Abstract: A method for forming an electrode for a fuel cell is disclosed. The method comprises combining an electrically conductive material (e.g., graphite) and a solid grindable resole resin binder, the binder being essentially free of nitrogen and nitrogen-containing compounds, and consolidating the electrically conductive material and the binder to form the fuel cell electrode. The use of a solid, grindable, single stage, nitrogen-free resole resin binder serves to increase the operating life of the electrode. One example binder comprises the reaction product of bisphenol A and a molar excess of an aldehyde, such as formaldehyde.

Abstract: A method for forming an electrode for a fuel cell is disclosed. The method comprises combining an electrically conductive material (e.g., graphite) and a solid grindable resole resin binder, the binder being essentially free of nitrogen and nitrogen-containing compounds, and consolidating the electrically conductive material and the binder to form the fuel cell electrode. The use of a solid, grindable, single stage, nitrogen-free resole resin binder serves to increase the operating life of the electrode. One example binder comprises the reaction product of bisphenol A and a molar excess of an aldehyde, such as formaldehyde.

Abstract: A polymer composition that can be used to cure a novolac resin at a lower temperature than conventional curing agents and with reduced emission of volatile compounds is disclosed. The curing agent composition is prepared by mixing and reacting in aqueous solution a phenolic monomer and an aldehyde in the presence of a basic catalyst to form an intermediate resin, and reacting the intermediate resin with an amine to form the curing agent. The aldehyde to phenolic monomer molar ratio in the reaction should be at least about 1.0:1. The preferred amine is hexamethylenetetramine, and it is preferred that the hexamethylenetetramine to phenolic monomer molar ratio is at least about 0.12:1. The curing agent releases minimal volatile compounds when used to cure novolac resins, and unlike conventional resole curing agents, has an indefinite shelf life in both the pure form and when blended with a novolac resin.

Abstract: A polymer composition that can be used to cure a novolac resin at a lower temperature than conventional novolac curing agents and with reduced emission of volatile compounds is disclosed. The novolac curing agent polymer composition is prepared by mixing and reacting in aqueous solution a phenolic monomer and an aldehyde in the presence of a basic catalyst to form an intermediate resin, and reacting the intermediate resin with an amine to form the polymer composition. The aldehyde to phenolic monomer molar ratio in the reaction should be at least about 1.0:1, and preferably is at least about 2.0:1. The preferred amine is hexamethylenetetramine, and it is preferred that the hexamethylenetetramine to phenolic monomer molar ratio is at least about 0.12:1. In a preferred version, the aldehyde is formaldehyde, and the phenolic monomer is selected from the group consisting of phenol, substituted phenols, and mixtures thereof, with phenol itself being the most preferred phenolic monomer.

Abstract: A flame retardant article produced by forming a thermoplastic material around at least a portion of a core of partially cured phenolic resin is disclosed. The article has reduced flammability and improved dimensional stability when exposed to flame compared to an article consisting solely of the thermoplastic material. By positioning the thermoplastic between the core and at least all surfaces of the article which may become directly exposed to fire or heat when the article is in use, it is possible to impart the flexibility, colorability and impact resistance characteristics of thermoplastic materials to the article. At the same time, the inner core of the phenolic resin reduces the flammability and improves the dimensional stability of the article when the article is exposed to flame.