Formaldehyde Melamines

Colourless white or pastel coloured mouldings can be produced from this resin using bleached wood pulp as a filler. Melamine-formaldehyde mouldings are more resistant to water than urea-formaldehyde resins and are not attacked by weak alkalies and they have a high heat resistance. 

Due to their superior water resistance, mouldings made in this resin have good staining resistance and have consequently been widely used in tableware. Their high heat resistance has lead to their extensive use as the top layer of decorative laminates for table tops and working surfaces. 

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Melamine - formaldehyde polymers. Melamine (2 4 6-triamino-1 3 5-triazine), obtained by heating dicyandiamide under pressure, condenses with formalin to give melamine - formaldehyde polymers (Beetle - Melamine), which have similar uses, but better stability to heat... 

The use of hydroxyethyl (also hydroxypropyl) methacrylate as a monomer permits the introduction of reactive hydroxyl groups into the copolymers. This offers the possibility for subsequent cross-linking with an HO-reactive difunctional agent (diisocyanate, diepoxide, or melamine-formaldehyde resin). Hydroxyl groups promote adhesion to polar substrates. 

The monomer used for preparing melamine formaldehyde is formed as follows ... 

Both melamine—formaldehyde (MF) and resorcinol—formaldehyde (RF) foUowed the eadier developments of phenol—, and urea—formaldehyde. Melamine has a more complex stmcture than urea and is also more expensive. Melamine-base resins requite heat to cure, produce colorless gluelines, and are much more water-resistant than urea resins but stiU are not quite waterproof. Because of melamine s similarity to urea, it is often used in fairly small amounts with urea to produce melamine—urea—formaldehyde (MUF) resins. Thus, the improved characteristics of melamine can be combined with the economy of urea to provide an improved adhesive at a moderate increase in cost. The improvement is roughly proportional to the amount of melamine used the range of addition may be from 5 to 35%, with 5—10% most common. 

Melamine reacts similarly to produce methylol derivatives, which form the familiar melamine—formaldehyde resins on heating (63) (see Aminoresins). 

Amino and Phenolic Resins. The largest use of formaldehyde is in the manufacture of urea—formaldehyde, phenol—formaldehyde, and melamine—formaldehyde resins, accounting for over one-half (51%) of the total demand (115). These resins find use as adhesives for binding wood products that comprise particle board, fiber board, and plywood. Plywood is the largest market for phenol—formaldehyde resins particle board is the largest for urea—formaldehyde resins. Under certain conditions, urea—formaldehyde resins may release formaldehyde that has been alleged to create health or environmental problems (see Amino RESINS AND PLASTICS). 

Urea—formaldehyde resins are also used as mol ding compounds and as wet strength additives for paper products. Melamine—formaldehyde resins find use in decorative laminates, thermoset surface coatings, and mol ding compounds such as dinnerware. 

Paraformaldehyde is used by resin manufacturers seeking low water content or more favorable control of reaction rates. It is often used in making phenol—, urea—, resorcinol—, and melamine—formaldehyde resins. 

It should be possible to form linear noncross-linked polymers of melamine—formaldehyde or phenol—formaldehyde by reaction of one mole of the patent with one mole of formaldehyde, but this is generally not the case. The melamine crystal itself is very insoluble in water and only becomes soluble as the formaldehyde molecules add on. If much less than 1.5 moles of formaldehyde pet mole of melamine ate used, the aqueous resin solution is very unstable. 

Fig. 2. Curves 1, 2, and 3 show the spectral radiance factor for equivalent coatings of separate toluenesulfonamide—melamine—formaldehyde Day-Glo pigments containing 0.5% of a dye, either Alberta Yellow, Rhodamine F5G, or Rhodamine B Extra. Curve 4 is for a bright nonfluorescent red-orange printing ink. The illuminant was Source C. A magnesium oxide-coated block was used as a comparison white.

Daylight fluorescent pigments (qv) are considered to be nontoxic. Since they are combinations of polymers and dyestuffs, the combined effect of the ingredients must be taken into account when considering the net toxic effect of these materials. Table 5 gives results of laboratory animal toxicity tests of standard modified melamine—formaldehyde-type pigments, the Day-Glo A Series, and the products recommended for plastic mol ding, Day-Glo Z-series. 

Amino resins are thermosetting polymers made by combining an aldehyde with a compound containing an amino (—NH2) group. Urea—formaldehyde (U/F) accounts for over 80% of amino resins melamine—formaldehyde accounts for most of the rest. Other aldehydes and other amino compounds are used to a very minor extent. The first commercially important amino resin appeared about 1930, or some 20 years after the introduction of phenol—formaldehyde resins and plastics (see Phenolic resins). 

In the eady 1920s, experimentation with urea—formaldehyde resins [9011-05-6] in Germany (4) and Austria (5,6) led to the discovery that these resins might be cast into beautiful clear transparent sheets, and it was proposed that this new synthetic material might serve as an organic glass (5,6). In fact, an experimental product called PoUopas was introduced, but lack of sufficient water resistance prevented commercialization. Melamine—formaldehyde resin [9003-08-1] does have better water resistance but the market for synthetic glass was taken over by new thermoplastic materials such as polystyrene and poly(methyl methacrylate) (see Methacrylic polya rs Styrene plastics). 

N,]S7-bis(methoxymethyl)uron was first isolated and described in 1936 (41), but was commercialized only in 1960. It is manufactured (42) by the reaction of 4 mol of formaldehyde with 1 mol of urea at 60°C under highly alkaline conditions to form tetramethylolurea [2787-01-1]. After concentration under reduced pressure to remove water, excess methanol is charged and the reaction continued under acidic conditions at ambient temperatures to close the ring and methylate the hydroxymethyl groups. After filtration to remove the precipitated salts, the methanolic solution is concentrated to recover excess methanol. The product (75—85% pure) is then mixed with a methylated melamine—formaldehyde resin to reduce fabric strength losses in the presence of chlorine, and diluted with water to 50—75% soHds. Uron resins do not find significant use today due to the greater amounts of formaldehyde released from fabric treated with these resins. 

Melamine—Formaldehyde Resins. The most versatile textile-finishing resins are the melamine—formaldehyde resins. They provide wash-and-wear properties to ceUulosic fabrics, and enhance the wash durabiHty of flame-retardant finishes. Butylated melamine —formaldehyde resins of the type used in surface coatings may be used in textile printing-ink formulations. A typical textile melamine resin is the dimethyl ether of trimethylolmelamine [1852-22-8] which can be prepared as follows ... 

Miscellaneous Resins. Much less important than the melamine—formaldehyde and urea—formaldehyde resins are the methylo1 carbamates. They are urea derivatives since they are made from urea and an alcohol (R can vary from methyl to a monoalkyl ether of ethylene glycol). 

Melamine—formaldehyde acts as an amine when dissolved in dilute acid, usually hydrochloric acid (HQ.). During polymerization, between 20—80... 

The recovery of fiber from broke (off-specification paper or trim produced in the paper mill) is compHcated by high levels of urea—formaldehyde and melamine—formaldehyde wet-strength resin. The urea resins present a lesser problem than the melamine resins because they cure slower and are not as resistant to hydrolysis. Broke from either resin treatment may be reclaimed by hot acidic repulping. Even the melamine resin is hydrolyzed rapidly under acidic conditions at high temperature. The cellulose is far more resistant and is not harmed if the acid is neutralized as soon as repulping is complete. 

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