Abstract: A binder composition comprising a blend of a crystalline phenolic compound having two or more hydroxyphenyl groups and a thermosetting spray dried phenolic resole resin is disclosed. The binder together with a filler is particularly useful in the preparation of molding compounds.

Abstract: A phenol-formaldehyde resole resin for use as a binder for glass fibers is acidified to a pH of 3 or less after base-catalyzed resinification. An increase in actual solids is observed compared with neutralized resin. Phenol-formaldehyde-urea-ammonia resins are surprisingly stable at pH 3 with desirable cure profiles.

Abstract: The use of whitening pigments comprising (a) a melamine-formaldehyde or phenol-formaldehyde polycondensation product and (b) a water-soluble fluorescent whitening agent of formula (1), wherein R1 and R2 are each independently of the other —OH, —Cl, —NH2, —O—C1-C4alkyl, —O—aryl, —NH—C1-C4alkyl, —N(C1-C4alkyl)2, —N(C1-C4alkyl)(C1-C4hydroxyalkyl), —N(C1-C4hydroxyalkyl)2, or —NH—aryl, for example aniline-mono- or -di-sulfonic acid or an anilinesulfon-amide, morpholino, S—C1-C4alkyl(aryl), or a radical of an amino acid, for example aspartic acid or inimoacetic acid, which radical is substited at the amino group, and M is hydrogen; sodium; potassium; calcium; magnesium; ammonium; mono-, di-, tri- or tetra-C1-C4alkylammoniun; mono-, di- or tri-C1-C4hydroxyalkylammonium; or ammonium di- or tri-substitue by a mixture of C1-C4 alkyl and C1-C4hydroxyalkyl groups, for whitening paper coating compositions.

Abstract: A resin composition useful in the fabrication of circuit boards comprises (i) 1˜15 W % of bismaleimide modified by barbituric acid (BTA) and its derivatives; and (ii) 20˜50 wt % of polyphenylene ether (PPE) chain-broken in a phenol resin; wherein the phenol resin is terpene phenol resin or dicyclopentadiene phenol resin. Other additives, such as curing agent, catalyst or inorganic particle additive can be added as well, based on requirements. According to the invention, terpene novolac resin and initiator (peroxide) are added in polyphenylene ether so that molecules are rearranged to form a PPE resin having lower molecular weight and higher crosslinking density. Furthermore, BMI/epoxy resin/PPE are combined in different weight percentages. Semi-interpenetrating polymer network structures are thus formed. Consequently, Tg and resistances both to heat and solvent of the resin are increased.

Abstract: A coating composition comprising a phenolic resin, an alkoxy silane, and an acid. The coating composition of the present invention promotes adhesion between a multiple layer coating composition and a substrate and between the respective layers of the multiple layer coating composition.

Abstract: A method for microencapsulating red phosphorus in polymerized urea resorcinol formaldehyde resin is disclosed. The method entails (i) preparing an aqueous mixture containing urea, resorcinol and formaldehyde, (ii) adding hexamethylene tetramine and optionally water to the mixture to yield a stabilized mixture (iii) dispersing red phosphorus in the to the stabilized mixture (iv) adding acid to the reaction mixture, and (v) collecting the resulting encapsulated red phosphorus. The product is suitable as flame retarding agent in molding compositions.

Abstract: A printing ink composition comprising: a vegetable oil; and a rosin-modified phenol resin having a weight average molecular weight of at least 30,000, the rosin-modified phenol resin being dissolved in the vegetable oil, wherein the printing ink composition has a content of a volatile organic solvent of not more than 3% by weight.

Abstract: A phenol-formaldehyde resole resin for use as a binder for glass fibers is acidified with sulfamic acid to a pH of 3 or less after base-catalyzed resinification. An increase in actual solids observed compared with neutralized resin, reflecting a desired improvement in efficiency.

Abstract: A phenolic molding composition containing 40 to 100 parts by weight of inorganic fiber, 30 to 90 parts by weight of natural silica powder with a mean particle size of from 20 to 150 &mgr;m, and 1 to 15 parts by weight of a rubber component, as main components, in 100 parts by weight of resol-based phenolic resin. Preferably, the inorganic fiber contains 50% or more by weight of glass fiber. Further preferably, the natural silica powder is shaped like pulverized powder. A pulley is molded of a phenolic molding composition defined above.

Abstract: The presently disclosed invention relates to a phenolic binder comprising a premix of a urea modified phenol-formaldehyde resole resin, a curing agent, and an additive selected from the group consisting of ammonium lignosulfonate, melamine and a melamine derivative. A method for reducing gaseous emissions in the manufacture of fibrous insulation materials is also disclosed.

Abstract: A flame-retardant polyacetal resin composition comprising 60 to 90% by weight of a polyacetal resin, 1 to 30% by weight of red phosphorus, 1 to 40% by weight of at least one resin selected from phenol resins and polycarbonate resins, and 0.1 to 5% by weight of a metal salt of a fatty acid. The polyacetal resin composition of the present invention is provided with flame retardancy while maintaining the excellent innate properties of polyacetal resins, so that it can be applied to the fields where the use of polyacetal resins has been restricted.

Abstract: The present invention is directed to compositions and a process leading to colorless or light colored aqueous phicinol-formaldelhyde resoles. Unlike previous technologies, these compositions lead to clear storage stable fast curing, high molecular weight resins. These materials are also capable of producing composite wood panels with superior water absorption and thickness swell test results when soaked in water. The invention essentially consists of an aqueous copolymer of phenol, formaldehyde, and a phenolic carboxylate (e.g. salicylic acid). Methylol phenols are formed under alkaline conditions in the presence of metal chelating agents. These are then condensed into a polymer under alkaline, neutral or acidic conditions. The finished aqueous polymer solution is then acidified to the desired pH using a benzoic acid or a phelnol-carboxylic acid.

Abstract: The invention relates to formulations and methods of manufacturing spray-dried phenol-formaldehyde resin that contain highly reactive phenolic compounds that include resorcinol, alkyl resorcinols, meta-amino phenol or/and phloroglucinol. The powder resin contains 0.02 to 0.09 moles of the free (unreacted) highly reactive phenolic compound per 100 parts of the solids of the dried phenol-formaldehyde resin. The powder resin composition has fast curing property and desirable shelf life for manufacturing wood composite products.

Abstract: An ink jet ink composition comprising from about 0.5% to about 30% by weight of a pigment, a carrier and a dispersant, the dispersant comprising an anionic derivative of an ethoxylated alkylphenol-formaldehyde resin, the ratio of dispersant:pigment being from about 0.1:1 to about 5:1.

Abstract: A fire retardant thermoplastic polyester comprising a phosphorus containing additive and a high charring polymer containing benzene rings in its main polymer backbone and that has a softening point of no less than about 120° C. exhibits improved fire resistance and no plate out of fire retardant additive during aging.

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: An ink jet printing method, comprising the steps of: A) providing an ink jet printer that is responsive to digital data signals; B) loading the printer with ink jet recording elements; C) loading the printer with an ink jet ink composition comprising from about 0.5% to about 30% by weight of a pigment, a carrier and a dispersant, the dispersant comprising an anionic derivative of an ethoxylated alkylphenol-formaldehyde resin, the ratio of dispersant:pigment being from about 0.1:1 to about 5:1; and D) printing on the ink jet recording element using the ink jet ink in response to the digital data signals.

Abstract: Stable emulsions for use in the field of adhesives have been prepared using a non lignin, nonionic surfactant in phenol-aldehyde/wax emulsions. The adhesives have utility for binding wood particles into a unitary mass such as used in the strandboard, chipboard, particles board, plywood, laminated veneer lumber and high and medium density fiberboard industries and exhibit storage stability.

Abstract: A combination of a semi-soluble methacrylic polymer and a sulfonated naphthalene condensation product, optionally with a semi-soluble or insoluble ethyl methacrylate polymer of high molecular weight, provides improved resistance to staining by acid colorants of fibrous polyamide substrate.

Abstract: This invention relates to a polyester based coating composition for anti-stain PCM outside panel and more particularly, to the polyester based coating composition for anti-stain PCM outside panel having the excellent combination of physical properties such as surface compactness, anti-contamination effect, acid resistance and self-cleaning effect, wherein the polyester based coating composition comprises: a) hydroxy unsaturated polyester resin and a melamine curing agent as main ingredients, b) sulfonic acid blocked with a secondary amine or epoxy resin, c) sulfonic acid blocked with a tertiary amine, d) an isocyanate compound blocked with malonate, e) a tin based curing catalyst, f) polyalkyl silicate, and g) an alkoxy compound; further, the polyester based coating composition for anti-stain PCM outside panel can demonstrate excellent properties of a film of paint such as appearance and workability even without the addition of any defoaming agent and leveling agent by adjusting the compatibility of both hyd

Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.

Abstract: A primer or coating composition that includes (A) an aqueous dispersion of a phenolic resin that includes water and a reaction product of a phenolic resin precursor, a modifying agent and, optionally, a multi-hydroxy phenolic compound wherein the modifying agent includes at least one functional moiety that enables the modifying agent to react with the phenolic resin precursor and at least one ionic moiety, and (B) a flexibilizer. According to one embodiment the modifying agent is an aromatic compound. According to another embodiment the ionic moiety of the modifying agent is sulfate, sulfonate, sulfinate, sulfenate or oxysulfonate and the dispersed phenolic resin reaction product has a carbon/sulfur atom ratio of 20:1 to 200:1.

Abstract: Tall oil pitch may be reacted with a phenol-containing organic compound and formaldehyde or reactive equivalent thereof to prepare a resin. The reactants may further include polyhydric organic compound, &agr;,&bgr;-unsaturated carboxyl compound or ester thereof, and hydroxyl-containing non-phenolic organic compound. The resin may be formulated with a colorant to provide an ink for lithographic, gravure or letterpress printing.

Abstract: A sizing composition which is a phenol-formaldehyde resin substantially free of urea or of a urea derivative and which has reduced emissions of isocyanates upon heating. Insulation products based on mineral wool, especially glass wool or rock wool, which are suitable for mass-produced thermal appliances and contain the sizing composition have reduced organic emissions during manufacturing and when used in thermal appliances.

Abstract: Disclosed is a taphole plugging composition for metal melting apparatus, the composition comprising (a) a refractory aggregate having a maximum particle size of 5 mm or less, (b) graphite and silicon nitride each having a maximum particle size of 0.2 mm or less, (c) a refractory clay, (d) a compatibilized binder mixture comprising a phenolic resin, a ketone compound and a pitch, and (e) an organic fine fiber.

Abstract: The presently disclosed invention relates to a phenolic binder comprising a premix of a urea modified phenol-formaldehyde resole resin, a curing agent, and an additive selected from the group consisting of ammonium lignosulfonate, melamine and a melamine derivative. A method for reducing gaseous emissions in the manufacture of fibrous insulation materials is also disclosed.

Abstract: A pultrusion process employing a resole-resorcinol resin system, having a much improved pot life and much lower formaldehyde odor over similar existing systems where the resole contains up to 3.5%, preferably 3%, most preferably not more than about 1.5% free formaldehyde.

Abstract: The invention relates to a printing ink which consists of pigments, an alkyd resin binder modified with fatty acids having an iodine number from 120 to 280 (g of I2/100 g), a phenolic resin-modified rosin binder and, if appropriate, further binders and further conventional constituents, such as lubricants, solvents, thickeners and thixotropic agents. The alkyd resin binder and the phenolic resin-modified rosin binder are present in proportions from 10 to 40% by weight and 60 to 90% by weight respectively, their sum giving 100% by weight. The alkyd resin has an acid number of Less than 11 and a hydroxyl number from 40 to 260 and has been prepared by reacting a) an unsaturated fatty acid having 6 to 20 carbon atoms or a mixture of such acids or their triglycerides with b) a polyol and c) a dicarboxylic acid.

Abstract: The invention relates to a pigment preparation comprising an organic pigment and 0.2 to 20% by weight, based on the total weight of the pigment preparation, of an ammonium polyphosphate or of an organophosphorus compound.

Abstract: Coating agent for producing an electric insulating coating on an electro steel sheet with good punching quality, weldability, annealing stability and high insulation resistance. Said agent comprises a metal organic and an organic film-forming agent and, optionally, chemically inert inorganic pigments and/or filler and other common additives such as antifoaming agents, leveling agents, catalyzers and the like.

Abstract: A process for forming a planarization film on a substrate that does not smoke or fume on heating includes applying a polymeric solution including a novolac resin having a weight average molecular weight between about 1000 and 3000 amu, which has been fractionated to remove molecules with molecular weight below about 350 amu, a surfactant selected from a group consisting of a non-fluorinated hydrocarbon, a fluorinated hydrocarbon and combinations thereof, and an optional organic solvent to a substrate, followed by heating the substrate.

Abstract: An aqueous phenol/formaldehyde resole resin is disclosed having improved speciation. An aqueous extended phenol/formaldehyde and polycarboxylic acid co-binder and low emissions process for making the same are also disclosed. Glass fiber products may be prepared using the co-binder.

Abstract: An adhesive composition based on resorcinol novolac or resorcinol-phenolic novolac contains 35-75% by weight of novolac, less than 25% by weight of water, and 10-40% by weight of an aliphatic divalent, trivalent alcohol. The adhesive composition may also contain up to 20% by weight of filter, based on the amount of novolac, water and alcohol. In a method for preparing the adhesive composition based on resorcinol novolac or resorcinol-phenolic novolac, the novolac is produced by conventional condensation, whereupon an aliphatic divalent, trivalent or tetravalent alcohol is added and water in the novolac is distilled off, resulting in an adhesive composition as defined above. Alternatively, the amount of water can be reduced in the condensation of the novolac to be replaced with an aliphatic divalent, trivalent or tetravalent alcohol.

Abstract: An aqueous phenolic resin dispersion that includes an aqueous continuous phase and, dispersed within the aqueous phase, the reaction product of a phenolic resin precursor and a modifying agent wherein the modifying agent includes at least one ionic group and at least one functional moiety that enables the modifying agent to undergo condensation with the phenolic resin precursor. The resulting dispersed phenolic resin reaction product includes at least one phenolic ring to which is bound the ionic group from the modifying agent. The pendant ionic group is a sulfate, sulfonate, sulfinate, sulfenate or oxysulfonate and the reaction-enabling moiety preferably is a hydroxy or hydroxyalkyl.

Abstract: A process of manufacture of phenolic resins using calcium catalysis not comprising any filtration stage. This result is obtained by holding back the precipitation of the calcium species by the combined use of a chelatant/sequestrant and of a dispersing anionic polymer. Resins which are stable in storage and with excellent water tolerance.

Abstract: The present invention relates to a glass fiber binding composition having an effective binding amount of a furan resin, an effective emulsifying amount of an emulsifier agent, and sufficient amount of water to result in a binding composition having from 0.5 to 80% N.V. The invention further pertains to a process of binding glass fibers at junctions of the fibers comprising the steps of providing glass fibers, applying an effect binding amount of an emulsified glass fiber binding composition to the junctions of the glass fibers, and curing the binder at the junctions of the glass fibers. Finally, the invention also discloses a glass fiber composition comprising a plurality of glass fibers having a plurality of junctions where two or more fibers meet, and an effective binding amount of an emulsified glass fiber binding composition applied to a portion of the junctions of the glass fibers.

Abstract: A binder composition of a phenolic novolac resin and a (lower) alkoxylated triazine-formaldehyde resin curing agent is disclosed. The triazine resins have sufficient carbon atoms in the alkoxy groups so as to provide a curing agent having a water solubility of less than 15%. The binder cures at high temperatures so as to provide improved flow and prolonged workability to the composition. The compositions are useful in refractory applications having a need for high temperature curing agents such as for maintenance and repair within refractory vessels by gunning/spraying, manufacture of electrodes by the Soderberg method, and for use in blast furnace tap holes.

Abstract: Particulate refractory aggregate containing elutable alkali is treated with a particulate active clay having a particle size of less than 0.5 mm in order to reduce the level of the elutable alkali. Sand recovered from spent foundry moulds and cores produced from alkaline binders can be treated to reduce its elutable alkali content and then recycled for further foundry use.

Abstract: A friction material for a synchronizer ring which exhibits good heat resistance, wear resistance and scorching resistance properties has 30 to 70% by weight of a carbon material, 10 to 40% by weight of a thermosetting resin, 5 to 30% by weight of metal fibers or metal particles and 5 to 40% by weight of inorganic fibers or inorganic particles, and having a porosity of 10 to 50%. The carbon is porous graphite particles of a size distribution in which not less than 50% of the entire number of said graphite particles have a particle diameter from 44 to 250 .mu.m. The thermosetting resin is a novolac type phenol resin, epoxy modified phenol resin, melamine modified phenol resin, cashew modified phenol resin, hydrocarbon resin modified phenol resin or cresol modified phenol resin.

Abstract: The invention relates to a method for manufacturing a product on a basis of mineral wool, including the steps of: i) preparing a phenol-formaldehyde resin, ammonia and a sugar preparation containing aqueous preparation; ii) applying the preparation to the mineral wool; and iii) curing the mineral wool with forming of the product, and to a kit for preparing the mineral wool product, including a container holding the resin preparation and a container holding the sugar preparation.

Abstract: Disclosed is a stabilized phenolic resin melamine dispersion comprising a liquid alkaline resole resin composition and solid melamine crystal dispersed throughout the resin composition. The liquid alkaline resole resin composition comprises the reaction product of combining formaldehyde and phenol at a formaldehyde to phenol mole ratio of about 0.5:1 to about 3.5:1 in the presence of a basic catalyst. The melamine crystal to phenol mole ratio ranges from about 0.01:1 to about 1:1. Moreover, the composition has a free formaldehyde content of at most about 0.5 weight percent. A method for making this dispersion is also disclosed.

Abstract: An electrodepositable coating composition is provided comprising (a) an active hydrogen-containing, cationic salt group-containing resin electrodepositable on a cathode; (b) a curing agent for transurethanation, transamidation or transesterification curing like at least a partially capped polyisocyanate curing agent; and (c) a catalytic mixture of bismuth and an amino acid or amino acid precursor. Optionally, an auxiliary acid may be present to increase the effectiveness of the amino acid in the mixture with bismuth.

Abstract: Processes for the preparation of polyphenol polymers useful as surface coatings wherein the process is carried out in the absence of organic solvents, and the polyphenol polymers are the reaction products of a phenolic polymer or copolymer, an amine, and an aldehyde, ketone, or mixture thereof; and the aqueous solutions resulting therefrom.

Abstract: A coated sand composition for light-alloy casting includes refractory particles blended with phenol resin, bromide and adsorbent which adsorbs decomposition product gas from the bromide.

Abstract: Broadly, the present invention relates to furan no-bake foundry binders where bisphenol A tar (BPAT) is used to replace a portion of the furfuryl alcohol and any conventional filler optionally included in for binder formulation. Reduction in the amount of furfuryl alcohol in the foundry binder formulation may lead to a reduction in the cost and an improvement in early strength of these formulations. Accordingly, in a furan no-bake foundry binder of a resin derived from a major proportion of furfuryl alcohol and optionally fillers, the improvement which comprises at least a fraction of said furfuryl alcohol being bisphenol A tar. Bisphenol A tar also can replace at least a fraction of any filler included in the binder formulation.

Abstract: An adhesive composition based on resorcinol novolac or resorcinol-phenolic novolac consisting essentially of 35-75% by weight of novolac, less than 25% by weight of water, and 10-40% by weight of an aliphatic divalent, trivalent or tetravalent alcohol. The adhesive composition may also contain up to 20% by weight of filler, based on the amount of novolac, water and alcohol. In a method for preparing the adhesive composition based on resorcinol novolac or resorcinol-phenolic novolac, the novolac is produced by conventional condensation, whereupon an aliphatic divalent, trivalent or tetravalent alcohol is added and water in the novolac is distilled off, resulting in an adhesive composition as defined above. Alternatively, the amount of water can be reduced in the condensation of the novolac to be replaced with an aliphatic divalent, trivalant or tetravalent alcohol.

Abstract: A phenol resin molding compound which comprises phenol resin, a curing agent for the phenol resin, hydrogenated NBR, chopped strands of glass fibers and powdery glass fibers having a length of about 10 to about 200 .mu.m has a considerably improved elongation and an elevated safely factor from cracking without any substantial lowering of the modulus of tensile elasticity.

Abstract: The invention is directed to purification of phenolic resins and to a process for preparing an organic photoresist coating composition. The process comprises reacting one or more phenols to form a crude phenolic resin. The crude phenolic resin formed is then separated from its reaction mixture and dissolved in an aqueous insoluble organic solvent in an organic solvent that is a solvent for the photoresist coating composition. The solution so formed is then mixed with an aqueous phase to extract water soluble impurities from the resin solution into the aqueous phase. Finally, the purified resin solution is further diluted with additional photoresist solvent.

Abstract: A guanidine-modified phenol-formaldehyde resole resin by reacting formaldehyde and phenol at a formaldehyde to phenol mole ratio above about 1.5:1 in the presence of an effective amount of an alkaline catalyst and in the presence of a catalytic amount of a guanidine salt. The resin is suitable for use in adhesives for high moisture content substrates.

Abstract: This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.