Patent GB-1406944-A (GB)
Title: Process for the manufacture of dispersions of thermosetting reaction products
IPC: C08G8/08
Filed: 1973-06-19
Abstract: 1406944 Aqueous phenolic resin dispersions HOECHST AG 19 June 1973 [19 June 1972 19 Sept 1972] 29022/73 Heading C3R An aqueous water-dilutable phenolic resin dispersion is prepared by heating a mixture consisting of phenol (II), at least one substituted monohydric phenol (I), HCHO or a HCHO donor, and at least one basic nitrogen compound selected from NH 3 , primary and secondary amines in the presence of water, a non-ionic emulsifier, and polyvinyl alcohol and hydroxyethylcellulose as protective colloids until a withdrawn sample of the dispersion has a B- time of 30 seconds to 10 minutes at 160‹ C., and then cooling whilst stirring and optionally whilst adding water, the mixture of phenols (I) and (II) being used in such amounts that the average functionality of ((I) + (II)) relative to HCHO is 2À1 to 2À8, the amount of HCHO being such that the molar ratio of HCHO to the sum of the phenols (I) and (II) is 1À0 to 1À4 : 1, the amount of basic nitrogen compound being 5-50 mol. per cent relative to the total weight of phenols (I) and (II), the amount of added water plus the water of reaction being 30-60% wt. relative to the weight of the total batch, the amount of emulsifier being 5-25% wt. based on the total weight of phenols, the weight ratio of polyvinyl alcohol to hydroxyethyl cellulose being 2 : 1 to 4 : 1 and their total sum being 5-25% wt. based on the total weight of the phenols. The phenolic reactant in the above process can alternatively be at least one substituted phenol of the general Formula (III) optionally in admixture with phenol (I) and/or phenol (II), wherein R 1  and R 2  are selected from a hydrogen atom or a radical CnH 2n+1  where n = 1-5, the -CR 1 R 2 - group being ortho or para to the phenolic OH groups. In an embodiment the phenolic reactants (I) and (II) is a solution of a styrenated phenol in phenol optionally in admixture with the substituted phenol (III). The solution of the styrenated phenol in phenol may be prepared in a first step by heating at 150-160‹ C. 1 mol. of styrene or a derivative thereof with a molar excess of phenol in the presence of 2-5% wt. oxalic acid, until 95% wt. of the styrene has reacted. In general the substituted phenol (I) can be any of the following: dimethylphenol, m-C 1-4  alkylphenol, p-tert-butylphenol, o- and/or p-n- and/or isopropenylphenol, o- and/or p-allylphenol, o- or pphenylphenol, o- and/or p-α- and/or #-phenylethylphenol, phenylisopropylphenol or -methylphenylethylphenol, or the alkylation products of olefines and phenols. Preferred phenols (III) are 1,1-di-(4<SP>1</SP>-hydroxyphenyl)-2-methylpropane and bisphenol A. Suitable emulsifiers are adducts of ethylene oxide and (i) alkylphenols, preferably p-n-nonylphenol, or (ii) polypropylene glycols, or (iii) abietic acid; polyoxyethylene alkyl ethers, esters, alkylamides or alkylamines, and polyethyleneimines. Plasticizers, e.g. dibutyl phthalate, triphenyl phosphate, tricresyl phosphate and wood oil can be added to the dispersion during or after manufacture. Many examples for preparing the dispersions are given. Uses.-Binders for lacquers, coatings, slag wool slabs, hard paper and fabrics, battery separators, oil and air filter papers, abrasives, brake linings, plywood, chipboards and hardboards.