Phenohc polymers

Fibers for commercial and domestic use are broadly classified as natural or synthetic. The natural fibers are vegetable, animal, or mineral ia origin. Vegetable fibers, as the name implies, are derived from plants. The principal chemical component ia plants is cellulose, and therefore they are also referred to as ceUulosic fibers. The fibers are usually bound by a natural phenoHc polymer, lignin, which also is frequentiy present ia the cell wall of the fiber thus vegetable fibers are also often referred to as lignocellulosic fibers, except for cotton which does not contain lignin. 

Lignite, generally leonardite, and lignite derivatives are appHed in water-based muds as thinners and filtration control agents. Leonardite is an oxidized lignite having a high content of humic acids, which may be described as carboxylated phenoHc polymers (59,60). Litde is known about the chemical stmcture. 

Enzymes may be classified generally into six groups the details of typical polymers produced via catalysis with respective enzymes are listed in Table 23.1. In the past, the target macromolecules for enzymatic polymerization have included polysaccharides, poly(amino acid)s, polyesters, polycarbonates, phenolic polymers, poly(aniline)s, and vinyl polymers. In this chapter, attention is focused on the enzymatic synthesis of phenohc polymers and polyesters, based on the increasing industrial application of these materials. Notably, most such polymers can be obtained from commercially available, inexpensive monomers by using industrially produced enzymes. Another important point is that the enzymatic process must be regarded as an environmentally benign synthetic pathway. Details of the enzymatic synthesis of other polymers are provided in recent pertinent reviews [3-10]. 

In addition to Hgnin, plants also contain structurally similar types of phenohc polymers, which are classified as tannins (see Section 8.3.6). 

Furfural is a resin former under the influence of strong acid. It will self-resinify as well as form copolymer resins with furfuryl alcohol, phenoHc compounds, or convertible resins of these. Conditions of polymerization, whether aqueous or anhydrous, inert or oxygen atmosphere, all affect the composition of the polymer. Numerous patents have issued relating to polymerization and to appHcations. Although the resins exhibit a degree of britdeness, they have many outstanding properties a number of appHcations are discussed under "Uses."... 

Under acidic conditions, furfuryl alcohol polymerizes to black polymers, which eventually become crosslinked and insoluble in the reaction medium. The reaction can be very violent and extreme care must be taken when furfuryl alcohol is mixed with any strong Lewis acid or Brn nstad acid. Copolymer resins are formed with phenoHc compounds, formaldehyde and/or other aldehydes. In dilute aqueous acid, the predominant reaction is a ring opening hydrolysis to form levulinic acid [123-76-2] (52). In acidic alcohoHc media, levulinic esters are formed. The mechanism for this unusual reaction in which the hydroxymethyl group of furfuryl alcohol is converted to the terminal methyl group of levulinic acid has recendy been elucidated (53). 

Positive-Tone Photoresists based on Dissolution Inhibition by Diazonaphthoquinones. The intrinsic limitations of bis-azide—cycHzed mbber resist systems led the semiconductor industry to shift to a class of imaging materials based on diazonaphthoquinone (DNQ) photosensitizers. Both the chemistry and the imaging mechanism of these resists (Fig. 10) differ in fundamental ways from those described thus far (23). The DNQ acts as a dissolution inhibitor for the matrix resin, a low molecular weight condensation product of formaldehyde and cresol isomers known as novolac (24). The phenoHc stmcture renders the novolac polymer weakly acidic, and readily soluble in aqueous alkaline solutions. In admixture with an appropriate DNQ the polymer s dissolution rate is sharply decreased. Photolysis causes the DNQ to undergo a multistep reaction sequence, ultimately forming a base-soluble carboxyHc acid which does not inhibit film dissolution. Immersion of a pattemwise-exposed film of the resist in an aqueous solution of hydroxide ion leads to rapid dissolution of the exposed areas and only very slow dissolution of unexposed regions. In contrast with crosslinking resists, the film solubiHty is controUed by chemical and polarity differences rather than molecular size. 

I ovolac Synthesis and Properties. Novolac resins used in DNQ-based photoresists are the most complex, the best-studied, the most highly engineered, and the most widely used polymers in microlithography. Novolacs are condensation products of phenoHc monomers (typically cresols or other alkylated phenols) and formaldehyde, formed under acid catalysis. Figure 13 shows the polymerization chemistry and polymer stmcture formed in the step growth polymerization (31) of novolac resins. 

Acid-C t lyzed Chemistry. Acid-catalyzed reactions form the basis for essentially all chemically amplified resist systems for microlithography appHcations (61). These reactions can be generally classified as either cross-linking (photopolymerization) or deprotection reactions. The latter are used to unmask acidic functionality such as phenohc or pendent carboxyhc acid groups, and thus lend themselves to positive tone resist apphcations. Acid-catalyzed polymer cross-linking and photopolymerization reactions, on the other hand, find appHcation in negative tone resist systems. Representative examples of each type of chemistry are Hsted below. 

Eig. 6. Decomposition of polymers as a function of temperature during heating. A, polymethylene B, polytetrafluoroethylene C, silicone D, phenoHc resin ... 

Aqueous solutions of 50% acrylamide should be kept between 15.5 and 38°C with a maximum of 49°C. Below 14.5°C acrylamide crystallizes from solution and separates from the inhibitor. Above 50°C the rate of polymer buildup becomes significant. Suitable materials of constmction for containers include stainless steel (304 and 316) and steel lined with plastic resin (polypropylene, phenoHc, or epoxy). Avoid contact with copper, aluminum, their alloys, or ordinary iron and steel. 

The amount and physical character of the char from rigid urethane foams is found to be affected by the retardant (20—23) (see Foams Urethane polymers). The presence of a phosphoms-containing flame retardant causes a rigid urethane foam to form a more coherent char, possibly serving as a physical barrier to the combustion process. There is evidence that a substantial fraction of the phosphoms may be retained in the char. Chars from phenohc resins (qv) were shown to be much better barriers to pyrolysate vapors and air when ammonium phosphate was present in the original resin (24). This barrier action may at least partly explain the inhibition of glowing combustion of char by phosphoms compounds. 

Syntactic Cellular Polymers. Syntactic cellular polymer is produced by dispersing rigid, foamed, microscopic particles in a fluid polymer and then stabilizing the system. The particles are generally spheres or microhalloons of phenoHc resin, urea—formaldehyde resin, glass, or siUca, ranging 30—120 lm dia. Commercial microhalloons have densities of approximately 144 kg/m (9 lbs/fT). The fluid polymers used are the usual coating resins, eg, epoxy resin, polyesters, and urea—formaldehyde resin. 

The commonly used resins in the manufacture of decorative and industrial laminates ate thermosetting materials. Thermosets ate polymers that form cross-linked networks during processing. These three-dimensional molecules ate of essentially infinite size. Theoretically, the entire cured piece could be one giant molecule. The types of thermosets commonly used in laminates ate phenoHcs, amino resins (melamines), polyesters, and epoxies. 

In the case of phenoHcs, it is possible to make linear thermoplastic polymers called novolaks, but this is done by reaction of less than one mole of formaldehyde with one mole of phenol the resulting resin has a large excess of free phenol. Usually in appHcation hexamethylene tetramine (HEXA) is added to the novolak. When heated, the HEXA breaks down into ammonia and formaldehyde and enters the reaction to form a light degree of cross-links in the final product. 

The biosynthesis process, which consists essentially of radical coupling reactions, sometimes followed by the addition of water, of primary, secondary, and phenohc hydroxyl groups to quinonemethide intermediates, leads to the formation of a three-dimensional polymer which lacks the regular and ordered repeating units found in other natural polymers such as cellulose and proteins. 

U.S. phenoHc resin manufacturers include AHiedSignal Inc./Bendix Ashland Chemical, Inc. Borden, Inc. Dexter Corp. Dyno Polymers Georgia-Pacific Corp. Neste Resins Corp. Occidental Chemical Corp. Owens-Corning Corp. Plastics Engineering Co. PMC, Inc. Resinoid Engineering... 

Carbon—Carbon Composites. Above 300°C, even such polymers as phenoHcs and polyimides are not stable as binders for carbon-fiber composites. Carbon—carbon composites are used at elevated temperatures and are prepared by impregnating the fibers with pitch or synthetic resin, foUowed by carbonization, further impregnation, and pyrolysis (91). 

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