GB1584800A - Phenol-formaldehyde resol resin binders for heat insulating materials - Google Patents

Phenol-formaldehyde resol resin binders for heat insulating materials Download PDF

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GB1584800A
GB1584800A GB5290977A GB5290977A GB1584800A GB 1584800 A GB1584800 A GB 1584800A GB 5290977 A GB5290977 A GB 5290977A GB 5290977 A GB5290977 A GB 5290977A GB 1584800 A GB1584800 A GB 1584800A
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weight
parts
phenol
binder
temperature
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KIEV KOM STROIINDUSTRII
KIEV KOMBINAT STROIINDUSTRII
TALLIN POLITEKHNI INST
Tallinsky Politekhnichesky Institut
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KIEV KOM STROIINDUSTRII
KIEV KOMBINAT STROIINDUSTRII
TALLIN POLITEKHNI INST
Tallinsky Politekhnichesky Institut
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Priority to GB5290977A priority Critical patent/GB1584800A/en
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/12Condensation polymers of aldehydes or ketones
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G14/00Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00
    • C08G14/02Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00 of aldehydes
    • C08G14/04Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00 of aldehydes with phenols
    • C08G14/06Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00 of aldehydes with phenols and monomers containing hydrogen attached to nitrogen
    • 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
    • C08L61/34Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C08L61/04, C08L61/18 and C08L61/20

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Description

(54) MODIFIED PHENOL-FORMALDEHYDE RESOL RESIN BINDERS FOR HEAT INSULATING MATERIALS (71) We, TALLINSKY POLITEKHNICHESKY INSTITUT, Union of Soviet Socialist Republics, Tallin, ulitsa Ekhitayate tee, 5, and KIEVSKY KOMBINAT STROIINDUSTRII, Union of Soviet Socialist Republics, Kiev ulitsa Stroiindustrii, 13; both Bodies Corporate of the Union of Soviet Socialist Republics, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- The present invention relates to the production of construction materials and, more specifically, to compositions of heat-insulating materials, which may find application for keeping precast concrete elements warm, for insulating walls, roofs, pipelines, tanks and cisterns.
It is an object of the present invention to introduce into the binder a readily available and easily prepared water-proofing additive permitting a reduction in the moisture absorption and an increase in the moisture resistance of the heatinsulating material.
According to one aspect of the invention there is provided a binder which comprises a modified resol phenol-formaldehyde resin which is the reaction product of phenol, formaldehyde, one or more alkylresorcinols, sodium hydroxide, and urea or dicyandiamide, or melamine, in the following proportions by weight: phenol 1 formaldehyde 0.74-4).96 sodium hydroxide 0.03).05 alkylresorcinol(s) 0.075-0.45 urea, or melamine, or dicyandiamide 0.15-0.35 Also according to the invention a heat-insulating material comprises from 85 to 98 parts by weight of mineral wool and from 15 to 2 parts by weight of a binder applied onto said wool, which binder is a modified resol phenol-formaldehyde resin based on phenol, formaldehyde, sodium hydroxide, a waterproofing additive, as well as urea, or dicyandiamide, or melamine, the waterproofing additive being an individual alkylresorcinol with a number of alkyl side chain carbons of from 2 to 8 or a mixture of alkylresorcinols, the ratio between phenol, formaldehyde, sodium hydroxide, alkylresorcinol(s), as well as urea, or dicyandiamide, or melamine, being as follows (parts by weight): phenol I formaldehyde 0.74to0.96 sodium hydroxide 0.03-0.05 alkylresorcinol with a number of alkyl side chain carbons of from 2 to 8, or a mixture of alkylresorcinols 0.075-0.45 urea, or dicyandiamide, or melamine 0.15-0.35 The proposed material can be made in the following preferred manner.
A reactor provided with a mechanical agitator, a thermometer and reflux condenser is charged, at a temperature of 46 to 700 C, with 100 parts by weight of phenol, with 3 to 5 parts by weight of sodium hydroxide (as a 20% by weight aqueous solution), and with 74 to 96 parts by weight of formaldehyde (as a 37 /n by weight aqueous solution).
Polycondensation is conducted with continuous stirring at a temperature of 50 to 600C for 6 to 10 hours. Then, the reactor is charged with 7.5 to 45 parts by weight of a mixture of alkylresorcinols or an individual alkylresorcinol with a number of alkyl side chain carbons of 2 to 8, and polycondensation is continued at a temperature of 50 to 700C for 1.5 to 4 hours. Thereafter, the reactor is charged with 15 to 35 parts by weight of urea, or dicyandiamide, or melamine, and polycondensation is conducted for 0.5 to 2.5 hours at a temperature of 50 to 700 C.
In order to obtain a heat-insulating material, the obtained aqueous solution of the binder, which is a modified resol phenol-formaldehyde resin, is applied onto mineral wool by spraying into a fibre-settling chamber or impregnating the mineral fibre, with subsequent heat treatment of the heat-insulating material. The selection of the ratio between the starting components for obtaining the binder according to the present invention ensures, after three months of storage, a binder viscosity of up to 150 cs and adequate miscibility with water (1:5). Besides, minimum quantities of free phenol (up to 2.0 wt%), formaldehyde (up to 2.5 wit%) and an alkali (up to 0.6 wit%) are achieved. Due to the introduction of the waterproofing additive into the binder composition, namely, alkylresorcinol with a number of alkyl side chain carbons of 2 to 8 or a mixture of alkylresorcinols, moisture does not permeate through the contact surface between the cured binder and the mineral fibre, which are the components of the heat-insulating material.
The adhesion of the heat-insulating material containing the proposed binder is 15% higher than in that with a binder of the same composition but not containing alkylresorcinol; besides, it has a reduced mass water absorption (30 to 40 /n instead of 350 to 400%) and an increased moisture resistance (residual adhesion after 72 hours of storage in a humid atmosphere is 1.5 to 2 times higher).
Besides, the proposed material, as compared to heat-insulating materials manufactured by such well known companies as "Rockwell AB" Sweden, "Alstr6m OY", Finland, "Jungers Verkstads AB", Sweden, containing in the binder composition special organosilicon additives, enables their replacement by simpler ones, such as alkylresorcinol or a mixture of alkylresorcinols. The water absorption of the aforementioned companies' optimum composition heatinsulating materials is from 30 to 45%.
The moisture resistance of the prior art binders included in heat-insulating materials is tabulated below.
Adhesion, kg Sample after 62 hrs of storage in Dry a humid of Binder sample atmosphere initial 1 2 3 4 Modified resol phenol formaldehyde resin on the basis of phenol, form aldehyde, sodium hydro xide, urea, taken in the following ratio (parts by weight): phenol- 100 formaldehyde -- 23.3 sodium hydroxide -- 22.5 urea17.9 6.4 2.2 34.3 Adhesion, kg Sample after 62 hrs of storage in Dry a humid 0% of Binder sample atmosphere initial 2 2 3 4 The same composition as above, the binder also being based on 22.8 parts by weight of a waterproofing additive a mixture of oil shale alkyl resorcinols of the follow ing composition, in parts by weight: resorcinol - 3 5-methylresorcinol -- 45 5-ethyiresorcinol - 10 4,5-dimethylresorcinol - 9 2,5-dimethylresor cinol- 15 higher homologs of alkylresorcinols -- 18 7.3 4.1 56.1 The same composition as above, except that the waterproofing additive is 20 parts by weight of hexylresorcinol 8.3 5.9 71.1 The same composition as above, except that the waterproofing additive is -aminopropylethoxy- silane in an amount of 2 wt% of the result ing resin weight 7.7 4.6 59.7 For a better understanding of the present invention, the following examples of its practical embodiment are given by way of illustration.
Example 1 A reactor provided with a mechanical agitator, a thermometer, and a reflux condenser is charged, at a temperature of 55+3 C with 100 parts by weight of phenol, 233 parts by weight of a 37% aqueous solution of formaldehyde, and 22.5 parts by weight of a 20% aqueous solution of sodium hydroxide. Polycondensation is conducted at the same temperature for 8 hours. Then, the reactor is charged with a waterproofing additive, namely, 22.8 parts by weight of a mixture of alkylresorcinols, and further polycondensation is conducted at. a temperature of 60+3 C for 2.5 hours. The last to be charged into the reactor are 17.9 parts by weight of urea, and the mixture is subjected to polycondensation at a temperature of 65+3 C for 1.5 hours.
In order to obtain a heat-insulating material, an aqueous solution (dilution ratio of 1:5) of the binder obtained above, which is a modified resol phenolformaldehyde resin, is applied onto mineral wool by a known method and is then subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes.
As the mixture of alkylresorcinols use is made of the product of heat treatment of oil shale, which is a mixture of various alkyl derivatives of resorcinol of the following average composition (in parts by weight): resorcinol 3 5-methylresorcinol 45 5-ethylresorcinol 10 4, 5-dimethylresorcinol 9 2,5-dimethylresorcinol 15 higher homologs of alkylresorcinols 18 The resulting binder has a refractive coefficient no=1.465 at a temperature of 20"C.
The obtained heat-insulation material possesses the following properties: adhesion 6.1 kg mass water absorption 37.4% and contains 3.3 parts by weight of the binder Adhesion is determined by measuring the force of pulling a thread from glass fabric filament, impregnated and cured with the binder included in the heat insulating material (cf. R.P. Uchingens and H. Sh. Girzonas, "Determination of Adhesion of Phenol-Formaldehyde Resins to Glass Fibres". Collection of Papers of the Heat Insulation Research Institute, Vilnius, No. 6, 1972).
Example 2 The process is conducted in a manner similar to that described in Example 1, except that the reactor is charged with 200 parts by weight of 37% aqueous solution of formaldehyde and, as the waterproofing additive, 7.5 parts by weight of an alkylresorcinol mixture of the composition described in Example 1.
The resulting binder has a refractive coefficient no=1.467 at a temperature of 20 C.
In order to obtain a heat-insulating material, the binder which is a modified resol phenol-formaldehyde resin, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool by a known method and the obtained heatinsulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 min.
The obtained heat-insulating material possesses the following properties: adhesion 6.8 kg mass water absorption 51.50/, and contains 3.7 parts by weight of the binder.
Example 3 The binder is synthesized as in Example 1, but the reactor is charged with 260 parts by weight of a 37% aqueous solution of formaldehyde and, as the waterproofing additive, 45 parts by weight of an alkylresorcinol mixture of the composition described in Example 1. The resulting binder which is a modified resol phenol-formaldehyde resin has a refractive coefficient no=1.465 at a temperature of 20"C.
In order to obtain a heat-insulating material, the binder, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool by a known method, and the heat-insulating material is subjected to heat treatment at a temperature of 140 to 200"C for 30 minutes.
The heat-insulating material possesses the following properties: adhesion 8.1 kg mass water absorption 38% and contains 2.0 parts by weight of the binder.
Example 4 The binder is synthesized as in Example 1, but the reactor is charged with 20 parts by weight of 4-hexylresorcinol as the waterproofing additive.
The resulting binder which is a modified resol phenol-formaldehyde resin has a refractive cE̲fficTent n,=1.466 at a temperature of 203C.
In order to obtain a heat-insulating material, the resulting binder, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool by a known method, and the obtained heat-insulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 min.
The heat-insulating material possesses the following properties: adhesion 8.3 kg mass water absorption 34% and contains 3.9 parts by weight of the binder.
Example 5 The binder is synthesized as in Example 1, but the reactor is charged with 35 parts by weight of 5-ethylresorcinol as the waterproofing additive.
The resulting binder which is a modified resol phenol-formaldehyde resin has a refractive coefficient no=1.465 at a temperature of 20"C.
In order to obtain a heat-insulating material, the resulting binder, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool by a known method, then the obtained heat-insulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes.
The heat-insulating material possesses the following properties: adhesion 7.8 kg mass water absorption 40% and contains 4.2 parts by weight of the binder.
Example 6 The binder is synthesized as in Example 1, except that 35 parts by weight of urea are taken.
The resulting binder which is a modified resol phenolformaldehyde resin has a refractive coefficient no=1.470 at a temperature of 20"C.
In order to obtain a heat-insulating material, the resulting binder, in the form of an aqueous solution (dilution ratio 1:5) is applied onto mineral wool by a known method, and the obtained heat-insulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 min.
The heat-insulating material possesses the following properties: adhesion 7.3 kg mass water absorption 50 /n and contains 15 parts by weight of the binder.
Example 7 Synthesis is conducted in a manner similar to that described in Example 1, but, instead of urea, the reactor is charged with 25 parts by weight of melamine.
The resulting binder which is a modified resol phenol-formaldehyde resin has a refractive coefficient no=1.469 at a temperature of 20"C.
In order to obtain a heat-insulating material, the resulting binder, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool, and the obtained heat-insulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 min.
The heat insulating material possesses the following properties: adhesion 6.9 kg mass water absorption 42 /n and contains 5.9 parts by weight of the binder.
Example 8 Synthesis is conducted as in Example 1, but, instead of urea, the reactor is charged with 25 parts by weight of dicyandiamide.
The resulting binder which is a modified resol phenol-formaldehyde resin has a refractive coefficient nod=1.468 at a temperature of 20"C.
In order to obtain a heat-insulating material, the resulting binder, in the form of an aqueous solution (dilution ratio of 1:5), is applied onto mineral wool, and the obtained heat-insulating material is subjected to heat treatment atartemperature of 140 to 2000C for 30 minutes.
The heat-insulating material possesses the following properties: adhesion 6.8 kg mass water absorption 39 /n and contains 5.1 parts by weight of the binder.
Example 9 The reactor provided with a mechanical agitator, a thermometer, and a reflux condenser is charged at a temperature of 50+3"C, with 100 parts by weight of phenol, 200 parts by weight of a 37% aqueous solution of formaldehyde, and 15 parts by weight of a 20% aqueous solution of sodium hydroxide. Polycondensation is conducted at the same temperature for 6 hours. Then, the reactor is charged with a waterproofing additive, namely, 7.5 parts by weight of a mixture of alkylresorcinols of the composition as described in Example 1. Polycondensation is conducted at a temperature of 55+3 C for 2.5 hours. The last to be charged into the reactor are 15 parts by weight of urea, and the mixture is subjected to polycondensation at a temperature of 55+3"C for 0.5 hours.
In order to obtain a heat-insulating material, an aqueous solution (dilution ratio of 1:5) of the resulting binder which is a modified resol phenol-formaldehyde resin is applied onto mineral wool by a known method, and the obtained heatinsulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes.
The resulting binder, a modified resol phenol-formaldehyde resin, has a refractive coefficient no=1.466 at a temperature of 20"C.
The obtained heat-insulating material possesses the following properties: adhesion 6.4 kg mass water absorption 50/ and contains 5 parts by weight of the binder.
Example 10 The reactor provided with a mechanical agitator, a thermometer, and a reflux condenser is charged, at a temperature of 65+3 C, with 100 parts by weight of phenol, 260 parts by weight of a 37 /n aqueous solution of formaldehyde, and 25 parts by weight of a 20% aqueous solution of sodium hydroxide.
Polycondensation is conducted at the same temperature for 10 hours. Then, the reactor is charged with a waterproofing additive, i.e. 45 parts by weight of a mixture alkylresorcinols of the composition as described in Example 1.
Polycondensation is conducted at a temperature of 65+3"C for 4 hours. The last to be charged into the reactor are 35 parts by weight of urea and the mixture is subjected to polycondensation at a temperature of 65+3 C for 2.5 hours.
In order to obtain a heat-insulating material, an aqueous solution (dilution ratio of 1:5) of the resulting binder which is a modified resol phenol-formaldehyde resin is applied onto mineral wool by a known method, and the obtained heatinsulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes.
The resulting binder, a modified resol phenol-formaldehyde resin, has a refractive coefficient no=1.469 at a temperature of 20"C.
The obtained heat-insulating material possesses the following properties: adhesion 7.5 kg mass water absorption 45 /n and contains 15 parts by weight of the binder.
WHAT WE CLAIM IS: 1. A heat-insulating material comprising from 85 to 98 parts by weight of mineral wool and from 15 to 2 parts by weight of a binder applied onto said wool, which binder is a modified resol phenol-formaldehyde resin based on phenol, formaldehyde, a waterproofing additive which is an individual alkylresorcinol with a number of alkyl side chain carbons of 2 to 8, or a mixture of alkylresorcinols, sodium hydroxide and urea, or dicyandiamide, or melamine, the ratio between phenol, formaldehyde, sodium hydroxide, alkylresorcinol(s), as well as urea, or dicyandiamide, or melamine, being as follows (parts by weight): phenol formaldehyde 0.74--0.96 sodium hydroxide 0.03-0.05 alkylresorcinol with a number of alkyl side chain carbons of 2 to 8, or a mixture of alkylresorcinols 0.075-0.45 urea, or dicyandiamide, or melamine 0.15-0.35
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (15)

**WARNING** start of CLMS field may overlap end of DESC **. condenser is charged at a temperature of 50+3"C, with 100 parts by weight of phenol, 200 parts by weight of a 37% aqueous solution of formaldehyde, and 15 parts by weight of a 20% aqueous solution of sodium hydroxide. Polycondensation is conducted at the same temperature for 6 hours. Then, the reactor is charged with a waterproofing additive, namely, 7.5 parts by weight of a mixture of alkylresorcinols of the composition as described in Example 1. Polycondensation is conducted at a temperature of 55+3 C for 2.5 hours. The last to be charged into the reactor are 15 parts by weight of urea, and the mixture is subjected to polycondensation at a temperature of 55+3"C for 0.5 hours. In order to obtain a heat-insulating material, an aqueous solution (dilution ratio of 1:5) of the resulting binder which is a modified resol phenol-formaldehyde resin is applied onto mineral wool by a known method, and the obtained heatinsulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes. The resulting binder, a modified resol phenol-formaldehyde resin, has a refractive coefficient no=1.466 at a temperature of 20"C. The obtained heat-insulating material possesses the following properties: adhesion 6.4 kg mass water absorption 50/ and contains 5 parts by weight of the binder. Example 10 The reactor provided with a mechanical agitator, a thermometer, and a reflux condenser is charged, at a temperature of 65+3 C, with 100 parts by weight of phenol, 260 parts by weight of a 37 /n aqueous solution of formaldehyde, and 25 parts by weight of a 20% aqueous solution of sodium hydroxide. Polycondensation is conducted at the same temperature for 10 hours. Then, the reactor is charged with a waterproofing additive, i.e. 45 parts by weight of a mixture alkylresorcinols of the composition as described in Example 1. Polycondensation is conducted at a temperature of 65+3"C for 4 hours. The last to be charged into the reactor are 35 parts by weight of urea and the mixture is subjected to polycondensation at a temperature of 65+3 C for 2.5 hours. In order to obtain a heat-insulating material, an aqueous solution (dilution ratio of 1:5) of the resulting binder which is a modified resol phenol-formaldehyde resin is applied onto mineral wool by a known method, and the obtained heatinsulating material is subjected to heat treatment at a temperature of 140 to 2000C for 30 minutes. The resulting binder, a modified resol phenol-formaldehyde resin, has a refractive coefficient no=1.469 at a temperature of 20"C. The obtained heat-insulating material possesses the following properties: adhesion 7.5 kg mass water absorption 45 /n and contains 15 parts by weight of the binder. WHAT WE CLAIM IS:
1. A heat-insulating material comprising from 85 to 98 parts by weight of mineral wool and from 15 to 2 parts by weight of a binder applied onto said wool, which binder is a modified resol phenol-formaldehyde resin based on phenol, formaldehyde, a waterproofing additive which is an individual alkylresorcinol with a number of alkyl side chain carbons of 2 to 8, or a mixture of alkylresorcinols, sodium hydroxide and urea, or dicyandiamide, or melamine, the ratio between phenol, formaldehyde, sodium hydroxide, alkylresorcinol(s), as well as urea, or dicyandiamide, or melamine, being as follows (parts by weight): phenol formaldehyde 0.74--0.96 sodium hydroxide 0.03-0.05 alkylresorcinol with a number of alkyl side chain carbons of 2 to 8, or a mixture of alkylresorcinols 0.075-0.45 urea, or dicyandiamide, or melamine 0.15-0.35
2. A heat-insulating material substantially as set forth in the preceding claim and as hereinbefore described with reference to the Examples.
3. A binder which comprises a modified resol phenol-formaldehyde resin and is the reaction product of phenol, formaldehyde, one or more alkylresorcinols, sodium hydroxide, and urea or dicyandiamide, or melamine, in the following proportions by weight: phenol 1 formaldehyde 0.74--0.96 sodium hydroxide 0.03-0.05 alkylresorcinol(s) 0.075-0.45 urea, or melamine, or dicyandiamide 0.15-0.35
4. A binder as claimed in Claim 3, wherein the one or more alkylresorcinols is either an individual alkylresorcinol with a number of alkyl side chain carbons of 2 to 8 or a mixture of alkylresorcinols.
5. A method of making a binder which comprises a modified resol phenolformaldehyde resin, comprising effecting condensation reactions between phenol, formaldehyde, sodium hydroxide, one or more alkylresorcinols, and urea, or dicyandiamide, or melamine, in the following proportions by weight: phenol 1 formaldehyde 0.7W0.96 sodium hydroxide 0.03-0.05 alkylresorcinol(s) 0.075-0.45 urea, or dicyandiamide or melamine 0.15-0.35
6. A method as claimed in Claim 5, wherein the one or more alkylresorcinols is either an individual alkylresorcinol with a number of alkyl side chain carbons of 2 to 8 or a mixture of alkylresorcinols.
7. A method as claimed in Claim 5 or 6 including carrying out an initial condensation reaction between phenol, formaldehyde and sodium hydroxide, which reaction is followed by a second condensation reaction between the product of the first condensation reaction and one or more alkylresorcinols, which second condensation reaction is followed by a third condensation reaction between the product of the second condensation reaction and urea, or dicyandiamide, or melamine.
8. A method as claimed in Claim 7, wherein the first condensation reaction is conducted at a temperature in the range 500 to 600C, the second condensation reaction is conducted at a temperature in the range 500 to 700 C, and the third condensation reaction is conducted at a temperature in the range 500 to 700 C.
9. A method as claimed in Claim 7 or 8, wherein the first condensation is conducted for 6 to 10 hours, the second condensation is conducted for 1.5 to 4 hours and the third condensation is conducted for 0.5 to 2.5 hours.
10. A method as claimed in Claim 5 and substantially as herein described with reference to any one of the Examples.
11. A binder made by the method claimed in any of Claims 5 to 10.
12. A method of making a heat-insulating material wherein the binder as claimed in Claim 3, 4 or 11 is mixed with mineral wool in the following proportions by weight: binder 0.15-0.02 mineral wool 0.85-0.98
13. Heat-insulating material made by the method claimed in Claim 12.
14. The heat-insulating material as claimed in Claims 1 or 13 which has an adhesion range from 6.1 to 8.3 kg, determined as hereinbefore described.
15. The heat-insulating material as claimed in Claim 1, 13 or 14 which has a mass water absorption range from 37.4% to 51.5%.
GB5290977A 1977-12-20 1977-12-20 Phenol-formaldehyde resol resin binders for heat insulating materials Expired GB1584800A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2657266A1 (en) * 2012-04-27 2013-10-30 URSA Insulation, S.A. Process for the preparation of a phenol-formaldehyde resin having a low amount of free formaldehyde, a phenol-formaldehyde resin resulting from this process, and the use of this resin as a binder for mineral wool insulation products
EP2865799B1 (en) * 2013-10-25 2018-07-04 URSA Insulation, S.A. Method for the manufacture of mineral wool insulation products having low formaldehyde emissions
WO2019180235A1 (en) 2018-03-23 2019-09-26 Foresa, Industrias Quimicas Del Noroeste, S.A.U. Monocomponent adhesive composition comprising formaldehyde-based resin with a free formal-dehyde content below 0,1 wt%, comprising resorcinol, alkylresorcinol and/or tannin

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2657266A1 (en) * 2012-04-27 2013-10-30 URSA Insulation, S.A. Process for the preparation of a phenol-formaldehyde resin having a low amount of free formaldehyde, a phenol-formaldehyde resin resulting from this process, and the use of this resin as a binder for mineral wool insulation products
WO2013160449A1 (en) * 2012-04-27 2013-10-31 Ursa Insulation S.A. Process for the preparation of a phenol-formaldehyde resin having a low amount of free formaldehyde, a phenol-formaldehyde resin resulting from this process, and the use of this resin as a binder for mineral wool insulation products
EP2841478B1 (en) 2012-04-27 2017-04-05 URSA Insulation, S.A. Process for the preparation of a phenol-formaldehyde resin having a low amount of free formaldehyde, a phenol-formaldehyde resin resulting from this process, and the use of this resin as a binder for mineral wool insulation products
EP2865799B1 (en) * 2013-10-25 2018-07-04 URSA Insulation, S.A. Method for the manufacture of mineral wool insulation products having low formaldehyde emissions
WO2019180235A1 (en) 2018-03-23 2019-09-26 Foresa, Industrias Quimicas Del Noroeste, S.A.U. Monocomponent adhesive composition comprising formaldehyde-based resin with a free formal-dehyde content below 0,1 wt%, comprising resorcinol, alkylresorcinol and/or tannin

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