaction... 

Base-Catalyzed Phenol-Formaldehyde Condensation (Resols)... 

Base-catalyzed phenol-formaldehyde (PF) board, mechanisms of formaldehyde release, 87... 

Resoles are usually mixtures of a number of methylol phenols, with small amounts of higher condensation products involving methylene and benzylic ether linkages. The kinetics of base-catalyzed phenol-formaldehyde reactions have been extensively researched. At high dilution and at a pH not exceeding 10, the rate equation can be expressed by Eq. (13), where [PhO ] denotes the concentration of phenoxide anion and [F] the concentration of unreacted formaldehyde, determined titrimetrically. " ... 

Epoxy NovolaC Resins. Epoxy novolacs are multifunctional epoxies based on phenolic formaldehyde novolacs. Both epoxy phenol novolac resins (EPN) and epoxy cresol novolac resins (ECN) have attained commercial importance (53). The former is made by epoxidation of the phenol-formaldehyde condensates (novolacs) obtained from acid-catalyzed condensation of phenol and formaldehyde (see Phenolic Resins). This produces random ortho- and para-methylene bridges. 

Stopping the polymer at this point requires the ratio of formaldehyde to phenol to be less than unity. Both methylene and ether bridges are known to be present. The reaction is either acid or base catalyzed, and branching is uncommon at this stage. The products are variously known as A stage resins, novolacs, or resole prepolymers. 

This reaction is carried out under base-catalyzed conditions and with a formaldehyde/phenol ratio greater than unity. The resulting product is called a C state resin or resite. 

The main processes for the manufacture of hydroxybenzaldehydes are based on phenol. The most widely used process is the saligenin process. Saligenin (2-hydroxybenzyl alcohol [90-01-7]) and 4-hydroxybenzyl alcohol [623-05-2] are produced from base-catalyzed reaction of formaldehyde with phenol (35). Air oxidation of saligenin over a suitable catalyst such as platinium or palladium produces sahcylaldehyde (62). 

Phenol-formaldehyde resins are the oldest thermosetting polymers. They are produced by a condensation reaction between phenol and formaldehyde. Although many attempts were made to use the product and control the conditions for the acid-catalyzed reaction described by Bayer in 1872, there was no commercial production of the resin until the exhaustive work by Baekeland was published in 1909. In this paper, he describes the product as far superior to amber for pipe stem and similar articles, less flexible but more durable than celluloid, odorless, and fire-resistant. ° The reaction between phenol and formaldehyde is either base or acid catalyzed, and the polymers are termed resols (for the base catalyzed) and novalacs (for the acid catalyzed). 

Phenolic resins were discovered by Baeyer in 1872 through acid-catalyzed reactions of phenols and acetaldehyde. Kleeberg found in 1891 that resinous products could also be formed by reacting phenol with formaldehyde. But it was Baekeland who was granted patents in 1909 describing both base-catalyzed resoles (known as Bakelite resins) and acid-catalyzed novolac products.2... 

Phenol-formaldehyde reactions, 399, 380 base-catalyzed, 400-402 Phenol-formaldehyde resins, modified, 410-411... 

A Friedel-Crafts-type reaction of phenols under basic conditions is also possible. Aqueous alkaline phenol-aldehyde condensation is the reaction for generating phenol-formaldehyde resin.34 The condensation of phenol with glyoxylic acid in alkaline solution by using aqueous glyoxylic acid generates 4-hydroxyphenylacetic acid. The use of tetraalkylammonium hydroxide instead of sodium hydroxide increases the para-selectivity of the condensation.35 Base-catalyzed formation of benzo[b]furano[60]- and -[70]fullerenes occurred via the reaction of C60CI6 with phenol in the presence of aqueous KOH and under nitrogen.36... 

The high-molecular-weight products formed by the condensation of phenols with carbonyl compounds (especially with formaldehyde) are known as phenolic resins. They are mixtures of structurally nonuniform compounds that are initially soluble and fusible but which can become crosslinked (cured) by subsequent reactions. One distinguishes between acid- and base-catalyzed condensations, since they lead to different end products the properties of the condensation polymer are also affected by the mole ratio of phenol to formaldehyde. 

Condensations with carbonyl compounds phenol-formaldehyde resins. Acid or base catalyzes electrophilic substitution of carbonyl compounds in ortho and para positions of phenols to form phenol alcohols (Lederer-Manasse reaction). 

Phenolic Resins. Phenolic resins [9003-354] (qv) are thermosets prepared by the reaction of phenol with formaldehyde, through either the base-catalyzed one-stage or the acid-catalyzed two-stage process. The liquid intermediate may be used as an adhesive and bonding resin for plywood, particle board, fiberboard, insulation, and cores for laminates. The physical properties for typical phenolic laminates made with wood are listed in Table 1. 

Calixarenes [77] are defined as [l.n]metacyclophanes with its basic structural unit consisting of phenolic groups linked by ortho-methylene groups. Two examples are shown in Fig. 25. Several reviews are available on this subject [77-79]. These compounds can be synthesized by the acid- or base-catalyzed condensation reaction of a substituted phenol with formaldehyde or an aldehyde (Fig. 26). Calixarenes have also been synthesized by a stepwise reaction that sequentially add phenolic groups followed by a cyclization step. More efficient convergent synthesis have also been developed [80-82], The bowl-like structural conformation generally... 

Calixarenes (23) are obtained from base-catalyzed condensations of / -snbstituted phenols with formaldehyde. ... 

The functionality may vary with reaction conditions. For example, in base-catalyzed copolymerization of phenol and formaldehyde, both monomers are bifunctional at ambient temperature, but phenol becomes trifunctional if the temperature is raised sufficiently. Copolymerization at ambient temperature can produce essentially linear, liquid, resole-type "prepolymers" of low molecular weight. Upon acidification and heat-curing, methylene and ether crosslinks formed by the now trifunctional phenol units transform the polymer into an insoluble resin [7] (see next page). The original Bakelite was such a "thermosetting" product. 

Condensation of phenol with formaldehyde is a base-catalyzed process in which one resonance form of the phenoxide ion attacks formaldehyde. The resulting trimethylol phenol is then crosslinked by heat, presumably by dehydration with the intermediate formation of benzylcarbocations. The resulting polymer is Bakelite. Since the cost of phenol is relatively high and... 

The contribution of the resonance forms XXI, XXII, XXIII, and XXIV to the structure of the anions is frequently overlooked, yet many base-catalyzed condensation reactions of phenol and pyrrole undoubtedly proceed through these resonance structures at the moment reaction occurs. The condensation of phenol with aqueous formaldehyde, the Kolbc synthesis (p. 197), and the Reimer-Tiemann reaction (p. 202) are striking examples of reactions which occur through the seemingly less important carbanion structure of the resonance hybrid. (See p. 133.)... 

Base-Catalyzed Condensation of -Substituted Phenols and Formaldehyde... 

Little is known about the overall mechanism of cyclic oligomer formation, although the mechanism of the initial stages of the sequence seems fairly clear. The first chemical event is the reaction of formaldehyde (formed in the Petrolite procedures by depolymerization of paraformaldehyde) with phenol to form 2-hydroxy-methyl- and 2,6-6w(hydroxymethyl)phenols in a base-catalyzed process, as shown in Fig. 3. Such compounds were characterized many years ago50), obtained from the action of aqueous formaldehyde on phenol in basic solution at room temperature. Subsequent condensation between the hydroxymethylphenols and the starting phenol occurs to form linear dimers, trimers, tetramers, etc. via a pathway that might involve o-quinonemethide intermediates which react with phenolate ions in a Michael-like reaction, as portrayed in Fig. 4. The condensation of hydroxymethyl-... 

Fig. 4. Base-catalyzed formation of linear oligomers from phenols and formaldehyde...

---