CA2407291C - Binder mixture and its use - Google Patents

Binder mixture and its use Download PDF

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Publication number
CA2407291C
CA2407291C CA2407291A CA2407291A CA2407291C CA 2407291 C CA2407291 C CA 2407291C CA 2407291 A CA2407291 A CA 2407291A CA 2407291 A CA2407291 A CA 2407291A CA 2407291 C CA2407291 C CA 2407291C
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Canada
Prior art keywords
binder
thermoreactive
powder coating
binder mixture
coating material
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA2407291A
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French (fr)
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CA2407291A1 (en
Inventor
Franz-Josef Muller
Vito Arbia
Bernd Wellhaus
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Hexion GmbH
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Hexion Speciality Chemicals GmbH
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Publication of CA2407291A1 publication Critical patent/CA2407291A1/en
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Publication of CA2407291C publication Critical patent/CA2407291C/en
Anticipated expiration legal-status Critical
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Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/04Condensation polymers of aldehydes or ketones with phenols only
    • C08L61/06Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J161/00Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
    • C09J161/04Condensation polymers of aldehydes or ketones with phenols only
    • C09J161/06Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Paints Or Removers (AREA)
  • Mold Materials And Core Materials (AREA)
  • Paper (AREA)
  • Epoxy Resins (AREA)
  • Braking Arrangements (AREA)
  • Reinforced Plastic Materials (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Dental Preparations (AREA)

Abstract

The invention relates to a binder mixture based on a pulverulent mix with non-thermoreactive phenolic resin and one or more thermoreactive condensation products, from the group consisting of phenolic resins, amino resins and epoxy resins, and a powder coating material or recycled powder coating material. The mixture can be used as a binder for textile nonwovens, moulding compounds, refractory materials, abrasive materials and friction materials, and also in the foundry industry.

Description

Binder mixture and its use The invention relates to binder mixtures based on a pulverulent mix of a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic, amino and epoxy resins. Binders of this kind are known from EP-B 0 254 807. They are used primarily for producing textile nonwovens, where they allow the production of high-grade products which do not disseminate any disruptive amine odour even at relatively high temperature and humidity levels.

One disadvantage of these binder mixtures is that their reactivity is not up to the requirements of a high-speed mass production operation, with the consequence that it is necessary either to use additional accelerators or to prolong the cycle times when producing corresponding mouldings. This is so in particular when the thermoreactive component used comprises the otherwise highly advantageous condensation products of bisphenols and formaldehyde.

It is therefore an object of the invention to provide binder mixtures which, just like the binder mixtures comprising a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic, amino and epoxy resins, are suitable for producing high-grade textile nonwovens which do not disseminate any disruptive odour even at relatively high temperature and humidity levels but whose reactivity is much greater than that of the aforementioned binders and which therefore permit short cycle times on curing even without accelerators.
This object is achieved by a binder mixture based on a pulverulent mix of a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic - la -resins, amino resins and epoxy resins, characterized in that it further comprises powder coating material. The binders are preferably used for producing textile nonwovens and also as binders for moulding compounds, refractory materials abrasives, friction linings, and in the foundry sector, It has been found that the reactivity of binder mixtures comprising a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic, amino and epoxy resins is substantially increased if powder coating material is added as a further binder component to the binder mixture.
For example, the B-stage time (in accordance with DIN 16916-02-C2, measured at 150 C) of a mixture of equal parts by weight of a phenol novolac and a resol based on bisphenol A (base binder) is 6 minutes-If this base binder is blended, for example, with varying amounts of a powder coating material based on 70% of reactive coating powder based on epoxy resins and 30% on reactive coating powder based on polyester resins, the binder mixtures obtained have the following B-stage times:

Base binder: Powder coating mixture ratio B-stage time 90:10 3 min., 30 s 80:20 2 min, 05 s 70:30 2 min, 05 s 60:40 3 min, 10 s 50:50 5 min, 30 s it has further been found that the strengths of textile nonwovens produced using these mixtures, as compared with those produced using base binder alone, are substantially increased. Moreover, even after storage at relatively high temperature and high humidity, no disruptive production of odours is perceived.

Non-thermoreactive phenolic resins are phenolic resins condensed in an acidic medium, with the general formula . 2 -friction linings, and in the foundry sector, as claimed in Claims 8 to 13.

It has been found that the reactivity of binder mixtures comprising a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic, amino and epoxy resins is substantially increased if powder coating material is added as a further binder component to the binder mixture.

For example, the B-stage time (in accordance with DIN 16916-02-C2, measured at 150 C) of a mixture of equal parts by weight of a phenol novolac and a resol based on bisphenol A (base binder) is 6 minutes.
if this base binder is blended, for example, with varying amounts of a powder coating material based on 70% of reactive coating powder based on epoxy resins and 30% on reactive coating powder based on polyester resins, the binder mixtures obtained have the following B-stage times:

Base binder: Powder coating mixture ratio B-stage time 90:10 3 min, 30 s 80:20 2 min, 05 s 70:30 2 min, 05 s 60:40 3 min, 10 s 50:50 5 min, 30 s It has further been found that the strengths of textile nonwovens produced using these mixtures, as compared with those produced using base binder alone, are substantially increased. Moreover, even after storage at relatively high temperature and high humidity, no disruptive production of odours is perceived.
Non-thermoreactive phenolic resins are phenolic resins condensed in an acidic medium, with the general formula H H on R

CHZ CSz 1-ld Ito where R and R' are identical or different and denote hydrogen or an alkyl chain having from 1 to 9 carbon atoms.
Starting products are phenol, cresols, xylenols or relatively long-chain alkylphenols, which are condensed in an acidic medium with formaldehyde or a compound which produces formaldehyde under condensation .10 conditions, the phenol/formaldehyde ratio being situated within a range from 1:0.6 to 1:0.9.

The thermoreactive resins, which may be used individually or in combination, may hail from three different groups: the phenolic resins, the amino resins, and the epoxy resins. The non-thermoreactive phenolic resin is employed together with one or more of these thermoreactive condensation products in a weight ratio of from 30:70 to 90:10.
Thermoreactive phenolic resins (resols) are reaction products from the alkaline condensation of a phenolic compound with formaldehyde or with a compound which produces formaldehyde under condensation conditions. As phenolic compounds it is possible to use phenols or mixtures of said classes of compound, including both mononuclear and polynuclear phenols.

Examples of such compounds are phenol itself and also its alkyl-substituted homologues, such as o-, m- or p-cresol, xylenes or more highly polyalkylated phenols, and also halogen-substituted phenols such as chloro-phenol or bromophenol and polyhydric phenols such as resorcinol or pyrocatechol, and also polynuclear phenols such as naphthols or bisphenols. The preferred phenolic compounds are bisphenol A and bisphenol F. The phenolic compounds and formaldehyde are preferably reacted in a molar ratio of from 1:1.0 to 1:4.0 with one another.

The phenolic resins for use in accordance with the invention, the thermoreactive and the non-thermo-reactive resins, ought together to have a free phenol content of less than 1%, and must be present in pulverulent form.

Thermoreactive amino resins which can be used include not only melamine--formaldehyde but also benzoguanamine-formaldehyde or urea-formaldehyde condensation products, and also the corresponding cocondensates.
They can be used alone, but are preferably used in a mixture (in any proportion) with the resols, as a thermoreactive binder component.

As epoxy resins it is possible to use any commercial solid epoxy resins, preferably epoxy resins based on bisphenol A and bisphenol F, and also epoxidized novrolacs.

All of the resins used are employed dry and in powder form with particle sizes in the range between 1 and 300 gm, preferably between 10 and 60 gm.
The powder coating materials used in the binders of the invention are pulverulent reactive coating materials which comprise as their binders thermosetting resins such as epoxy resins or polyester resins, but also polyurethane resins or acrylic resins as well, which can be used in the form of one single type or as a mixture. They may be colourless or pigmented, with separation according to shade generally being unnecessary- The preferred powder coating materials are recycled powder coating materials. Such materials are obtained as what is known as overspray from paint booths, as off-specification batches in the production of powder coating materials, as filter dusts during the production and processing of powder coating materials, or as residues from the grinding of the powders. The particle sizes of the recycled powder coating materials employed, at from 1 to 300 m, preferably between 10 and 60 gm, are situated in approximately the same range as those of the resins. Where recycled powder coating materials are used whose particle size is too small for the desired application, larger particle sizes can be obtained through agglomeration of individual particles.

The recycled powder coating materials used in the binder mixtures of the invention are as yet uncrosslinked. They contain reactive groups such as carboxyl, epoxy, hydroxyl, amino, amide or capped isocyanate groups which on heating are able to react with one another and with the reactive groups of the non-thermoreactive phenolic resins and of the thermoreactive condensation products from the group consisting of phenolic, amino, and epoxy resins.

The use of these powder coating materials and/or recycled powder coating materials together with phenolic resins as binders for fibre nonwovens and fibre nonwoven mouldings is known from WO 95/30034 and WO 96/16218_ Both of these patent applications provide a possibility for utilizing the powder coating residues which are produced as "waste".

In accordance with the present invention, powder coating materials and/or recycled powder coating materials serve to improve further the already good profile of properties of high-grade binder mixtures comprising phenolic resin as one binder component. This opens up the possibility of using the binder mixtures of the invention not only as binders in the production of textile nonwovens but instead, quite generally, in all traditional fields of application where solid phenolic resin binders are employed. In particular, therefore, the binder mixtures of the invention find application as binders for moulding compounds, refractory materials, abrasive materials, friction linings, and foundry sands in the foundry industry. It is a further advantage of these binder mixtures that their use in the respective fields of application can be implemented using the techniques which are customary and known for these applications.

The binder mixtures of the invention are composed of a mix of a non-thermoreactive phenolic resin and one or more thermoreactive condensation products from the group consisting of phenolic resins, amino resins and epoxy resins, and also a powder coating material. The non-thermoreactive phenolic resin is in combination with the thermoreactive condensation product in a weight ratio of from 30:70 to 90:10. This mix is combined with powder coating material in a weight ratio of from 90:10 to 50:50, so that the binder mixture has the following composition:
from 90 to 50 parts by weight of a mixture of a non-thermoreactive phenolic resin with a thermoreactive condensation product in a weight ratio of from 30:70 to 90:10 and from 10 to 50 parts by weight of a powder resin.

The binder mixture is prepared by mixing the individual pulverulent components with one another. It is unimportant here whether individual components, of whatever type, are premixed with one another beforehand or whether all of the constituents are combined simultaneously and mixed with one another. At room temperature, the storage life of the mixture is practically limitless.
The binder mixture is generally cured without the addition of a further curing agent or accelerator, by heating at a temperature in the range from 100 to 220 C, preferably from 140 to 180 C.

Claims (11)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A binder mixture based on a pulverulent mix of a non-thermoreactive phenolic resin and one or more thermoreactive condensation products each consisting of a phenolic resin or an amino resin, wherein the binder mixture further comprises a powder coating material, wherein the non-thermoreactive phenolic resin and the thermoreactive condensation product are in a weight ratio of from 30:70 to 90:10, and wherein the mix of non-thermoreactive phenolic resin with the thermoreactive condensation product and the powder coating material are in a weight ratio of from 90:10 to 50:50.
2. A binder mixture according to claim 1, wherein the powder coating material is a recycled powder coating material.
3. A binder mixture according to claim 1 or 2, wherein the powder coating material is a reactive coating powder based on epoxy resins and/or polyester resins.
4. A binder mixture according to claim 3, wherein the powder coating material further comprises reactive coating powders based on polyurethane and/or acrylic resins.
5. A binder mixture according to any one of claims 1 to 4, wherein the thermoreactive phenolic resin is a reaction product of an alkaline condensation of a bisphenol with formaldehyde.
6. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder in the production of textile nonwovens.
7. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder for moulding compounds.
8. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder for refractory materials.
9. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder for abrasive materials.
10. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder for friction linings.
11. Use of the binder mixture as defined in any one of claims 1 to 5 as a binder in the foundry industry.
CA2407291A 2001-03-14 2002-03-05 Binder mixture and its use Expired - Fee Related CA2407291C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10112620A DE10112620A1 (en) 2001-03-14 2001-03-14 Binder mixtures and their use
DE10112620.4 2001-03-14
PCT/EP2002/002389 WO2002072698A1 (en) 2001-03-14 2002-03-05 Binding agent mixture and the use thereof

Publications (2)

Publication Number Publication Date
CA2407291A1 CA2407291A1 (en) 2002-10-22
CA2407291C true CA2407291C (en) 2011-09-20

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CA2407291A Expired - Fee Related CA2407291C (en) 2001-03-14 2002-03-05 Binder mixture and its use

Country Status (15)

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US (1) US20040029999A1 (en)
EP (1) EP1373407B1 (en)
JP (1) JP2004538341A (en)
KR (1) KR100898841B1 (en)
AT (1) ATE340218T1 (en)
BR (1) BR0204478B1 (en)
CA (1) CA2407291C (en)
CZ (1) CZ297776B6 (en)
DE (2) DE10112620A1 (en)
ES (1) ES2269734T3 (en)
MA (1) MA26307A1 (en)
MX (1) MXPA02010729A (en)
PL (1) PL206894B1 (en)
WO (1) WO2002072698A1 (en)
ZA (1) ZA200208538B (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7323534B2 (en) 2004-10-15 2008-01-29 Hexion Specialty Chemicals, Inc. Phenol-formaldehyde resole resins, method of manufacture, methods of use, and articles formed therefrom
US7989575B2 (en) * 2004-10-15 2011-08-02 Momentive Specialty Chemicals Inc. Phenol-formaldehyde resole resins, method of manufacture, methods of use, and articles formed therefrom
KR100732205B1 (en) * 2005-06-03 2007-06-27 정인수 Method for making adhesives recycling recovered powder coating paint and powder coating paint waste and product thereof
JP4723390B2 (en) * 2006-01-26 2011-07-13 中央発條株式会社 High durability spring and its coating method
WO2011010559A1 (en) * 2009-07-23 2011-01-27 旭有機材工業株式会社 Phenol resin composition for shell molding, resin-coated sand for shell molding, and shell molding die obtained using the same
JP2016190968A (en) * 2015-03-31 2016-11-10 住友ベークライト株式会社 Resol type phenolic resin for friction material and method for producing the same, adhesive for friction material and wet type friction plate

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1200039A (en) * 1981-12-26 1986-01-28 Hiroaki Koyama Resin composition containing granular or powdery phenol-aldehyde resin
DE3625443A1 (en) * 1986-07-28 1988-02-11 Ruetgerswerke Ag METHOD FOR PRODUCING TEXTILE FABRICS
DE4317470C2 (en) * 1993-05-26 2001-06-07 Henkel Kgaa Thermally crosslinkable heat seal adhesive and its use
JPH09512575A (en) * 1994-05-03 1997-12-16 テオデユール・ナームローゼ・フエンノートスハプ Binder composition for producing non-woven material
DE4441765A1 (en) * 1994-11-24 1996-05-30 Teodur Nv Binder composition for the production of nonwoven fabrics and method for producing nonwoven molded parts
US6604567B1 (en) * 2002-02-14 2003-08-12 Ashland Inc. Free radically cured cold-box binders containing an alkyl silicate

Also Published As

Publication number Publication date
KR100898841B1 (en) 2009-05-21
EP1373407B1 (en) 2006-09-20
EP1373407A1 (en) 2004-01-02
MXPA02010729A (en) 2003-03-10
BR0204478B1 (en) 2011-05-03
CA2407291A1 (en) 2002-10-22
DE10112620A1 (en) 2002-09-19
ZA200208538B (en) 2003-08-06
PL206894B1 (en) 2010-10-29
ES2269734T3 (en) 2007-04-01
JP2004538341A (en) 2004-12-24
CZ20023704A3 (en) 2003-02-12
BR0204478A (en) 2003-06-03
DE50208203D1 (en) 2006-11-02
MA26307A1 (en) 2004-10-01
US20040029999A1 (en) 2004-02-12
PL357381A1 (en) 2004-07-26
WO2002072698A1 (en) 2002-09-19
CZ297776B6 (en) 2007-03-28
KR20030007609A (en) 2003-01-23
ATE340218T1 (en) 2006-10-15

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