Phenolic resin-containing cellulosic overlays for woody substrates
阅读：262发布：2024-02-03
专利汇可以提供Phenolic resin-containing cellulosic overlays for woody substrates专利检索，专利查询，专利分析的服务。并且Disclosed are improved resin-containing, cellulosic overlays for overlaying woody substrates and processes for preparing same. The overlays are produced by admixing an aqueous slurry of cellulosic fibers and a high molecular weight, alkaline, water-solubilized, phenol-formaldehyde resole resin and then precipitating the resin with an acidic agent selected from sulfuric, hydrochloric, phosphoric, acetic, citric and p-toluenesulfonic acids. The preferred resin used in the overlays is prepared by the basecatalyzed methylolation of an acid-catalyzed phenol-formaldehyde novolac resin having a formaldehyde : phenol mole ratio of from 0.6 to 0.95. Methylolation is effected by reacting the novolac resin at moderately elevated temperatures with sufficient formaldehyde so that the resulting resole resin has a formaldehyde : phenol mole ratio of from 1.4 to 2.0.，下面是Phenolic resin-containing cellulosic overlays for woody substrates专利的具体信息内容。
1. IN A PROCESS FOR PRODUCING A RESIN-CONTAINING, CELLULOSIC OVERLAY USEFUL FOR OVERLAYING WOODY SUBSTRATES COMPRISING ADMIXING AN AQUEOUS SLURRY OF CELLULOSIC FIBERS AND AN ALKALINE, WATER-SOLUBILIZED, PHENOL-FORMALDEHYDE RESOLE RESIN, PRECIPITATING SAID RESIN ONTO SAID FIBERS BY ACIDIFICATION OF SAID SLURRY, AND FORMING A DRY SHEET FROM THE ACIDIFIED SLURRY, THE IMPROVEMENT WHEREIN: A. SAID PHENOL-FORMALDEHYDE RESOLE RESIN IS PRODUCED BY CONDENSATION OF PHENOL AND FORMALDEHYDE UNDER ACIDIC CONDITIONS TO FORM A NOVOLAC RESIN HAVING A FORMALDEHYDE :PHENOL MOLE RATIO OF FROM 0.6 TO 0.95; AND METHYLOLATION OF SAID NOVOLAC RESIN WITH SUFFICIENT ADDITIONAL FORMALDEHYDE TO PRODUCE A RESOLE RESIN HAVING A FORMALDEHYDE PHENOL MOLE RATIO OF FROM 1.4 TO 2.0; AND B. SAID ACIDIFICATION IS EFFECTED BY ADDING TO SAID SLURRY AN ACID SELECTED FROM SULFURIC, HYDROCHLORIC, PHOSPHORIC, ACETIC, CITRIC AND P-TOLUENESULFONIC ACIDS.
2. The process of claim 1 wherein said acid is sulfuric acid.
3. The process of claim 1 wherein the formaldehyde : phenol mole ratio of said novolac resin is from 0.7:1 to 0.9:1 and the formaldehyde : phenol mole ratio of said resole resin is from 1.5 to 1.7.
4. The process of claim 3 wherein said acid is sulfuric acid.
5. The process of claim 1 wherein the formaldehyde : phenol mole ratio of said novolac resin is from 0.75 to 0.85 and the formaldehyde : phenol mole ratio of said resole resin is 1.55:1 to 1.65:1.
6. The process of claim 5 wherein said acid is sulfuric acid.
7. The process of claim 1 wherein the formaldehyde : phenol mole ratio of said novolac resin is about 0.8 and the formaldehyde : phenol mole ratio of said resole resin is about 1.6.
8. The process of claim 7 wherein said acid is sulfuric acid.
9. The process of claim 1 wherein said phenol-formaldehyde resole resin is produced by a process comprising maintaining an aqueous solution comprising phenol and formaldehyde in proportions of from 0.75 to 0.85 mole of formaldehyde per mole of phenol and having a pH of from 0.5 to 1.5 at a first temperature of at least 80*C. until substantially all said phenol has been comsumed; cooling the resulting reaction mixture; adjusting the cooled reaction mixture to a pH above about 8.0 and adding additional formaldehyde to the cooled reaction mixture; and maintaining the reaction mixture at a second elevated temperature within the range of from about 40*C. to about 80*C. until substantially all formaldehyde therein has been consumed, the amount of said additional formaldehyde being such that said resole resin has a formaldehyde : phenol mole ratio of from 1.55 to 1.65.
10. The process of claim 9 wherein said acid is sulfuric acid.
11. The process of claim 1 wherein said phenol : formaldehyde resole resin has a number-average molecular weight of from about 850 to about 950 and a weight-average molecular weight of from about 2,850 to about 3,150.
12. The process of claim 11 wherein said acid is sulfuric acid.
13. An overlay produced by the process of claim 1.
14. An overlay produced by the process of claim 2.
15. An overlay produced by the process of claim 3.
16. An overlay produced by the process of claim 4.
17. An overlay produced by the process of claim 5.
18. An overlay produced by the process of claim 6.
19. An overlay produced by the process of claim 7.
20. An overlay produced by the process of claim 8.
21. An overlay produced by the process of claim 9.
22. An overlay produced by the process of claim 10.
23. An overlay produced by the process of claim 11.
24. An overlay produced by the process of claim 12.
25. The process of claim 1 wherein said methylolation is effected at a pH of from about 8 to about 11.
26. The process of claim 1 wherein said methylolation is effected at a temperature of from 40* to 80*C.
27. The process of claim 1 wherein said methylolation is effected at a temperature of from 40* to 80*C. and at a pH of from about 8 to about 11.
28. The process of claim 3 wherein said methylolation is effected at a pH of from about 8 to about 11.
29. The process of claim 3 wherein said methylolation is effected at a temperature of from 40* to 80*C.
30. The process of claim 3 wherein said methylolation is effected at a temperature of from 40* to 80*C. and at a pH of from about 8 tO about 11.
31. The process of claim 7 wherein said methylolation is effected at a pH of from about 8 to about 11.
32. The process of claim 7 wherein said methylolation is effected at a temperature of from 40* to 80*C.
33. The process of claim 7 wherein said methylolation is effected at a temperature of from 40* to 80*C. and at a pH of from about 8 to about 11.
34. In a process for producing a resin-containing, cellulosic overlay useful for overlaying woody substrates comprising admixing an aqueous slurry of cellulosic fibers and an alkaline, water-solubilized, phenol-formaldehyde resole resin, precipitating said resin onto said fibers by acidification of said slurry, and forming a dry sheet from the acidified slurry, the improvement wherein: a. said phenol-formaldehyde resole resin has a formaldehyde: phenol mole ratio of from 1.4 to 2.0, a number-average molecular weight of from about 850 to about 950, and a weight-average molecular weight of from about 2,850 to about 3,150, said resole resin being produced by methylolating a novolac resin having a formaldehyde:phenol mole ratio of from 0.6 to 0.95; and b. said acidification is effected by adding to said slurry an acid selected from sulfuric, hydrochloric, phosphoric, acetic, citric and p-toluenesulfonic acids.
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