Resole resin

In practice, ammonia is most frequendy used. With hexa, the initial reaction steps differ, but the final resole resins are identical, provided they contain the same number of nitrogen and CH2 groups. Most nitrogen from ammonia or hexa is incorporated as diben2ylamine with primary, tertiary, and cycHc amine stmctures as minor products. 

With a bulk process, resole resins, in neat or concentrated form, must be produced in small batches (ca 2—9.5 m ) in order to maintain control of the reaction and obtain a uniform product. On the other hand, if the product contains a large amount of water, such as Hquid plywood adhesives, large reactors (19 m ) can be used. Melt-stable products such as novolaks can be prepared in large batches (19—38 m ) if the exotherms can be controlled. 

The in situ process is simpler because it requires less material handling (35) however, this process has been used only for resole resins. When phenol is used, the reaction system is initially one-phase alkylated phenols and bisphenol A present special problems. As the reaction with formaldehyde progresses at 80—100°C, the resin becomes water-insoluble and phase separation takes place. Catalysts such as hexa produce an early phase separation, whereas NaOH-based resins retain water solubiUty to a higher molecular weight. If the reaction medium contains a protective coUoid at phase separation, a resin-in-water dispersion forms. Alternatively, the protective coUoid can be added later in the reaction sequence, in which case the reaction mass may temporarily be a water-in-resin dispersion. The protective coUoid serves to assist particle formation and stabUizes the final particles against coalescence. Some examples of protective coUoids are poly(vinyl alcohol), gum arabic, and hydroxyethjlceUulose. 

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. 

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). 

Heat resistance is an important characteristic of the bond. The strength of typical abrasive stmctures is tested at RT and at 300°C. Flexural strengths are between 24.1 and 34.4 MPa (3500—5000 psi). An unmodified phenoHc resin bond loses about one-third of its room temperature strength at 298°C. Novolak phenoHc resins are used almost exclusively because these offer heat resistance and because the moisture given off during the cure of resole resins results in undesirable porosity. Some novolaks modified with epoxy or poly(vinyl butyral) resin are used for softer grinding action. 

Air and Oil Filters. Liquid resole resins are used to coat and penetrate the cellulose fibers of filters and separators in order to increase strength and stiffness and protect against attack by the environment. The type of phenoHc to be used depends on both the final property requirements and the papermaking process. 

Different phenoHc resins are used for different types of wood for example, plywood adhesives contain alkaline-catalyzed Hquid resole resins. Extension with a filler reduces cost, minimizes absorption, and increases bond strength. These resins have an alkaline content of 5—7% and are low in free phenol and formaldehyde. Because many resins have a high water content and limited storage stabiHty, they are frequently made at or near the mill producing the plywood product. The plywood veneers are dried, coated with resin, stacked for pressing, and cured at 140—150°C. 

Fig. 3. Second cycle voltage profiles of carbons representative of regions (I), (2), and (3). a) JMI synthetic graphite, b) Crowley petroleum pitch heated to 550°C, and c) a resole resin heated to 1000°C.

Phenolics or phenol-aldehydes include the important commercial phenolic resin bakelite based on phenol and formaldehyde. A one-step process produces resol resin from more than one molecule of formaldehyde per phenol molecule. A two-step process uses an excess of phenol to produce novolacs - resins that have no reactive methylol groups and must be mixed with an aldehyde o undergo further reaction. 

Resol resins thermoset on heating and are used for adhesives. Novolacs require a further source of formaldehyde in the form of hexamethylenetetramine to produce molding powders. Phenolic moldings are resistant to heat, chemicals, and moisture with good electrical and heat insulation qualities. Complex phenols from, e.g., cashew-nut shell liquid, are used in making brake... 

RESOLE RESINS AND NETWORKS 7.4.1 Resole Resin Syntheses... 

Quinone methides are the key intermediates in both resole resin syntheses and crosslinking reactions. They form by the dehydration of hydroxymethylphenols or dimethylether linkages (Fig. 7.24). Resonance forms for quinone methides include both quinoid and benzoid structures (Fig. 7.25). The oligomerization or crosslinking reaction proceeds by nucleophilic attack on the quinone methide carbon. 

Resole resins are generally crosslinked under neutral conditions between 130 and 200° C or in the presence of an acid catalyst such as hydrochloric acid, phosphoric acid, p-toluenesulfonic acid, and phenolsulfonic acid under ambient conditions.3 The mechanisms for crosslinking under acidic conditions are similar to acid-catalyzed novolac formation. Quinone methides are the key reaction intermediates. Further condensation reactions in resole resin syntheses under basic conditions at elevated temperatures also lead to crosslinking. 

A number of analytical techniques such as FTIR spectroscopy,65-66 13C NMR,67,68 solid-state 13 C NMR,69 GPC or size exclusion chromatography (SEC),67-72 HPLC,73 mass spectrometric analysis,74 differential scanning calorimetry (DSC),67 75 76 and dynamic mechanical analysis (DMA)77 78 have been utilized to characterize resole syntheses and crosslinking reactions. Packed-column supercritical fluid chromatography with a negative-ion atmospheric pressure chemical ionization mass spectrometric detector has also been used to separate and characterize resoles resins.79 This section provides some examples of how these techniques are used in practical applications. 

TABLE 7.8 FTIR Absorption Band Assignment of Resole Resins... 

Various ionization methods were used to bombard phenol-formaldehyde oligomers in mass spectroscopic analysis. The molecular weights of resole resins were calculated using field desorption mass spectroscopy of acetyl-derivatized samples.74 Phenol acetylation was used to enable quantitative characterization of all molecular fractions by increasing the molecular weights in increments of 42. 

Dynamic DSC scans of resole resins show two distinguishable reaction peaks, which correspond to formaldehyde addition and die formation of edier and metiiy-lene bridges characterized by different activation energies. Kinetic parameters calculated using a regression analysis show good agreement widi experimental values.75... 

NaOH-catalyzed resole resin, 409 Naphthalene diisocyanate (NDI), 201 Naphthalene tetracarboxylic dianhydride (NDTA), 282... 

Phenol-formaldehyde resole resins, preparations of, 429 Phenolic-based networks, 376 Phenolic compounds, 62 Phenolic cyanate resins, 418... 

Resole resin syntheses, 398-406 Retro Friedel-Crafts alkylation, 342 Riffle, J. S 375 Rigid block copolymers, 53 Rigid foams... 

Resole resins are formed by having formaldehyde in excess, usually in mole ratio of about 2 1 on the phenol. By contrast, novolak resins are formed by having phenol in excess, generally in mole ratio of 1.25 1 on formaldehyde. The pH at which these prepolymers are fabricated is also different resoles are formed under alkaline conditions and the novolaks under acidic conditions. 

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