Abstract: Stable dispersions of phenolic resins, particularly bisphenol-A/formaldehyde resins, for use in e.g., baking enamels, coatings, adhesives, binders, etc., are disclosed. The dispersions have low levels (e.g., <0.1% by weight) of free aldehyde, thereby reducing environmental harms associated with aldehyde emissions. Low free aldehyde levels are achieved using melamine as an aldehyde scavenger during preparation. It has now been discovered that melamine, in contrast to other scavengers of aldehydes, does not adversely affect dispersion stability, interfere with later processing operations, or negatively impact the final resin product quality (e.g., after curing).

Abstract: Storage stable aqueous dispersions of a heat-reactive hydrophilic phenolic resin (e.g., phenol/formaldehyde) are disclosed. The dispersions comprise a base resin that is the reaction product of an aromatic alcohol and an aldehyde, and an etherified resin component selected from the group consisting of an etherified phenol/aldehyde resin, an etherified cresol/aldehyde resin, and mixtures thereof. The dispersions further comprise a protective colloid (e.g., polyvinyl alcohol). The addition of the etherified resin component in an amount of at least about 20% by weight of the base resin provides storage stability, but does not adversely affect the desirable physical and chemical characteristics (e.g., chemical resistance) of end products made from such dispersions. Moreover, the dispersions of the present invention can avoid the use of etherified resin components derived from bisphenol-A and/or xylenols, which present heath concerns in food coating applications.