Phenol formaldehyde laminating

Phenol-formaldehyde laminates are generally used with mineral acids, salts, and chlorinated aromatic hydrocarbons. When graphite is used as a filler, the laminate is suitable for use with hydrofluoric acid and certain fluoride salts. Refer to Table 3.17 for the compatibility of phenol-formaldehyde with selected corrodents. Reference [1] provides a more comprehensive listing. 

Phenol/formaldehyde-laminated textile Phenol/formaldehyde-laminated textile + flame-retardant PVC, filled PVC... 

Phenol—formaldehyde resins are used as mol ding compounds (see Phenolic resins). Their thermal and electrical properties allow use in electrical, automotive, and kitchen parts. Other uses for phenol—formaldehyde resins include phenoHc foam insulation, foundry mold binders, decorative and industrial laminates, and binders for insulating materials. 

Particle board and wood chip products have evolved from efforts to make profitable use of the large volumes of sawdust generated aimually. These products are used for floor undedayment and decorative laminates. Most particle board had been produced with urea—formaldehyde adhesive for interior use resin demand per board is high due to the high surface area requiring bonding. Nevertheless, substantial quantities of phenol—formaldehyde-bonded particle board are produced for water-resistant and low formaldehyde appHcations. 

This includes wire enamels on a base of polyvinyl formal, polyurethane or epoxy resins as well as moulding powder plastics on phenol-formaldehyde and similar binders, with cellulose fillers, laminated plastics on paper and cotton cloth base, triacetate cellulose films, films and fibres of polyethylene terephthalate. 

Laminating resins. CNSL resins are added to laminates based on phenol-formaldehyde, epoxy, etc. to reduce brittleness and to improve flexibility of the product. The resins also exhibit better age hardening and improved bonding to the substrate [133,134,137,168]. 

Phenolics are also used in a variety of other applications such as adhesives, paints, laminates for building, automobile parts, and ion exchange resins. Global production of phenol-formaldehyde resins exceeded 5 billion pounds in 1997. 

Phenol-formaldehyde (phenolic) plastics The chemical resistance is affected by the phenol used, cresols giving the best acid resistance whilst xylenols are often used to obtain the best alkali resistance. For chemical-resistant applications the fillers used in moulding powder and reinforcing material in laminates should be inorganic, e.g. asbestos or glass. The resins are usually dark in colour. 

Phenolic phenol formaldehydes (PFs) are the low-cost workhorse of the electrical industry (particularly in the past) low creep, excellent dimensional stability, good chemical resistance, good weatherability. Molded black or brown opaque handles for cookware are familiar applications. Also used as a caramel colored impregnating plastics for wood or cloth laminates, and (with reinforcement) for brake linings and many under-the-hood automotive electricals. There are different grades of phenolics that range from very low cost (with low performances) to high cost (with superior performances). The first of the thermosets to be injection-molded (1909). 

Unlike phenol-formaldehyde polymers, the amino resins are not themselves deeply coloured, but are of a naturally light appearance. They can be easily pigmented to give a variety of shades, which leads to application in uses where good appearance is highly valued, for example in decorative tableware, laminated resins for furniture, and modem white electrical plugs and sockets. 

The route to crosslinked phenol-formaldehyde resins via resoles corresponds to that used by Baekeland in his original commercial technique. They now tend to be used for adhesives, binders, and laminates. The resole... 

A widely used polymeric resin for making construction laminates (Formica), low-cost dinnerware, and so on, is melamine (C3N6H6) formaldehyde. It is harder than phenol formaldehyde. 

It has been demonstrated that red oak OSL could be used to replace 35% to 40% of the phenol (or phenolic resin solids) in phenol-formaldehyde resins used to laminate maple wood and to bond southern pine flake boards (wafer-board and/or strandboard) without adversely affecting the physical bond properties. While this pulping process and by-product lignin do not commercially exist at this time in the United States, lignins from such processes are projected to cost 40% to 50% less than phenol as a polymer raw material. 

Amino resins are lighter in color and have better tensile strength and hardness than phenolic resins their impact strength and heat and water resistance are less than those of phenolics. The melamine—formaldehyde resins are harder and have better heat and moisture resistance than the urea resins, but they are also more expensive. The physical properties of the melamine—formaldehyde laminates are Us ted in Table 1. 

The types of adhesives suitable for laminating beams are restricted by the conditions of application and by their end-use requirements. A wider choice of adhesives for plywood depends on whether softwoods or hardwoods are used, whether they are required for internal or external exposures, or whether they are to be used for ornamental or structural purposes. Thus phenol-formaldehyde types would be used for marine or exterior construction uses urea-formaldehyde types would be advantageous for cold pressing, or melamine-urea adhesives might be preferred for hardwood plywood, or lumber-core panels used in furniture production. 

Phenol-formaldehyde (PF) was the first fully synthetic macromolecular material ( Bakelite , 1907). In a slightly precured condition and provided with fillers, it is, as a moulding powder, available for processing into end-use articles such as bulb fittings, switch housings, coils, laminated wood and foam for thermal insulation. 

Phenol-formaldehyde resins are used in the core assembly and in conjunction with the kraft paper give the characteristic brown colour to the back of the laminate. Features of these resins making them suitable for the purpose include ... 

In dry conditions decorative laminates will shrink, and in damp they will expand unless suitable precautions are taken the associated movements can give rise to stress cracking of laminates and the bowing of composite boards. Since the phenol-formaldehyde resins are more stable in this respect than melamine-formaldehyde, laminates with phenolic kraft cores have dimensional stability better than those with melamine core papers—and thick laminates incorporating many plies of phenolic core paper are more stable than thin laminates with fewer plies. 

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... 

Phenol-formaldehyde resins find numerous applications in such areas as wood composites, fiber bonding, laminates, foundry resins, abrasives, friction and molding materials, coatings and adhesives, and flame retardants (JL). From a specialty chemicals standpoint, they are also used as developer resins in carbonless papers (2.). Conventional methods of preparation involve condensation of a phenol with formaldehyde under either acidic (novolak) or basic (resole) conditions (2). Their typical molecular weight range is from 800-4000 daltons (D) and includes a wide variety of alkyl or aryl substituted phenols (A)- The... 

The phenol/furfural resins have a greater hydrocarbon solvent tolerance than phenol/formaldehyde resins. This is an advantage in the preparation of resin solutions used for the impregnation of paper or cloth for laminating. 

In the manufacture of bonded insulating materials, the fibers in the fleece shaft or on the conveyor belt are sprayed with an aqueous binder, generally a phenol-formaldehyde resin. The binder content in the bonded insulating material is 3 to 4%. Compaction to the desired density and hardening of the resin binder occurs in a tunnel kiln, through which the fibers are continuously transported on a conveyor belt. The compaction is achieved with a second belt which exerts the required pressure on the upper surface of the continuous sheet. This is often followed by laminating the sheet with e.g. paper, aluminum or plastic foil. Finally the product is rolled up or cut into sheets. 

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