Phenol formaldehyde coatings

B. G. Bufkin and J. R. Grave, Survey of the Applications, Properties, and Technology of Crosslinked Emulsions V, J. Coatings Tech. 50(12), 65 (1978). Reviews interstitially crosslinked coatings. Phenol-formaldehyde dispersed in water, etc. Sealants, adhesives, architectural coatings. 

Wei et al. (2002) have dip coated phenol-formaldehyde novolak resin containing a small amount of hexamethylene tetramine onto the surface of green tubular supports of fine phenol-formaldehyde novalac resin particles. During pyrolysis, the hexamethylamine has mobility that reduces the creation of large pores in the surface during pyrolysis. Because the selective layer and support have similar composition, there is also less stress during pyrolysis from shrinkage. The supported membranes were pyrolyzed at 900°C. The concentration of the solution used for the selective layer and the thickness had a considerable effect on the separation performance. 

Although the use of simple diluents and adulterants almost certainly predates recorded history, the use of fillers to modify the properties of a composition can be traced as far back as eady Roman times, when artisans used ground marble in lime plaster, frescoes, and po22olanic mortar. The use of fillers in paper and paper coatings made its appearance in the mid-nineteenth century. Functional fillers, which introduce new properties into a composition rather than modify pre-existing properties, were commercially developed eady in the twentieth century when Goodrich added carbon black to mbber and Baekeland formulated phenol— formaldehyde plastics with wood dour. 

A frequently cited example of protection from atmospheric corrosion is the Eiffel Tower. The narrow and, for that age, thin sections required a good priming of red lead for protection against corrosion. The top coat was linseed oil with white lead, and later coatings of ochre, iron oxide, and micaceous iron oxide were added. Since its constmction the coating has been renewed several times [29]. Modern atmospheric corrosion protection uses quick-drying nitrocellulose, synthetic resins, and reaction resins (two-component mixes). The chemist Leo Baekeland discovered the synthetic material named after him, Bakelite, in 1907. Three years later the first synthetic resin (phenol formaldehyde) proved itself in a protective paint. A new materials era had dawned. 

The term aminoplastics has been coined to cover a range of resinous polymers produced by interaction of amines or amides with aldehydes. Of the various polymers of this type that have been produced there are two of current commercial importance in the field of plastics, the urea-formaldehyde and the melamine-formaldehyde resins. There has in the past also been some commercial interest in aniline-formaldehyde resins and in systems containing thiourea but today these are of little or no importance. Melamine-phenol-formaldehyde resins have also been introduced for use in moulding powders, and benzoguanamine-based resins are used for surface coating applications. 

At one time urea-formaldehyde was used extensively in the manufacture of plywood but the product is today less important than heretofore. For this purpose a resin (typically U-F molar ratio 1 1.8)-hardener mixture is coated on to wood veneers which are plied together and pressed at 95-110°C under pressure at 200-800 Ibf/in (1.38-5.52 MPa). U-F resin-bonded plywood is suitable for indoor application but is generally unsuitable for outdoor work where phenol-formaldehyde, resorcinol-fonnaldehyde or melamine modified resins are more suitable. 

Phenol formaldehyde. Eormaldehyde is a respiratory irritant but is not classified as asthmagen. Powder coatings containing triglycidyl isocyanurate are possible asthmagens (unclassified)... 

A reaction vessel explosion at BASF s resins plant in Cincinnati (July 19, 1990) killed one and injured 71. The BASF facility manufactures acrylic, alkyd, epoxy, and phenol-formaldehyde resins used as can and paper-cup liner coatings. The explosion occurred when a flammable solvent used to clean a reaction vessel vented into the plant and ignited. The cleaning solvent that was not properly vented to a condenser and separator, blew a pressure seal, and fdled the 80-year-old building with a white vapor cloud. 

Phenolic coatings Phenolic is reacted with formaldehyde under heat to form a completely insoluble material. They are usually applied in an alcohol solution by spray, dip or roller. During their curing, they release water, which must be removed. They have maximum chemical and solvent resistance but poor alkaline resistance. 

Phenol-formaldehydes may no longer hold the centre-stage where synthetic polymers are concerned, but they are still of some commercial importance. They are produced for electrical mouldings, appliance handles, household fittings, and also as adhesives and specialised surface coatings. 

Proppants are solid particles used to hold open the fracture after conclusion of the well treatment. Criteria to choose the economically most effective proppant for a given set of formation conditions have been discussed (7 6). While sand is the most commonly used proppant because of its low cost, resin-coated sand, sintered bauxite, and A O particles have also been used because of their greater compressive strength and resistance to dissolution at high temperature and pH (55). While epoxy resins are most commonly used, the use of other resins such as phenol-formaldehyde has been described. 

Uses Preparation of sodium and butyl benzoates, benzoyl chloride, phenol, caprolactum, and esters for perfume and flavor industry plasticizers manufacture of alkyl resins preservative for food, fats, and fatty oils seasoning tobacco dentifrices standard in analytical chemistry antifungal agent synthetic resins and coatings pharmaceutical and cosmetic preparations plasticizer manufacturing (to modify resins such as polyvinyl chloride, polyvinyl acetate, phenol-formaldehyde). 

In the development of a reactive non-chrome post-treatment, a variety of phenolic resins were synthesized and commercial phenolic resins evaluated. It was found that phenol-formaldehyde resins, creso1-forma1dehyd e condensates, ortho-novo 1 ak resins, and phenol-formaldehyde emulsions gave positive results when employed as post-treatments over zinc and iron phosphate conversion coatings. The above materials all possessed drawbacks. The materials in general have poor water solubility at low concentrations used in post-treatment applications and had to be dried and baked in place in order to obtain good performance. The best results were obtained with poly-4-vinylphenol and derivatives thereof as shown in the following structure (8,9,10)... 

To produce composites, a binder rather than a size is usually required. A variety of high-temperature, high-strength compounds now available facilitate comparability of the fibers with matrix compounds. Insulation fibrous glass has been paired with phenol formaldehyde resins and a mineral oil lubricant. The binder may be up to 12 percent by weight of the final product (Barnhart, 1976). The composite compositions are discretely different from those of textiles in which fiber coatings are usually less than 0.5 percent of the total. 

When two polymeric systems are mixed together in a solvent and are spin-coated onto a substrate, phase separation sometimes occurs, as described for the application of poly (2-methyl-1-pentene sulfone) as a dissolution inhibitor for a Novolak resin (4). There are two ways to improve the compatibility of polymer mixtures in addition to using a proper solvent modification of one or both components. The miscibility of poly(olefin sulfones) with Novolak resins is reported to be marginal. To improve miscibility, Fahrenholtz and Kwei prepared several alkyl-substituted phenol-formaldehyde Novolak resins (including 2-n-propylphenol, 2-r-butylphenol, 2-sec-butylphenol, and 2-phenylphenol). They discussed the compatibility in terms of increased specific interactions such as formation of hydrogen bonds between unlike polymers and decreased specific interactions by a bulky substituent, and also in terms of "polarity matches" (18). In these studies, 2-ethoxyethyl acetate was used as a solvent (4,18). Formation of charge transfer complexes between the Novolak resins and the poly (olefin sulfones) is also reported (6). 

Further materials that have been evaluated as supports for solid-phase synthesis include phenol-formaldehyde polymers [239,240], platinum electrodes coated with polythiophenes [241], proteins (bovine serum albumin) [242], polylysine [243], soluble poly (vinyl alcohol) [244], various copolymers of vinyl alcohol [4,245,246], and soluble dendrimers [14,247]. 

CA 20, 1141(1926)(Description of chlorate expls used in Russia) F)A.C.Scott Mexco, Ltd, BritP 248089(1926) CA 21, 652(1927) (Crysts of O-carrying substs, such as K chlorate are coated with synthetic resin such as may be formed from a phenol, a phenol formaldehyde, or from urea or thiourea. Other ingredients such as MNN, DNT, a perchlorate or woodmeal may be added) G)Dr. Roman, NC 3, l6l-3(1932)(Compn props of some chlorate... 

We now compare theoretical predictions with experimental results obtained using silica sand coated with a 4% resin consisting of 100 parts by weight of a phenol-formaldehyde novolac and 5, 10, or 15 parts of hexamethylenetetramine (hexa) as hardener (Aranguren et al., 1984). 

With the advent of the polymer or plastic age, scientists had yet another group of chemicals to coat and treat the ancient raw material, wood. During World War II, phenol-formaldehyde, based on the research of the Forest Products Laboratory, was used to treat wood veneer and to form the composite into airplane propellers. Today, this same "Compreg" is used for cutlery handles throughout the world. 

The first demonstration of the industrial importance of heme peroxidases in grafting applications has been the development of hybrid resins from renewable sources to replace phenol-formaldehyde based resins. Phenolic resins are widely used in surface coatings, adhesives, laminates, molding, friction materials, abrasives, flame retardants, carbon membranes, glass fiber laminates, fiberboards, and protein-based wood adhesives, [5]. Table 7.1 and Fig. 7.2 summarize some of the... 

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