Methylols

Urea - formaldehyde polymers. Formalin and urea (usually in the molecular proportions of 3 2) condense in the presence of ammonia, pyridine or hexamine to give urea - formaldehyde polymers, known commercially as Bedle or Plaskon, and are widely used as moulding powdens. It is believed that the intermediate products in the condensation are methylol-urea and dimethylol-urea ... 

Polymerisation may occur as a result of dehydration of these compounds to methylene and dimethylene urea or more probably by a stepwise loss of water between the molecules of methylol and dimethylol-urea. 

Hexamethylolmelamine can further condense in the presence of an acid catalyst ether linkages can also form (see Urea Eormaldehyde ). A wide variety of resins can be obtained by careful selection of pH, reaction temperature, reactant ratio, amino monomer, and extent of condensation. Eiquid coating resins are prepared by reacting methanol or butanol with the initial methylolated products. These can be used to produce hard, solvent-resistant coatings by heating with a variety of hydroxy, carboxyl, and amide functional polymers to produce a cross-linked film. 

See also N-methylol-2-pyrrolidinone.) PYRROLE AND PYRROLE DERIVATIVES] (Vol 20)... 

Methylol Formation. Polyacrylamide reacts with formaldehyde to form an /V-methylo1 derivative. The reaction is conducted at pH 7—8.8 to avoid cross-linking, which will occur at lower pH. The copolymer can also be prepared by copolymerizing acrylamide with commercially available A/-methylolacrylamide [924-42-5] C4H2NO2. These derivatives are useful in several mining appHcations (49,50). They are also useful as chemical grouts. 

Vapor-Phase Condensations of Acetic Acid or Esters with Formaldehyde. Addition of a methylol group to the a-carbon of acetic acid or esters, foUowed by dehydration, gives the acrylates. 

These are water-soluble crystalline compounds sold as concentrated aqueous solutions. The methylol groups are highly reactive (118—122) and capable of being cured on the fabric by reaction with ammonia or amino compounds to form durable cross-linked finishes, probably having phosphine oxide stmctures after post-oxidizing. This finishing process, as developed by Albright Wilson, is known as the Proban process. 

Diall l Phosphite and Related Retardants. Pyrovatex CP is based on the reaction product of a dialkyl phosphite and acrylamide [79-06-17 the adduct is methylolated with formaldehyde [50-00-0] (66—68) ... 

THP—Amide Process. THP has also been made directly from phosphine [7803-5-27] and formaldehyde. The THP so generated contains one less mole of formaldehyde than either THPC or THPOH. It can be used in a THP—amide flame-retardant finish. The pad formulation contains THP, TMM, methylol urea, and a mixed acid catalyst (93—95). 

Formaldehyde condenses with itself in an aldol-type reaction to yield lower hydroxy aldehydes, hydroxy ketones, and other hydroxy compounds the reaction is autocatalytic and is favored by alkaline conditions. Condensation with various compounds gives methylol (—CH2OH) and methylene (=CH2) derivatives. The former are usually produced under alkaline or neutral conditions, the latter under acidic conditions or in the vapor phase. In the presence of alkahes, aldehydes and ketones containing a-hydrogen atoms undergo aldol reactions with formaldehyde to form mono- and polymethylol derivatives. Acetaldehyde and 4 moles of formaldehyde give pentaerythritol (PE) ... 

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

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... 

The aromatic ring of a phenoxy anion is the site of electrophilic addition, eg, in methylolation with formaldehyde (qv). The phenoxy anion is highly reactive to many oxidants such as oxygen, hydrogen peroxide, ozone, and peroxyacetic acid. Many of the chemical modification reactions of lignin utilizing its aromatic and phenoHc nature have been reviewed elsewhere (53). 

Zinc acetate catalyst produces essentially 100% o-methylol phenol (8) in the first step. The second step gives an approximately equal quantity of 2,2 -(5, 45%) and 2,4 -diphenyhnethylene (6, 45%) bridges, indicating Htde chelate-directing influence. In addition, a small quantity (10%) of methylene ether units (9) (diben2yl ether) is observed at moderate reaction temperature. 

Rate studies show that base-cataly2ed reactions are second order and depend on the phenolate and methylene glycol concentrations. The most likely path involves a nucleophilic displacement by the phenoxide on the methylene glycol (1), with the hydroxyl as the leaving group. In alkaline media, the methylolated quinone intermediate is readily converted to the phenoxide by hydrogen-ion abstraction (21). 

Fig. 1. Possible pathways and rate constants for the methylolation of phenol.

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 some resole appHcations, such as foam and foundry binders, a rapid cure of a Hquid resin is obtained at RT with strong acid. The reactions proceed in the same manner as those of novolak resin formation. Methylol groups react at ortho and para phenoHc hydrogen to give diphenyknethane units (41). 

Gas chromatography (gc) has been used extensively to analyze phenoHc resins for unreacted phenol monomer as weU as certain two- and three-ring constituents in both novolak and resole resins (61). It is also used in monitoring the production processes of the monomers, eg, when phenol is alkylated with isobutylene to produce butylphenol. Usually, the phenoHc hydroxyl must be derivatized before analysis to provide a more volatile compound. The gc analysis of complex systems, such as resoles, provides distinct resolution of over 20 one- and two-ring compounds having various degrees of methylolation. In some cases, hemiformals may be detected if they have been properly capped (53). 

Phenolic resin substantially increases open time and peel strength of the formulation (80). For example, higher methylol and methylene ether contents of the resin improves peel strength and elevated temperature resistance. Adhesive properties are also influenced by the molecular weight distribution of the phenoHc low molecular weight reduces adhesion (82). 

Reaction with Aldehydes and Ketones. Formaldehyde combines with primary and secondary alkanolamines in the presence of alkali to give methylol derivatives. For the reaction of monoethanolamine with formaldehyde (12), the reaction scheme shown in Figure 1 occurs. 

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