Patent GB-909567-A (GB)
Title: Improvements in manufacture of resins
IPC: C08G59/62
Filed: 1959-11-13
Abstract: High molecular weight synthetic resins are made by subjecting to dehydrohalogenation, in the presence of an alkaline dehydrohalogenating agent, a mixture of (1) one mol. of a dichlorohydrin ether of a polyhydric alcohol, and (2) one or more mols. of a monochlorohydrin ether of hydroxyalkyl and hydroxyaliphatic ethers of dihydric phenols, either without or with the addition of (3) a dihydric phenol, and either without or with the addition of (4) a glycidyl chlorohydrin ether of a dihydric phenol, and, when a dihydric phenol is added, either without or with the addition of epichlorohydrin.  Complex aliphatic-modified epoxy resins having terminal glycidyl groups and intermediate aliphatic and aromatic groups linked by ether oxygen are obtained when (1) and (2) are subjected to dehydrohalogenation as in Examples 16 to 19.  The epoxide resins are useful for esterification with drying oil or other acids to form esters, and for reaction with cross-linking agents such as amines and polyamines, diisocyanates, amine-aldehyde and phenol-aldehyde resins to form complex or insoluble products.  High molecular weight dihydric phenols are made by dehydrohalogenation of (1) and (2) with 2 mols. of (3) for each mol. of (1) as in Example 23.  The dihydric phenols may be subjected to esterification through the alcoholic hydroxyl groups present, or to crosslinking through these groups with di-isocyanates, or to cross-linking through the terminal phenolic hydroxyl groups with polyepoxides or epichlorohydrin.  High molecular weight polymeric products which are free from epoxide groups are made by dehydrologenation of (1) and (2) with one mol. of (3) for each mol. of (1) as in Example 22.  The products may be used in admixture with other resins or esterified through their alcoholic groups or cross-linked through these groups. Epoxide resins may also be obtained by reaction of the high molecular weight dihydric phenols with excess epichlorohydrin and aqueous caustic alkali as in Examples 24 and 25, or, in a single stage process, by dehydrohalogenating a mixture of (1), (2), (3) and epichlorohydrin as in Example 26. These epoxide resins may be further reacted as for the complex aliphatic modified epoxide resins.  A similar range of epoxide resins, high molecular weight dihydric phenols and epoxidefree polymers may be obtained by replacing the dihydric phenol wholly or in part by a glycidyl chlorohydrin ether of a dihydric phenol.  Thus complex dihydric phenols are obtained when there is an excess of phenolic hydroxyl groups over chlorohydrin groups.  Epoxide resins are produced when there is an excess of chlorohydrin groups.  High molecular weight polymers are obtained when the reactants contain an equal number of chlorohydrin groups and phenolic hydroxyl groups.ALSO:Epoxy resins of the general formula: <FORM:0909567/IV (b)/1> are made by subjecting a mixture of a dichlorohydrin ether o a polyhydric alcohol and a monochlorohydrin ether of a hydroxyalkyl or hydroxyaliphatic ether of a dihydric phenol to dehydrohalogenation with an alkaline dehydrohalogenating agent, where R11 is the divalent residue of the polyhydric alcohol, R is the hydrocarbon residue of the dihydric phenol and R1 is a divalent residue of at least 2 carbon atoms selected from aliphatic hydrocarbon groups or hydroxy-substituted hydrocarbon ether-substituted, or hydroxy-substituted hydrocarbon ether-substituted, aliphatic hydrocarbon groups, m and n can be zero or an integer and m plus n is at least 1.  The products obtained will vary depending on the proportions of the reactants used.  Epoxy resins of the formula: <FORM:0909567/IV (b)/2> wherein R, R1 and R11 are as above and R3 represents the residue of a dihydric phenol, are made by subjecting 1 mol of a dichlorohydrin ether as above defined, 1 mol of a monochlorohydrin ether as above defined, 1 mol of a dihydric phenol and 1 mol of epichlorohydrin to dehydrohalogenation with an alkaline agent.  The proportions of the four ingredients may be varied but the number of chlorohydrin groups should be in excess of the number of phenolic hydroxyl groups to produce a product having terminal epoxide groups.  More complex products are obtained when the glycidyl chlorohydrin ether of a dihydric phenol is used in addition to the dihydric phenol. Suitable dehydrohalogenating agents are caustic soda, alkali metal complexes and salts such as sodium silicate, sodium aluminate and sodium zincate.  The reaction may take place in a solvent such as dioxane, methyl isobutyl ketone, or xylol, or caustic soda may be used in aqueous solution.  The amount of alkali should be sufficient to dehydrohalogenate both the dichlorohydrin ether and the monochlorohydrin ether and also any added chlorohydrin when epichlorohydrin is used.  The dichlorohydrin ethers may be made by reacting a polyhydric alcohol with epichlorohydrin in the presence of a catalyst such as BF3 or an etherate thereof. Suitable alcohols include glycols, diethylene glycol, triethylene glycol, hexanetriol, glycerol, polyethylene and polypropylene glycols, and dihydroxyalkyl ethers of dihydric phenols such as bisphenol and resorcinol.  The hydroxyalkyl or hydroxyaliphatic ethers of dihydric phenols are made by reacting 1 mol of dihydric phenol with 1 mol of a simple or substituted alkyl or aliphatic chlorohydrin or carbonate or epoxide.  More complex derivatives of the dihydric phenol are made by reacting 1 mol of the dihydric phenol with 1 mol of a monochlorohydrin ether or monoglycide ether of a di, tri or higher polyhydric alcohol.  The monochlorohydrin ethers are made by reacting 1 mol of the hydroxy aliphatic ether of the dihydric phenol with 1 mol of epichlorohydrin in the presence of a condensation catalyst, such as BF3 or an etherate thereof.  Detailed examples are given.