Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G14/00—Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00
  • C08G14/02—Condensation 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
  • C08G14/04—Condensation 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
  • C08G14/06—Condensation 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
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D161/00—Coating compositions based on condensation polymers of aldehydes or ketones; Coating compositions based on derivatives of such polymers
  • C09D161/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C09D161/04, C09D161/18 and C09D161/20
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J161/00—Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
  • C09J161/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C09J161/04, C09J161/18 and C09J161/20
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/47—Condensation polymers of aldehydes or ketones
  • D21H17/48—Condensation polymers of aldehydes or ketones with phenols

Definitions

• the present invention relates to a phenolic resin composition used by impregnating a fiber base material, and an article using the same.
• Phenolic resin is used as a binder for filters, laminates, friction materials, etc., because it has excellent properties such as heat resistance, mechanical properties, and low cost. These are produced by impregnating a fiber base material with a phenol resin diluted with a solvent such as methanol or acetone, drying it at room temperature, and thermally curing it.
• Phenol resins are highly hydrophilic resol-type phenols that can be used in the form of an aqueous solution or emulsion for applications that require ammonia-free or solvent-free for environmental friendliness and work environment improvement. Resin is used. Water-soluble resol resins are excellent in abrasive grain holding power and heat resistance, and are used, for example, as binders for coated abrasives.
• this resol-type phenolic resin contains unreacted phenols and aldehydes, which are undesirable substances from the viewpoint of protecting the atmospheric environment and protecting the human environment.
• a resol-type phenolic resin with a reduced formaldehyde content it is sufficient to react an excessive amount of phenols with aldehydes.
• it contains a large amount of unreacted phenols its curability is poor, and the resulting cured product does not satisfy the mechanical strength required by the market.
• resol-type phenolic resins obtained by using an excessive amount of phenols relative to aldehydes contain a large amount of unreacted phenols, and therefore are not preferable from the environmental and occupational safety and health standpoints.
• Patent Document 1 discloses a method for producing a resole resin that can reduce the amount of unreacted monomers such as formaldehyde and phenol, and a resin composition for sizing mineral fibers containing this resole resin. is described.
• US Pat. No. 5,300,000 discloses the preparation of liquid resins exhibiting free phenol levels of 0.5% or less by blending 0.1 to 0.5 moles of glycine per mole of starting phenol with a phenol-formaldehyde condensate. method is described.
• Patent Document 1 The inventors of the present invention believe that the resin composition of Patent Document 1 is not impregnated into fine gaps in operations such as impregnation into a fiber base material, and is likely to cause poor impregnation and poor curing, so that sufficient strength after curing can be obtained. I found that there are cases where it is not possible.
• the present invention has been made in view of the above problems, and an object of the present invention is to obtain a resin composition that can be uniformly applied to and impregnated into a fiber base material and that can provide a cured product with excellent mechanical strength.
• a liquid phenolic resin composition used for impregnating or coating an organic fiber base material is Phenols and aldehydes, which are starting materials, are reacted in the presence of a basic catalyst under conditions where the molar ratio of [aldehydes]/[phenols] is 0.8 or more and 3.0 or less to form a resol type obtaining a phenolic resin; a step of adding glycine in an amount of 0.01 mol or more and less than 1.0 mol to the resol-type phenol resin with respect to 1 mol of the phenol as the starting material to obtain a phenol resin composition; A phenolic resin composition is provided.
• an article comprising an organic fiber base material and the phenolic resin composition impregnated or applied to the organic fiber base material.
• the air permeability of the fiber base material is 250 cm 3 /cm 2 /s or less
• the phenolic resin composition is Phenols and aldehydes, which are starting materials, are reacted in the presence of a basic catalyst under conditions where the molar ratio of [aldehydes]/[phenols] is 0.8 or more and 3.0 or less to form a resol type obtaining a phenolic resin; a step of adding glycine in an amount of 0.01 mol or more and less than 1.0 mol to the resol-type phenol resin with respect to 1 mol of the phenol as the starting material to obtain a phenol resin composition;
• a phenolic resin composition is provided.
• an article comprising a woven fabric substrate and the phenolic resin composition impregnated or applied to the woven fabric substrate.
• a phenolic resin composition having excellent impregnating properties with respect to a fiber base material and a cured product thereof having high mechanical strength, and an article obtained by impregnating a fiber base material with this phenolic resin composition. be done.
• the phenolic resin composition of the present embodiment is a phenolic resin composition for impregnation, which is used by impregnating an organic fiber base material or a woven fabric base material.
• the phenolic resin composition of this embodiment contains a water-soluble resol-type phenolic resin and glycine.
• phenols and aldehydes which are starting materials, are basic under the condition that the molar ratio of [aldehydes] / [phenols] is 0.8 or more and 3.0 or less.
• a step of reacting in the presence of a catalyst to obtain a water-soluble resol-type phenolic resin It can be obtained by adding glycine in an amount of 0.01 mol or more and less than 1.0 mol to this resol-type phenolic resin per 1 mol of phenol as a starting material.
• the phenolic resin composition of the present embodiment is produced by the above method, so that the resol-type phenolic resin contained therein is appropriately suppressed from increasing in molecular weight, and the phenolic resin composition containing the phenolic resin composition impregnates the fiber base material. It has the right viscosity to As a result, the phenolic resin composition is excellent in impregnating and coating properties with respect to fiber substrates such as organic fiber substrates or woven fabric substrates.
• the good impregnability and coatability referred to in the present invention means that the phenolic resin composition enters (penetrates) not only the surface of the fiber base material but also almost all the spaces between the fibers constituting the fiber base material, It also means that the resol-type phenolic resin contained in the phenolic resin composition remains attached to the surface of the fiber, and is present uniformly without concentration bias in the thickness direction of the fiber base material.
• the article obtained by curing the phenolic resin composition impregnated in the fiber base material has high mechanical strength.
• the phenolic resin composition of the present embodiment contains a water-soluble resol-type phenolic resin and glycine by being produced by the above method.
• the phenolic resin composition of the present embodiment reduces the amounts of free aldehyde and free phenol, which are unreacted residual monomers inevitably contained in the water-soluble resol-type phenolic resin. Therefore, the environmental load and the load on the human body are reduced.
• glycine reduces the amount of free aldehyde and free phenol
• the reaction or interaction between glycine and free aldehyde and free phenol in the phenolic resin composition reduces these free aldehyde and free phenol. It is believed that free phenol exists as an inactive compound.
• the phenolic resin composition of the present embodiment improves the stability over time of the phenolic resin composition by containing glycine.
• the temporal stability of the resin composition means that the characteristics of the resin composition change little over time. Changes in the properties of the resin composition over time include an increase in the molecular weight of the phenol resin contained in the resin composition and an increase in the viscosity of the resin composition.
• the phenol resin composition of the present embodiment maintains its pH within a predetermined range due to the buffering action of glycine, so that the resol-type phenol resin contained in the resin composition has a high molecular weight, and unreacted free formaldehyde and Further polymerization reaction with free phenol is inhibited, resulting in little or no increase in the viscosity of the phenolic resin or change in the properties of the resin composition.
• the phenolic resin composition of the present embodiment contains a water-soluble resol-type phenolic resin, and this water-soluble resol-type phenolic resin is a starting material of phenols and aldehydes, [aldehydes] / [phenols] It is a resol-type phenolic resin obtained by reacting in the presence of a basic catalyst under conditions where the molar ratio is 0.8 or more and 3.0 or less.
• the resol-type phenolic resin produced under the above conditions has high water solubility, and therefore the resin composition containing it has excellent handleability.
• glycine is used in an amount of 0.01 mol or more and less than 1.0 mol with respect to 1 mol of the phenol that is the starting material used in the production of the resol-type phenol resin. be.
• the lower limit of the amount of glycine to be used is preferably 0.05 mol or more, more preferably 0.08, per 1 mol of the phenol that is the starting material used in the production of the resol-type phenolic resin. more than a mole.
• the upper limit of the amount of glycine used is preferably 0.98 mol or less, more preferably 0.95 mol, relative to 1 mol of the phenol that is the starting material used in the production of the resol-type phenolic resin.
• phenol resin composition of the present embodiment is inexpensive because the production cost is reduced.
• a phenolic resin composition containing a water-soluble resol-type phenolic resin and glycine according to the present embodiment is obtained by the following (step I) and (step II).
• step I Reacting phenols and aldehydes as starting materials in the presence of a basic catalyst under conditions where the molar ratio of [aldehydes]/[phenols] is 0.8 or more and 3.0 or less. to obtain a water-soluble resol-type phenolic resin.
• Step II Add 0.01 mol or more and less than 1.0 mol of adding an amount of glycine.
• Phenols as starting materials used for the synthesis of the water-soluble resol-type phenolic resin in (Step I) include phenol; cresols such as o-cresol, m-cresol and p-cresol; o-ethylphenol , m-ethylphenol, ethylphenols such as p-ethylphenol; butylphenols such as isopropylphenol, butylphenol, p-tert-butylphenol; p-tert-amylphenol, p-octylphenol, p-nonylphenol, p-cumyl Alkylphenols such as phenol; Halogenated phenols such as fluorophenol, chlorophenol, bromophenol and iodophenol; Monohydric phenol substituted products such as p-phenylphenol, aminophenol, nitrophenol, dinitrophenol and trinitrophenol; , 1-naphthol, 2-naphthol, and
• Aldehydes as starting materials used for the synthesis of the water-soluble resol-type phenolic resin in (Step I) include formaldehyde, paraformaldehyde, trioxane, acetaldehyde, propionaldehyde, polyoxymethylene, chloral, hexamethylenetetramine, Furfural, glyoxal, n-butyraldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, tetraoxymethylene, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde and the like.
• Examples of the basic catalyst used for the synthesis of the water-soluble resol-type phenolic resin in (Step I) include hydroxides of alkali metals or alkaline earth metals such as sodium hydroxide, potassium hydroxide, and calcium hydroxide. carbonates such as sodium carbonate and calcium carbonate; oxides such as lime; sulfites such as sodium sulfite; phosphates such as sodium phosphate; ammonia, trimethylamine, triethylamine, monoethanolamine, diethanolamine, triethanolamine, Amines such as hexamethylenetetramine and pyridine are included.
• Step I Water is used as the reaction solvent used for synthesizing the water-soluble resol-type phenolic resin in (Step I). Carrying out the reaction of (step I) in an aqueous solvent facilitates the addition of water-soluble glycine in the subsequent step (step II).
• the phenol (P) and the aldehyde (F) have a blending molar ratio (F/P) of 0.8 or more, preferably 0.8 or more and 3.0 or less, more preferably
• the reaction kettle is charged at a ratio of 1.0 to 2.8, more preferably 1.2 to 2.5, and the above-mentioned basic catalyst as a polymerization catalyst is added. , by refluxing for an appropriate time (eg, 3-6 hours).
• the weight average molecular weight of the water-soluble resol-type phenolic resin produced is small, and the fiber base is In some cases, the coating property on the material is insufficient, or the desired mechanical strength, heat resistance, and other properties are not obtained. If the molar ratio (F/P) of the phenols (P) and the aldehydes (F) exceeds 3.0, the gelation of the resin tends to proceed during the reaction, resulting in a decrease in reaction efficiency. In addition, it is not preferable because a water-insoluble high-molecular-weight resol-type phenolic resin is produced.
• the reaction temperature is, for example, 40°C to 120°C, preferably 60°C to 100°C.
• gelation can be suppressed, and a water-soluble resol-type phenolic resin having a desired molecular weight can be obtained.
• the weight average molecular weight of the water-soluble resol-type phenolic resin is preferably 250-3000, more preferably 300-2000.
• a resol-type phenolic resin having a molecular weight within the above range has water solubility and is excellent in impregnating and coating properties with respect to fiber substrates.
• the basic catalyst used in (Step 1) is, for example, 1 to 10% by mass, preferably 1 to 8% by mass, more preferably 2 to 5% by mass, relative to the starting phenols. used in By using the basic catalyst in an amount within the above range, the reaction efficiency between phenols and aldehydes can be improved, and thus the amounts of phenols and aldehydes remaining as unreacted products can be reduced.
• Step II is performed following (Step I).
• the reaction mixture containing the resol-type phenolic resin obtained in (Step I) is added with 0.01 mol or more and 1.0 A submolar amount of glycine is added.
• the lower limit of the amount of glycine to be added is preferably 0.05 mol or more, more preferably 0.08 mol or more, relative to 1 mol of the starting phenol used in (step I).
• the upper limit of the amount of glycine to be added is preferably 0.98 mol or less, more preferably 0.95 mol or less, relative to 1 mol of the starting phenol used in (Step I).
• the resulting resol-type phenolic resin composition can have an appropriate range of impregnating properties and coating properties with respect to fiber substrates.
• free aldehydes and free phenols remaining unreacted in (step I) can be reduced.
• glycine is preferably added to the reaction mixture obtained in (Step I) gradually over a given amount of time.
• Glycine is added at a temperature of 60° C. to 75° C., preferably 60° C. to 65° C., at a rate of 0.5 to 20% by mass, preferably 1 to 10% by mass of the total amount of glycine per minute. %, more preferably 2.8% to 4% by weight.
• glycine may be used in the form of an aqueous solution.
• glycine may be used in the form of a metal salt such as sodium salt.
• the temperature is preferably kept constant for an additional 10-180 minutes, preferably 30-100 minutes, to further reduce unreacted free aldehydes and free phenols. After that, the temperature of the reaction mixture is slowly cooled to about room temperature to obtain the phenol resin composition of the present embodiment.
• the phenolic resin composition obtained through the above steps has a content of unreacted free phenols of 1% by mass or less, preferably 0.8% by mass or less, more preferably 0.8% by mass or less, relative to the entire phenolic resin composition. is reduced to 0.6% by mass or less.
• the phenolic resin composition obtained using the above process has a content of unreacted free aldehydes of 1% by mass or less, preferably 0.8% by mass or less, based on the entire phenolic resin composition. More preferably, it is reduced to 0.6% by mass or less.
• the pH of the phenolic resin composition obtained using the above steps is close to neutral, for example, 6 to 8, preferably 6.5 to 7.8, more preferably 6.8 to 7.5. Such pH is achieved by the presence of glycine in the resin composition.
• the phenol resin composition of the present embodiment has excellent stability over time by having a pH within the above range.
• Organic fiber substrates or woven fabric substrates are used as fiber substrates.
• Organic fiber substrates include, for example, wood pulp, linter pulp, cotton linter, paper, kenaf, shoot, bamboo and other natural fiber substrates, aramid fiber, polyester fiber, poly toilet seat sol fiber, acrylic fiber, acrylonitrile fiber, Examples include organic synthetic fibers such as polyimide fibers and polyamide fibers. One of these organic fiber substrates may be used alone, or two or more thereof may be used in combination.
• woven fabric substrate a woven fabric having air permeability of 250 cm 3 /cm 2 /s or less, preferably 220 cm 3 /cm 2 /s or less is used.
• woven fabric substrates in particular glass fibers, metal fibers or ceramic fibers are used.
• the fiber base material may contain additives.
• additives include wollastonite, diatomaceous earth, silica, barium sulfate, calcium carbonate, silicon oxide, cashew dust, and graphite, which are generally known as reinforcing materials and fillers. These reinforcing materials and fillers are not particularly limited, and two or more of them can be used in combination.
• the article of this embodiment can be used, for example, as a friction material.
• F/P molar ratio 2.4
• Example 5 A resin composition was obtained in the same manner as in Example 1, except that 640 g of glycine (0.8 mol relative to phenol) was used.
• Comparative example 2 4000 ml of water was added to the resin composition obtained in Comparative Example 1 to obtain a resin composition.
• Table 1 shows the solid content (non-volatile content) (%), free phenol amount, free formaldehyde amount, and water dilutability of the resin compositions obtained in each example and comparative example.
• Resin adhesion amount (%) [(weight of composite - weight of substrate) / weight of substrate] x 100 (Strength of impregnated paper)
• the strength of the impregnated paper was measured in accordance with JIS P 8113 using a precision universal testing machine AG-IS 5kN (manufactured by Shimadzu Corporation) at a test speed of 1 mm/min under normal temperature and pressure.

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Engineering & Computer Science (AREA)
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• Polymers & Plastics (AREA)
• Health & Medical Sciences (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Manufacturing & Machinery (AREA)
• Phenolic Resins Or Amino Resins (AREA)
• Reinforced Plastic Materials (AREA)
• Compositions Of Macromolecular Compounds (AREA)

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• 2022
  • 2022-11-11 JP JP2023521416A patent/JP7338809B1/ja active Active
  • 2022-11-11 WO PCT/JP2022/042047 patent/WO2023095640A1/ja not_active Ceased
  • 2022-11-11 CN CN202280077509.9A patent/CN118284636A/zh active Pending
  • 2022-11-11 EP EP22898424.1A patent/EP4438645A4/en active Pending

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