Formaldehyde, para

The chemistry of melamines and phenoHcs is quite similar. In both cases formaldehyde [50-00-0] is added to the reactive sites on the patent ring to form methylol phenols (3) or methylol melamines (4) (see Phenolresins Aminoresins). There ate six reactive sites on the triazine ring of melamine [108-78-1] (1) so it is possible to form hexamethylolmelamine. However, the most common degree of methylolation is 1.5—2.0. The ortho and para positions of phenol ate active thus phenol can be trimethylolated (2). However, as with melamine, lower degrees of methylolation such as 1.2—2.5 ate... 

Alkaline Catalysts, Resoles. Resole-type phenoHc resins are produced with a molar ratio of formaldehyde to phenol of 1.2 1 to 3.0 1. For substituted phenols, the ratio is usually 1.2 1 to 1.8 1. Common alkaline catalysts are NaOH, Ca(OH)2, and Ba(OH)2. Whereas novolak resins and strong acid catalysis result in a limited number of stmctures and properties, resoles cover a much wider spectmm. Resoles may be soHds or Hquids, water-soluble or -insoluble, alkaline or neutral, slowly curing or highly reactive. In the first step, the phenolate anion is formed by delocali2ation of the negative charge to the ortho and para positions. 

Resoles. The advancement and cure of resole resins foUow reaction steps similar to those used for resin preparation the pH is 9 or higher and reaction temperature should not exceed 180°C. Methylol groups condense with other methylols to give dibenzyl ethers and react at the ortho and para positions on the phenol to give diphenyknethylenes. In addition, dibenzyl ethers eliminate formaldehyde to give diphenyknethanes. 

In addition to the above possible mechanisms the possibility of reaction at w-positions should not be excluded. For example, it has been shown by Koebner that o- and p-cresols, ostensibly difunctional, can, under certain conditions, react with formaldehyde to give insoluble and infusible resins. Furthermore, Megson has shown that 2,4,6-trimethylphenol, in which the two ortho- and the one para-positions are blocked, can condense with formaldehyde under strongly acidic conditions. It is of interest to note that Redfam produced an infusible resin from 3,4,5,-trimethylphenol under alkaline conditions. Here the two m- and the p-positions were blocked and this experimental observation provides supplementary evidence that additional functionalities are developed during reaction, for example in the formation of quinone methides. 

AmbersoU STI37 para-octy phenol-formaldehyde resole 30 0... 

The absence of methylol (-CH2OH) groups in all six lower molecular weight resorcinol-formaldehyde condensates which have been isolated [119] reflects the high reactivity of resorcinol under acid or alkaline conditions. It also shows the instability of its para-hydroxybenzyl alcohol groups and their rapid conversion to jpara-hydroxybenzyl carbonium ions or quinone methides. This explains how identical condensation products are obtained under acid or alkaline reaction conditions [119]. In acid reaction conditions methylene ether-linked condensates are also formed, but they are highly unstable and decompose to form stable methylene links in 0.25 to 1 h at ambient temperature [121,122]. 

The first step in the hase-catalyzed reaction is an attack hy the phe-noxide ion on the carhonyl carhon of formaldehyde, giving a mixture of ortho- and para-suhstituted mono-methylolphenol plus di- and trisuhsti-tuted methylol phenols ... 

These intermediates are too small to be used alone, but need to be enlarged and modified to obtain compatibility with other resins. In the case of the phenol formaldehyde resins this is achieved by either using para-substituted phenols where the substituent contains at least four carbon atoms or by reacting the intermediate with the natural resin, rosin, and then esterifying with glycerol or pentaerythritol. These resins have a limited use in stoved epoxy finishes where colour is not an important factor. 

Alkyl-substituted phenols have different reactivities than phenol toward reaction with formaldehyde. Relative reactivities determined by monitoring the disappearance of formaldehyde in phenol-paraformaldehyde reactions (Table 7.3) show that, under basic conditions, meta-cresol reacts with formaldehyde approximately three times faster titan phenol while ortho- and para-cresols react at approximately one-third the rate of phenol.18 Similar trends were observed for the reactivities of acid-catalyzed phenolic monomers with formaldehyde. 

Linear novolac resins prepared by reacting para-alkylphenols with paraformaldehyde are of interest for adhesive tackifiers. As expected for step-growth polymerization, the molecular weights and viscosities of such oligomers prepared in one exemplary study increased as the ratio of formaldehyde to para-nonylphenol was increased from 0.32 to 1.00.21 As is usually the case, however, these reactions were not carried out to full conversion, and the measured Mn of an oligomer prepared with an equimolar phenol-to-formaldehyde ratio was 1400 g/mol. Plots of apparent shear viscosity versus shear rate of these p-nonylphenol novolac resins showed non-Newtonian rheological behavior. 

Since a small amount of water is always present in novolac resins, it has also been suggested that some decomposition of HMTA proceeds by hydrolysis, leading to the elimination of formaldehyde and amino-methylol compounds (Fig. 7.15).42 Phenols can react with the formaldehyde elimination product to extend the novolac chain or form methylene-bridged crosslinks. Alternatively, phenol can react with amino-methylol intermediates in combination with formaldehyde to produce ortho-or para-hydroxybenzylamines (i.e., Mannich-type reactions). 

The reaction of benzoxazine in die presence of 2,6-xylenol does not occur until 135 C, presumably because die hydrogen-bonded intermediate depicted for the 2,4-xylenol reaction (Fig. 7.19) cannot occur. All three types of linkages are obtained in diis case. Para-para methylene-linked 2,6-xylenol dimers, obtained from the reaction of 2,6-xylenol with formaldehyde, formed in the decomposition of the benzoxazine (or with other by-products of that process) dominate. Possible side products from benzoxazine decomposition include formaldehyde and CH2=NH, either of which may provide the source of methylene linkages. Hie amount of ortho-para linkages formed by reaction of 2,6-xylenol with benzoxazine is low. Ortho-ortho methylene-linked products presumably form by a decomposition pathway from benzoxazine (as in Fig. 7.18). 

Resole syntheses entail substitution of formaldehyde (or formaldehyde derivatives) on phenolic ortho and para positions followed by methylol condensation reactions which form dimers and oligomers. Under basic conditions, pheno-late rings are the reactive species for electrophilic aromatic substitution reactions. A simplified mechanism is generally used to depict the formaldehyde substitution on the phenol rings (Fig. 7.21). It should be noted that this mechanism does not account for pH effects, the type of catalyst, or the formation of hemiformals. Mixtures of mono-, di-, and trihydroxymethyl-substituted phenols are produced. 

Phenol reacts with formaldehyde in either the ortho or the para position to form monohydroxymethyl-substituted phenols, which further react with formaldehyde to form di- and trihydroxymethyl-substituted phenols (Fig. 7.22). 

Crosslinking resoles in the presence of sodium carbonate or potassium carbonate lead to preferential formation of ortho-ortho methylene linkages.63 Resole networks crosslinked under basic conditions showed that crosslink density depends on the degree of hydroxymethyl substitution, which is affected by the formaldehyde-to-phenol ratio, the reaction time, and the type and concentration of catalyst (uncatalyzed, with 2% NaOH, with 5% NaOH).64 As expected, NaOH accelerated the rates of both hydroxymethyl substitution and methylene ether formation. Significant rate increases were observed for ortho substitutions as die amount of NaOH increased. The para substitution, which does not occur in the absence of the catalyst, formed only in small amounts in the presence of NaOH. 

The diarylation reaction is especicdly common with phenols (the diaryl product here is called a bisphenol). The reaction is normally carried out in alkaline solution on the phenolate ion. The hydroxymethylation of phenols with formaldehyde is called the Lederer-Manasse reaction. This reaction must be carefully controlled, since it is possible for the para and both ortho positions to be substituted and for each of... 

Tubular reactors are used for some polycondensations. Para-blocked phenols can be reacted with formalin to form linear oligomers. When the same reactor is used with ordinary phenol, plugging will occur if the tube diameter is above a critical size, even though the reaction stoichiometry is outside the region that causes gelation in a batch reactor. Polymer chains at the wall continue to receive formaldehyde by diffusion from the center of the tube and can crosslink. Local stoichiometry is not preserved when the reactants have different diffusion coefficients. See Section 2.8. 

Reaction of trans-1,2-cyclohexanediol with para-formaldehyde in the presence of Indion 130 as catalyst to yield the corresponding cyclic formal has been successfully carried out (Matkar and Sharma, 1995). A conversion of 52% was realized with 70% selectivity towards cyclohexanediol formal the other side products are rrans-hexahydrobenzo-l,3,5-trioxypin, di(tra i -2-hydroxycyclo-hexyloxy) methane. 

The use of cyclodextrins can allow stereo-, regio-, and optical selectivity, and thus molecular traffic control may be realized (Syamala et al. 1986). It has been claimed that the reaction of phenol with aqueous formaldehyde in the presence of cyclodextrins gives a 3 1 mixture of para to ortho at 38 % conversion in the absence of cyclodextrins, the ratio of para to ortho is around 2 3. 

COMPLEX REACTION SCHEME BETWEEN FORMALDEHYDE AND SODIUM PARA PHENOL SULPHONATE CONSTANT Kl=0.16, K2=0.05, K3=0.15, K4=0.14... 

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... 

Cyclic thiourea derivatives having three different types of cyclophane structure (ortho-meta, meta-meta and meta-para) and a lariat-type thiourea have been synthesized, using reaction of isothiocyanate with amine.230 Cyclic thioureas have been obtained from formaldehyde aminals and sulfur (Sg) (Scheme 77).231... 

---