Thermosets melamine-formaldehyde

For example, U.S. Pat. No. 3,367,917 [15] describes a thermosetting melamine-formaldehyde-benzoguanamine resinous molding composition containing a hbrous hller, such as a-cellulose pulp, in an amount between 25 and 42% by weight. 

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. 

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). 

Poly(vinyl alcohol) is employed as a modifier of thermosetting resins used as adhesives in plywood and particle board manufacture (314,315). The polymer is added to urea-formaldehyde or urea—melamine—formaldehyde resins to improve initial grab, to increase viscosity, and, in general, to improve the characteristics of the board. 

Amino Resins. Amino resins (qv) include both urea- and melamine—formaldehyde condensation products. They are thermosets prepared similarly by the reaction of the amino groups in urea [57-13-6] or melamine [108-78-1] with formaldehyde to form the corresponding methylol derivatives, which are soluble in water or ethanol. To form plywood, particle board, and other wood products for adhesive or bonding purposes, a Hquid resin is mixed with some acid catalyst and sprayed on the boards or granules, then cured and cross-linked under heat and pressure. 

The thermoplastic or thermoset nature of the resin in the colorant—resin matrix is also important. For thermoplastics, the polymerisation reaction is completed, the materials are processed at or close to their melting points, and scrap may be reground and remolded, eg, polyethylene, propjiene, poly(vinyl chloride), acetal resins (qv), acryhcs, ABS, nylons, ceUulosics, and polystyrene (see Olefin polymers Vinyl polymers Acrylic ester polymers Polyamides Cellulose ESTERS Styrene polymers). In the case of thermoset resins, the chemical reaction is only partially complete when the colorants are added and is concluded when the resin is molded. The result is a nonmeltable cross-linked resin that caimot be reworked, eg, epoxy resins (qv), urea—formaldehyde, melamine—formaldehyde, phenoHcs, and thermoset polyesters (qv) (see Amino resins and plastics Phenolic resins). 

The generic thermosets are the epoxies and the polyesters (both widely used as matrix materials for fibre-reinforced polymers) and the formaldehyde-based plastics (widely used for moulding and hard surfacing). Other formaldehyde plastics, which now replace bakelite, are ureaformaldehyde (used for electrical fittings) and melamine-formaldehyde (used for tableware). 

Interesting developments were also taking place in the field of thermosetting resins. The melamine-formaldehyde materials appeared commercially in 1940 whilst soon afterwards in the United States the first contact resins were used. With these materials, the forerunners of today s polyester laminating resins, it was found possible to produce laminates without the need for application of external pressure. The first experiments in epoxide resins were also taking place during this period. 

This group includes many plastics produced by condensation polymerization. Among the important thermosets are the polyurethanes, epoxy resins, phenolic resins, and urea and melamine formaldehyde resins. 

Sanding is carried out at this stage and, after clean-up, the final colour or top-coat is applied. There is some variation in the resin chemistry used. Alkyds crosslinked with melamine-formaldehyde are widely used for non-metallic pigmentation. Metallics are usually based on acrylics for better durability. The acrylic may be thermoset with melamine-formaldehyde or a thermoplastic lacquer (plasticised copolymer of methyl methacrylate). A thickness of about 50ftm is applied and stoved for 20 min at 130°C (lacquers receive a bake-sand-bake process for a smoother appearance). 

Good quality steel is used and electrozinc is preferred for washing machines. Steel is pretreated with iron phosphate for economy electrozinc with a fine crystal zinc phosphate. No primer is normally used 25-40/im of finish is applied direct to metal. The required properties are best obtained with a thermosetting acrylic or polyester/melamine-formaldehyde finish. Self-reactive acrylics are usually preferred these resins contain about 15 Vo 7V-butoxymethyl acrylamide (CH2=CH —CO —NH —CHj—O —C4H,) monomer and cure in a manner similar to butylated melamine-formaldehyde resins. Resistance or anti-corrosive properties may be upgraded by the inclusion of small amounts of epoxy resin. Application is usually by electrostatic spray application from disc or bell. Shapes are complex enough to require convected hot-air curing. Schedules of 20 min at 150-175°C are... 

Important thermosetting plastics include the phenolics, melamine-formaldehyde, epoxides and polyester resins used in glass-reinforced plastics. (See also Sections 14.5 and 14.9.)... 

Well-known thermosetting plastics include the phenolics, urea-formaldehyde and melamine-formaldehyde plastics, polyesters and epoxides. 

Urea-formaldehyde resins are the most prominent examples of the thermosetting resins usually referred to as amino resins, comprising ca. 80% of the amino resins produced worldwide. Melamine-formaldehyde resins constitute most of the remainder of this class of resins, with other minor amounts of resins being produced from the other aldehydes or amino compounds (especially aniline), or both. 

Thermosets differ molecularly from thermoplastics in that their individual chains are anchored to one another through crosslinks. The resulting network creates cohesive materials that demonstrate better thermal stability, rigidity, and dimensional stability than thermoplastics. Some examples of traditional thermosets are melamine-formaldehyde resins, which are used to treat fabrics to make them wrinkle-free, and Bakelite (a phenol-formaldehyde resin), a historically important polymer used in many applications, such as costume jewelry, electrical switches, and radio casings. 

The polymers can be categorised as formaldehyde containing and formaldehyde free and as thermoset or thermoplastic resins. Typical formaldehyde containing resins are melamine formaldehyde sulfonamide resins, where the sulfonamide is ortho and para toluenesulfonamide. The sulfonamide, which is a solvent for the dye, undergoes a condensation polymerisation with formaldehyde and melamine, the latter acting as a cross-linking agent. Non-formaldehyde, thermoplastic resins are usually polyamides and polyesters. 

The chemical structures of thermosets are generally much more diverse than the commodity thermoplastics. The most common types of thermosets are the phenol-formaldehydes (PF), urea-formaldehydes (UF), melamine-formaldehydes (MF), epoxies (EP), polyurethanes (PU), and polyimides (PI). Appendix 2 shows the chemical structure of these important thermosetting polymers. 

Another use of urea is for resins, which are used in numerous applications including plastics, adhesives, moldings, laminates, plywood, particleboard, textiles, and coatings. Resins are organic liquid substances exuded from plants that harden on exposure to air. The term now includes numerous synthetically produced resins. Urea resins are thermosetting, which means they harden when heated, often with the aid of a catalyst. The polymerization of urea and formaldehyde produces urea-formaldehyde resins, which is the second most abundant use of urea. Urea is dehydrated to melamine, which, when combined with formaldehyde, produces melamine-formaldehyde resins (Figure 96.2). Melamine resins tend to be harder and more heat-resistant than urea-formaldehyde resins. Melamine received widespread attention as the primary pet food and animal feed contaminant causing numerous cat and dog deaths in early... 

In the early 1930 s, a second type of resin prepared from formaldehyde was introduced to the market—namely, urea-formaldehyde resins. A few years later, melamine-formaldehyde resins also appeared. The same basic process is employed in polymerization of all these resins it consists of the catalyzed reaction of formaldehyde with the second ingredient—phenol, urea, or melamine—to evolve water and produce three-dimensional, cross-linked thermosetting polymers. 

Addition of glycerol, phthalic anhydride and butylated melamine formaldehyde resins is sometimes found to improve the thermosetting properties of silicone resins. Methylsilyl triacetate has the same effect in certain cases. Some silicone resins can be advantageously modified by the addition of polyvinyl acetyl resins or nitroparaffins. 

Alpha-cellulose-filled melamine-formaldehyde has long been used for unbreakable, scratch-resistant, dishwasher-safe dinnerware. Its thermosetting nature has made it the logical choice for the rapidly-expanding microwaveable tray market. Unfortunately, owing to the disposability requirement of the product, the cost has made melamine prohibitive. 

By means of chemical reactions thermosetting plastics form three-dimensional structures. In the example above the nitrogen compound urea reacts with formaldehyde (methanal), in which process three molecules combine and a molecule of water is formed. In this example two H atoms react, but all other H atoms ( ) enter into the same reaction. Since urea is a three-dimensional molecule, the network will also be three-dimensional. For instance switches and sockets are made of UF. Other thermosetting plastics are polyurethane PU (insulation) and melamine-formaldehyde MF (panels). 

Melamine, having three amino groups and six labile hydrogen atoms, will also form thermoset resins with formaldehyde (melamine-formaldehyde polymers). The chemistry is similar to that for the urea resins. 

Wood Composites—these are resin-bonded composite boards where the particles are wood shavings, flakes, chips, or fibers bonded with thermosetting adhesives that can be urea formaldehyde, melamine formaldehyde, phenol formaldehyde, or diisocyanate. In recent years, the markets for OSB and MDF board have been rapidly increasing. Most particle board production uses urea-formaldehyde as a binder that is acid setting. Hence, sodium borates (alkaline) can interfere with the setting. As a result, boric acid has been the major boron compound used as the flame retardant in particle board.28 29 Typically, a loading of 12%-15% of boric acid in MDF is required to meet the ASTM E-84 Class A rating. If sodium borate is used as a flame retardant, phenol-formaldehyde binder, that is compatible with alkaline chemicals, is commonly used. 

The most important thermosets are phenolic resins (PF) urea-formaldehyde resins (UF) melamine-formaldehyde resins (MF) unsaturated polyester resins (UP) epoxide resins (EP)... 

Determination of MCT. The coating systan used consists of a thermosetting acrylic latex, Hycar 2600X256 (EFGoodrich Chenical Division) containing 15 wt.% of a partially methylated melamine formaldehyde, Cymel 373 (American Cyanamid Corporation). Adjustment of the pH level of the coating was achieved by the addition of p—toluene sulfonic acid. 

Melamine-Formaldehyde. These resins became commercial in the 1930s. Their combination of high thermosetting reactivity, cured hardness, and resistance to heat, weather, and chemical environments made them particularly valuable for their good appearance and durability (Table 15.23). 

CNC CATALYST PM is a metallic salt accelerator designed as the complete catalyst for use with thermosetting resins. This catalyst is especially efficient for use with modified urea-formaldehyde, glyoxal, ethylene urea, triazone and melamine-formaldehyde resins. 

Chemical nature Modified melamine formaldehyde thermosetting resin... 

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