Classifications

• • 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
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
  • C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
  • C08G8/24—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with mixtures of two or more phenols which are not covered by only one of the groups C08G8/10 - C08G8/20
• • 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
  • C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
  • C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
  • C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
  • C08G8/20—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with polyhydric phenols
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
  • C08H6/00—Macromolecular compounds derived from lignin, e.g. tannins, humic acids
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
  • C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
  • C08L61/16—Condensation polymers of aldehydes or ketones with phenols only of ketones with phenols

Definitions

• the present invention relates to a method for producing a lignin-modified resol type phenolic resin.
• Phenol resins are excellent among thermosetting resins in various aspects such as heat resistance, mechanical properties, moldability, and cost, and are used for various purposes such as molding materials and laminates.
• phenolic resin is manufactured using petroleum as a raw material. For this reason, the production of phenolic resins may lead to global warming due to carbon dioxide emissions.
• petroleum is a resource that is becoming depleted, and this poses a major problem in terms of the future stable supply of phenolic resins.
• a method for synthesizing a lignin-modified phenolic resin includes: a) dissolving lignin in an aqueous composition containing a compound selected from the group consisting of phenol, cresol, resorcinol, and combinations thereof; b) reacting the composition in which lignin is dissolved with an alkali to alkalize the lignin, and c) reacting the composition formed in step b) with aldehydes at a predetermined temperature, and It is disclosed that the method is carried out under conditions of predetermined pH.
• Patent Document 1 Upon study by the present inventor, it was found that the method for producing a lignin-modified phenolic resin described in Patent Document 1 has room for improvement in terms of yield.
• the present invention was made in view of the above problems, and was completed based on the inventor's knowledge that a lignin-modified resol type phenolic resin can be obtained in high yield by adjusting the production conditions.
• a method for producing a lignin-modified resol type phenolic resin comprising a step of obtaining.
• the step of obtaining a third mixture includes the step of further adding a phenolic compound and/or a vegetable oil to the second mixture,
• the third mixture is heated at a temperature of 60°C to 105°C, and the phenolic compound and/or vegetable oil, the lignins, the phenols, and the aldehyde are heated.
• a method for producing a lignin-modified resol-type phenolic resin comprising the step of reacting the above in the presence of the basic catalyst to obtain a lignin-modified resol-type phenolic resin.
• a method for producing a lignin-modified resol type phenolic resin comprising the step of reacting the above in the presence of the basic catalyst to obtain
• a step of obtaining a first mixture containing phenols, water and lignins a step in which the ratio of the phenols to the water is 1:0.03 to 1:1.5 in mass ratio of phenols:water; heating the first mixture at a temperature of 70° C. to 120° C.
• a method for producing a lignin-modified resol type phenolic resin comprising: [10] A method for producing a lignin-modified resol type phenolic resin according to item [9], comprising: After said step of obtaining a second mixture and before said step of obtaining a third mixture, A method for producing a lignin-modified resol type phenolic resin, further comprising the step of reducing the water from the second mixture by distilling the second mixture.
• a method for producing a lignin-modified resol type phenolic resin according to item [9] or [10], comprising: In the step of obtaining the third mixture, during or after obtaining the second mixture, a strong acid is added and heated to cause the lignins and the phenols to react, thereby producing phenolated lignins. a step of distilling and dehydrating said third mixture and solvating it with alcohols or ketones; and adding aldehydes and aldehydes to the solution containing alcohols or ketones.
• a method for producing a lignin-modified resol type phenolic resin comprising: adding a basic catalyst to adjust the pH to 7.5 to 12 to obtain a third mixture.
• a method for producing a lignin-modified resol type phenolic resin with improved yield is provided.
• the method for producing a lignin-modified resol type phenolic resin according to the first embodiment of the present invention includes the following (step a) to (step d).
• step a) A step of mixing phenols, water, and lignins to obtain a first mixture.
• Step b) The first mixture obtained in the above (Step a) is heated at a temperature of 70°C to 120°C at a pH of 7 or less to dissolve the lignins in the phenols and water, and then Step of obtaining a mixture.
• Step c A step of adding aldehydes and a basic catalyst to the second mixture obtained in the above (Step b) to adjust the pH to 7.5 to 12 to obtain a third mixture.
• Step d The third mixture obtained in the above (Step c) is heated at a temperature of 60°C to 105°C to remove lignins, phenols, and aldehydes contained in the third mixture. is reacted in the presence of a basic catalyst to obtain a lignin-modified resol type phenolic resin.
• a first mixture containing phenols, water, and lignins is prepared.
• the ratio of phenols to water is 1:0.03 to 1:1.5 in terms of mass ratio of phenols:water.
• the first mixture containing phenols, water, and lignins in the above (step a) is prepared by (a1) adding separately prepared phenols, water, and lignins into a container and mixing them. By (a2) first mixing phenols and water to obtain a phenol/water mixed solvent, and then by mixing lignins with this mixed solvent, (a3) first mixing phenols and lignins.
• the lignin in the means (a1) to (a3) above may be in any form of solid, dispersion, or solution.
• the hydrated lignin in the means (a4) above may be in the form of a solid or an aqueous solution.
• the phenols and water used in the above (step a) are such that the ratio of phenols to water contained in the first mixture obtained is 1:0.03 to 1:1 (mass ratio) of phenols:water. It is used in an amount of .5.
• the ratio of phenols to water in the first mixture is phenols:water (mass ratio), preferably 1:0.1 to 1:1.0, more preferably 1:0.2. ⁇ 1:0.6.
• step a lignins and phenols are used in an amount such that the mass ratio of lignins:phenols is, for example, 1:10 to 2:1, preferably 1:4 to 4:3. used in the amount.
• step a The phenol used in the above (step a) functions not only as a solvent but also as a raw material monomer for the resol type phenolic resin.
• lignins are easily soluble in phenols and poorly soluble in water under conditions of pH 7 or lower, so in (step b) following (step a), lignins are dissolved in this mixture. It can be appropriately dispersed and easily dissolved in a solvent. As a result, a homogenized reaction solution in which lignins and phenols are well compatible can be obtained, and the reaction efficiency of lignins in (step d) can be improved.
• the phenols used in the above (step a) include phenol, phenol derivatives, and combinations thereof.
• a phenol derivative a phenol having an arbitrary substituent introduced into the benzene ring and having a molecular weight of 150 or less can be used.
• the substituent include a hydroxy group; a lower alkyl group such as a methyl group, an ethyl group, a propyl group, and a butyl group; a halogen atom such as fluorine, chlorine, bromine, and iodine; an amino group; a nitro group; and a carboxy group.
• the lignins used in the above (step a) include lignin, lignin derivatives, or a combination thereof.
• Lignin along with cellulose and hemicellulose, is a major component forming the structure of plants, and is also one of the most abundant aromatic compounds in nature. Lignin is partially bonded and exists as lignocellulose in plants, so lignin often refers to substances obtained from plants through decomposition, etc. Examples include kraft lignin, lignin sulfonic acid, and soda.
• Examples include pulp lignin such as lignin and soda-anthraquinone lignin; organosol lignin; lignophenol in which phenol is added to high-temperature, high-pressure water-treated lignin or blasted lignin during extraction with concentrated sulfuric acid; and phenolized lignin.
• the origin of lignin is not particularly limited, and includes wood and herbs that contain lignin and form woody parts, such as coniferous trees such as cedar, pine, cypress, and spruce, beech, white birch, oak, zelkova, and eucalyptus.
• Examples include broad-leaved trees such as, grasses (herbs) such as rice, wheat, corn, and bamboo.
• the term "lignin derivative” refers to a compound having a unit structure constituting lignin or a structure similar to a unit structure constituting lignin.
• the lignin derivative has a phenol derivative as a unit structure. Since this unit structure has chemically and biologically stable carbon-carbon bonds and carbon-oxygen-carbon bonds, it is resistant to chemical deterioration and biological decomposition.
• lignin derivatives include guaiacylpropane (ferulic acid) represented by formula (A) of the following formula (1), syringylpropane (sinapinic acid) represented by the following formula (B), and syringylpropane (sinapinic acid) represented by the following formula (C).
• Examples include 4-hydroxyphenylpropane (coumaric acid).
• the composition of lignin derivatives varies depending on the biomass used as the raw material.
• Lignin derivatives containing a guaiacylpropane structure are mainly extracted from conifers.
• Lignin derivatives containing mainly guaiacylpropane and syringylpropane structures are extracted from broad-leaved trees.
• Lignin derivatives mainly containing a guaiacylpropane structure, a syringylpropane structure, and a 4-hydroxyphenylpropane structure are extracted from herbs.
• the lignin derivative is preferably one obtained by decomposing biomass. Since biomass captures and fixes atmospheric carbon dioxide during the process of photosynthesis, biomass contributes to suppressing the increase in atmospheric carbon dioxide, and industrial use of biomass can help reduce global warming. This can contribute to suppressing the Examples of biomass include lignocellulose biomass.
• lignocellulosic biomass include leaves, bark, branches, and wood of plants containing lignin, and processed products thereof.
• plants containing lignin include the above-mentioned broad-leaved trees, coniferous trees, and herbs.
• Biomass decomposition methods include chemical treatment, hydrolysis treatment, steam explosion method, supercritical water treatment method, subcritical water treatment method, mechanical treatment method, sulfuric acid cresol method, pulp manufacturing method, etc. Can be mentioned. From the viewpoint of environmental load, steam explosion method, subcritical water treatment method, and mechanical treatment method are preferred. From the viewpoint of cost, the pulp manufacturing method is preferred. Moreover, from the viewpoint of cost, it is preferable to use a by-product of biomass utilization.
• Lignin derivatives can be prepared, for example, by decomposing biomass at 150 to 400° C., 1 to 40 MPa, and for 8 hours or less in the presence of various cooking liquors or solvents. Further, the lignin derivative can be prepared by the method disclosed in JP-A No. 2009-084320, JP-A No. 2012-201828, and the like.
• lignin derivatives include those obtained by decomposing lignocellulose, which is a combination of lignin, cellulose, and hemicellulose.
• the lignin derivative may include a lignin decomposition product, a cellulose decomposition product, a hemicellulose decomposition product, etc. which are mainly composed of a compound having a lignin skeleton.
• the lignin derivative may also contain biomass-derived or process-derived inorganic substances, but when used in the application of this embodiment, the content of the inorganic substance should be 10% by mass or less based on the entire lignin derivative used. preferable.
• the lignin derivative has many reaction sites where the curing agent acts through an electrophilic substitution reaction on the aromatic ring, and since the less steric hindrance in the vicinity of the reaction site, the better the reactivity, the It is preferable that at least one of the ortho-position and para-position of the ring is unsubstituted, and lignin derived from coniferous trees or herbs, which contains a large amount of guaiacyl nucleus or 4-hydroxyphenyl nucleus structure as the aromatic unit of lignin, is preferable.
• the lignin derivative those disclosed in JP-A No. 2009-084320, JP-A No. 2012-201828, etc. can be used.
• the lignin derivative may also have a functional group (lignin secondary derivative).
• the functional groups possessed by the lignin secondary derivative are not particularly limited, but, for example, two or more of the same functional groups are preferably capable of reacting with each other or reacting with other functional groups.
• Specific examples include, in addition to epoxy groups and methylol groups, vinyl groups having carbon-carbon unsaturated bonds, ethynyl groups, maleimide groups, cyanate groups, and isocyanate groups.
• lignin derivatives into which a methylol group has been introduced (methylolated) are preferably used.
• Such lignin secondary derivatives undergo self-crosslinking due to a self-condensation reaction between methylol groups, and also crosslink to alkoxymethyl groups and hydroxyl groups in the crosslinking agent described below.
• a lignin-modified novolac type phenolic resin having a particularly homogeneous and rigid skeleton and excellent solvent resistance is obtained.
• the lignin derivative used in this embodiment may have a carboxyl group.
• Lignin obtained through pulp processing or high-temperature, high-pressure water treatment may have carboxyl groups.
• Lignin-modified novolac type phenolic resin obtained from a lignin derivative having a carboxyl group has many crosslinking points for the curing agent described below, so it is possible to improve the crosslinking density of the resulting crosslinked product, resulting in improved solvent resistance. A crosslinked product with excellent properties can be obtained.
• the carboxyl group can be confirmed by the presence or absence of absorption of a peak at 172 to 174 ppm when subjected to 13 C-NMR analysis attributed to the carboxyl group. can.
• the lignin used in this embodiment has a weight average molecular weight of, for example, 2,000 or more and 100,000 or less.
• the lower limit of the weight average molecular weight is preferably 3,000 or more, more preferably 4,000 or more, and even more preferably 5,000 or more.
• the upper limit of the weight average molecular weight is preferably 90,000 or less, more preferably 80,000 or less, and even more preferably 60,000 or less. Lignins having a weight average molecular weight within the above range are easily soluble in the above mixed solvent and have excellent handling properties.
• the weight average molecular weight is a polystyrene-equivalent number average molecular weight measured by gel permeation chromatography, and can be determined by the method described in Examples.
• a lignin derivative is dissolved in a solvent to prepare a measurement sample.
• the solvent used at this time is not particularly limited as long as it can dissolve the lignin derivative, but from the viewpoint of measurement accuracy of gel permeation chromatography, for example, tetrahydrofuran and N-methyl-2-pyrrolidone are preferable. .
• the lignin used in the production of the lignin-modified novolak phenolic resin used in this embodiment may contain insoluble matter due to biomass, process-derived inorganics, and plant-derived high molecular weight organic matter. In addition to selection, insoluble matter is determined by filtration. In order to increase the lignin modification rate of the obtained lignin-modified resol type phenolic resin, the insoluble content of the lignin used is preferably 30% by mass or less in an appropriate solvent.
• the number average molecular weight and weight average molecular weight of the target lignin can be calculated from a calibration curve showing the relationship between the retention time and molecular weight of standard polystyrene prepared separately. Refractive index is preferred as the detection mode.
• the molecular weight of the standard polystyrene used to create the calibration curve is not particularly limited, but for example, the weight average molecular weight is 2,110,000, 1,090,000, 427,000, 190,000. , 37,900, 18,100, 5,970, 2,420 and 500 standard polystyrene (manufactured by Tosoh) can be used.
• the volatile content of lignins is preferably 60% by mass or less, more preferably 50% by mass or less, and even more preferably 40% by mass or less.
• the main volatile content is often water, and can be calculated by, for example, spreading 4 g in an aluminum cup and drying it at 80°C for 20 hours.
• lignins obtained by decomposing biomass When using lignins obtained by decomposing biomass, a large amount of low molecular weight components may be mixed in, which may cause volatile matter and odor during heating, and a decrease in the softening point. These components can be used as they are, or can be removed by heating, drying, etc. the lignin to adjust the softening point and odor.
• the lignins used in the above (step a) may be used in the form of a solid, dispersion, or solution, or may be used as hydrated lignins in the form of a solid or an aqueous solution.
• the lignin aqueous solution may be distilled to reduce the amount of water contained in the lignin aqueous solution.
• the first mixture containing phenols, water, and lignin obtained in the above (step a) is subjected to a step of reducing the amount of water contained in the first mixture before (step b). You may also serve it.
• the step of reducing the amount of water contained in the first mixture can be performed using, for example, a distillation method.
• the ratio of phenols to water in the first mixture finally obtained is 1:0.01 to 1 in terms of mass ratio of phenols:water. : It is preferable to carry out until it becomes 0.5.
• the yield of the lignin-modified resol type phenolic resin in (step d) can be improved.
• Step b) In (step b) in the method of the present embodiment, the first mixture obtained in the above (step a) is heated at a temperature of 70°C to 120°C at a pH of 7 or less to remove lignins, phenols and Dissolve in water to obtain a second mixture.
• the first mixture containing lignins, phenols, and water obtained in the above (step a) is adjusted to pH 7 or less, and further heated at a temperature of 70°C to 120°C.
• the pH of the first mixture can be adjusted by adding any acid or alkali.
• the pH of the first mixture is preferably 1-7, more preferably 2-6.
• lignin can be dissolved in phenols and water.
• heating is performed at a temperature of 70°C to 120°C, preferably 80°C to 100°C. By heating at a temperature within the above range, lignins are easily dissolved in the mixed solvent.
• step c) In (step c) in the method of this embodiment, aldehydes and a basic catalyst are added to the second mixture obtained in the above (step b) to adjust the pH to 7.5 to 12, and the You will get a mixture of three.
• the aldehydes used in (step c) include formaldehyde, paraformaldehyde, trioxane, acetaldehyde, propionaldehyde, polyoxymethylene, chloral, hexamethylenetetramine, furfural, glyoxal, n-butyraldehyde, caproaldehyde, allylaldehyde, Examples include benzaldehyde, crotonaldehyde, acrolein, tetraoxymethylene, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde, paraxylene dimethyl ether, and the like.
• Preferred examples include formaldehyde, paraformaldehyde, trioxane, polyoxymethylene, acetaldehyde, paraxylene dimethyl ether, and combinations thereof.
• One type of aldehyde may be used alone, or two or more types may be used in combination. Among these, it is preferable to use formaldehyde or acetaldehyde from the viewpoint of productivity and low cost.
• the basic catalyst used in (step c) includes 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; lime, etc. Sulfites such as sodium sulfite; phosphates such as sodium phosphate; amines such as ammonia, trimethylamine, triethylamine, monoethanolamine, diethanolamine, triethanolamine, hexamethylenetetramine, and pyridine.
• step c in addition to the aldehydes and the basic catalyst, a phenol compound and/or a vegetable oil different from the phenols and lignins used in the above (step a) may be added.
• a phenolic compound or vegetable oil in addition to the aldehydes and the basic catalyst, a phenol compound and/or a vegetable oil different from the phenols and lignins used in the above (step a) may be added.
• step d a resol type phenolic resin is produced by reacting the lignins and phenols used in (step a), the phenolic compound or vegetable oil, and aldehydes. is generated.
• Phenol compounds that can be used in (step c) include alkylphenols.
• alkylphenol it is preferable to use a phenol having an alkyl group and having a molecular weight exceeding 150. Specific examples include amylphenol, tertiary aminophenol, hexylphenol, heptylphenol, octylphenol, tertiary octylphenol, and nonylphenol.
• tertiary nonylphenol decylphenol, undecylphenol, dodecylphenol, tridecylphenol, tetradecylphenol, pentadecylphenol, cardanol, cardol, urushiol, hexadecylphenol, methyl cardle, heptadecylphenol, laccol, thiol, Examples include octadecylphenol.
• One type of phenol compound may be used alone, or two or more types may be used in combination.
• Examples of vegetable oils that can be used in (step c) include cashew oil, castor oil, soybean oil, tung oil, linseed oil, tannin, pyrogallol, and tall oil.
• One type of vegetable oil may be used alone, or two or more types may be used in combination. Further, either one of the phenol compound and the vegetable oil may be used, or a combination of these may be used.
• step c When a phenolic compound and/or vegetable oil is added to the second mixture in (step c), the phenolic compound and/or vegetable oil are first mixed into the second mixture and then heated. Alternatively, the vegetable oil is dissolved in the solvent (mixed solvent of phenols and water) in (step a) to obtain a mixed solution (step c-1), and then the above-mentioned basic catalyst is added to this mixed solution. , the pH is adjusted to 7.5 to 12 (step c-2), and then the above-mentioned aldehydes are mixed into the pH-adjusted mixed solution to obtain a third mixture (step c-3). It is preferable.
• the phenolic compound and/or vegetable oil can be easily dissolved in the second mixture by adding the phenolic compound and/or vegetable oil to the second mixture before adding the basic catalyst. It is possible.
• the order in which they are added to the second mixture in (step c) may be in any order.
• a premixed mixture of phenolic compound and vegetable oil can be added to the second mixture.
• the aldehydes used in (step c) have a blending molar ratio (F/P) of phenols (P) and aldehydes (F) of 0.8 or more, preferably 0.8 or more and 5.0 or less, More preferably, it is used in an amount of 1.0 or more and 3.5 or less, even more preferably 1.2 or more and 2.5 or less.
• the basic catalyst used in (step c) is used in an amount of 1 to 30% by mass based on the total amount of phenols, lignins, aldehydes, and, if used, the phenolic compound and/or vegetable oil.
• the amount thereof is preferably 1 to 200% by mass based on the phenol used in (step a).
• the amount thereof is preferable to use them so that their total amount falls within the above range.
• Step d) In (step d) in the method of the present embodiment, the third mixture obtained in the above (step c) is heated at a temperature of 60°C to 105°C, and the lignins contained in this third mixture, Phenols and aldehydes are reacted in the presence of a basic catalyst to obtain a lignin-modified resol type phenolic resin.
• a phenolic compound and/or vegetable oil is used in the above (step c)
• step d lignins, phenols, phenolic compounds and/or vegetable oil, and aldehydes are reacted under a basic catalyst, A lignin-modified resol type phenolic resin is obtained.
• step d) the third mixture is heated at a temperature of 60°C to 105°C.
• the heating temperature in (step d) may be appropriately selected depending on the type of lignins and phenols contained in the third mixture, as well as the phenolic compound and/or vegetable oil if used, and the physical properties of the target resol type phenolic resin. I can do it.
• the heating time in (step d) is, for example, 10 minutes to 100 minutes, preferably 30 minutes to 60 minutes.
• the amount of free phenol contained therein is preferably 5.0% by mass or less, more preferably 5.0% by mass or less based on the lignin-modified resol type phenolic resin. In an embodiment, it is 4.0% by mass or less.
• the lower limit of the amount of free phenol contained in the lignin-modified resol type phenolic resin is not particularly limited, but is, for example, 0.1% by mass or more, preferably 0.5% by mass, based on the lignin-modified resol-type phenolic resin. That's all.
• the lignin-modified resol type phenolic resin Since the amount of free phenol is below the above upper limit, the lignin-modified resol type phenolic resin has excellent handling properties and has a wide range of applications. Furthermore, since the amount of free phenol is equal to or higher than the above lower limit, no special equipment or process is required to completely remove free aldehyde, and therefore manufacturing costs can be reduced.
• the method for producing a lignin-modified resol type phenolic resin according to the second embodiment of the present invention includes the following (step i) to (step iv).
• step i) A step of obtaining a first mixture containing phenols, water and lignins.
• Step ii The first mixture obtained in the above (Step i) is heated at a temperature of 70°C to 120°C at a pH of 7 or less to dissolve the lignins in the phenols and water, and then Step of obtaining a mixture.
• Step iii-1 When or after obtaining the second mixture obtained in the above (step ii), a strong acid is added and heated to cause the lignins and phenols to react, resulting in phenolization.
• a step of obtaining a reaction mixture containing lignins. (Step iii-2) Adding aldehydes and a basic catalyst to the reaction mixture containing the phenolated lignins obtained in the above (Step iii-1), adjusting the pH to 7.5 to 12, Obtaining a third mixture.
• Step iv The third mixture obtained in the above (Step iii-2) is heated at a temperature of 60°C to 105°C, and the phenolated lignins and aldehydes are reacted in the presence of a basic catalyst.
• Step i) (Step i) in this embodiment is the same as (Step a) in the first embodiment.
• Step ii) (Step ii) in this embodiment is the same as (Step b) in the first embodiment.
• step iii-1) in the method of the present embodiment a strong acid is added during or after obtaining the second mixture, which is an aqueous solution containing lignins and phenols, obtained in (step ii). , and then heated to react the lignins and phenols to obtain phenolated lignin.
• step iii-1 before carrying out (step iii-1), the aqueous solution (second mixture) in which the lignins and phenols obtained in (step ii) are dissolved is distilled, and the phenols contained therein are distilled. Water may be removed. By performing the dehydration step, the reaction efficiency between lignins and phenols can be improved.
• Examples of strong acids used in the reaction between lignins and phenols include sulfuric acid with a concentration of 65% by mass or more, phosphoric acid with a concentration of 85% by mass or more, hydrochloric acid with a concentration of 38% by mass or more, p-toluenesulfonic acid, trifluoroacetic acid, Examples include, but are not limited to, trichloroacetic acid, formic acid, and the like.
• the reaction between lignins and phenols can be carried out, for example, by heating the second mixture at a temperature of 90°C to 120°C, preferably 100°C to 115°C.
• Phenolized lignins obtained by the above method have a lignin skeleton and a large number of phenolic hydroxyl groups that are reactive groups. Therefore, phenolized lignin can react with aldehydes using the phenolic hydroxyl group as a reactive group to generate a phenol resin containing a lignin skeleton (lignin-modified phenol resin).
• the reaction mixture containing the same may be dehydrated and the solvent may be replaced by solvating with alcohols, ketones, etc.
• the dehydration treatment for example, a distillation method can be used.
• the alcohols used include methanol, ethanol, propanol, 1-methoxy-2-propanol, etc.
• the ketones include acetone, methyl ethyl ketone, etc.
• step iii-2) in the method of the present embodiment aldehydes and a basic catalyst are added to the reaction mixture containing the phenolated lignins obtained in the above (step iii-1), and the pH is adjusted to 7. .5 to 12 to obtain a third mixture.
• Step iii-2) in this embodiment is the same as (Step c) in the first embodiment.
• Step iv) In (step iv) in this embodiment, the third mixture obtained in (step iii-2) is heated at a temperature of 60°C to 105°C, and the phenolated lignins and aldehydes are removed using a basic catalyst.
• a phenol resin containing a lignin skeleton (lignin-modified resol type phenol resin) is obtained by reacting in the presence of the phenol resin.
• Step iv) of this embodiment can be carried out under the same conditions as (Step d) in the first embodiment.
• a lignin derivative used in the synthesis of a lignin-modified novolac type phenolic resin was prepared by the following procedure. 1500 parts by weight of cedar wood flour with a moisture content of 50% by weight, 5000 parts by weight of pure water as a cooking liquid, 180 parts by weight of sodium hydroxide, 120 parts by weight of sodium carbonate, and 7.5 parts by weight of 9,10-anthraquinone as a cooking aid. was charged into a stainless steel autoclave with a capacity of 10 L, and a cooking reaction was carried out at 170° C. for 3 hours with stirring.
• the cooking liquor was cooled to room temperature, the pulp components were removed with a screen, and the black liquor containing lignin was separated. Dilute sulfuric acid was added to the separated black liquor to adjust the pH to 8, and the resulting precipitate was centrifuged. After washing twice with 500 parts by mass of water, the precipitate was suspended in 5 times the amount of water, and the pH was readjusted to 2 with dilute sulfuric acid. The precipitated lignin was centrifuged again, washed with water, filtered by suction, spread on a vat, air-dried, and dried in a vacuum oven at 70°C or lower to obtain brown powdery alkali lignin (solid content 59% by mass).
• 150 parts by weight (in terms of solid content) of hydrated lignin was obtained from 140 parts by mass.
• a part of the obtained water-containing lignin was further dried in a vacuum oven at 80° C. or lower to obtain alkali lignin with a solid content of 99% by mass.
• the solid content rate was calculated from the residual rate after putting 4 g of a sample into an aluminum cup and heating and drying it at 135°C for 1 hour.
• the number average molecular weight (Mn) of the obtained lignin derivative was 2,000, and the weight average molecular weight (Mw) was 14,000.
• the quantitative ratio of phenol to water in the first mixture was phenol:water (mass ratio) of 1:0.7.
• the first mixture obtained in the first step is heated to 90°C and stirred for 20 minutes to dissolve alkali lignin with a solid content of 99% by mass in the phenol/water mixed solvent. It was visually confirmed that there were no floating objects. The resulting mixture was used as a second mixture.
• the second mixture obtained in the second step is cooled to 60°C, then 20 parts by weight of a 50% aqueous sodium hydroxide solution is added, and then 146.4 parts by weight of 37% formaldehyde is heated. was added carefully to obtain a third mixture.
• the third mixture obtained in the third step was reacted at 60°C for 60 minutes, and further heated to 85°C and reacted for 80 minutes. Thereafter, it was rapidly cooled and adjusted to a desired viscosity by adding pure water. Thereafter, a trace amount of fibrous insoluble matter was removed through a 200 mesh filter to obtain a lignin-modified resol type phenolic resin.
• the nonvolatile content of the obtained lignin-modified phenol resin was 55% by mass, the water solubility was 25 times or more, the solution resin viscosity was 756 mPa ⁇ s, the free phenol was 4.9% by mass, and the amount of free formaldehyde was 0.6% by mass.
• Ta The nonvolatile content of the obtained lignin-modified phenol resin was 55% by mass, the water solubility was 25 times or more, the solution resin viscosity was 756 mPa ⁇ s, the free phenol was 4.9% by mass, and the amount of free formaldeh
• Example 2 (First step) 100 parts by weight of phenol was charged into a four-necked flask equipped with a stirrer, a cooling tube, and a thermometer. Then, the temperature of this phenol was adjusted to 60°C. Next, while stirring, 169.5 parts by weight of brown powdered hydrated lignin with a solid content of 59% by mass prepared in Example 1 was added in portions to obtain a first mixture. The quantitative ratio of phenol to water in the first mixture was phenol:water (mass ratio) of 1:0.7. (Second step) The first mixture obtained in the first step was treated under the same conditions as in the second step of Example 1 to dissolve the water-containing lignin, thereby obtaining a second mixture.
• the second mixture was treated under the same conditions as in the third step of Example 1 to obtain a third mixture.
• the third mixture obtained in the third step was reacted at 60°C for 60 minutes, and further heated to 85°C and reacted for 80 minutes. Thereafter, it was rapidly cooled and adjusted to a desired viscosity by adding pure water. Thereafter, a trace amount of fibrous insoluble matter was removed through a 200 mesh filter to obtain a lignin-modified resol type phenolic resin.
• the nonvolatile content, water solubility, solution resin viscosity, free phenol content, and free formaldehyde content of the obtained lignin-modified phenolic resin are shown in Table 1.
• the third mixture obtained in the third step was reacted at 60° C. for 60 minutes, and further heated to 85° C. and reacted for 40 minutes. Thereafter, it was rapidly cooled and adjusted to a desired viscosity by adding pure water. Thereafter, a trace amount of fibrous insoluble matter was removed through a 200 mesh filter to obtain a lignin-modified resol type phenolic resin.
• the nonvolatile content, water solubility, solution resin viscosity, free phenol content, and free formaldehyde content of the obtained lignin-modified phenolic resin are shown in Table 1.
• lignin-modified resol type phenolic resin The nonvolatile content, water solubility, solution resin viscosity, free phenol content, and free formaldehyde content of the obtained lignin-modified phenolic resin are shown in Table 1.
• Example 6 (Example 6) 100 parts by weight of phenol was charged into a four-necked flask equipped with a stirrer, a cooling tube, and a thermometer. Then, the temperature of this phenol was adjusted to 60°C. Next, while stirring, 169.5 parts by weight of brown powdered hydrated lignin with a solid content of 59% by mass prepared in Example 1 was added in portions to obtain a first mixture. The quantitative ratio of phenol to water in the first mixture was phenol:water (mass ratio) of 1:0.7. (Second step) The first mixture obtained in the first step was treated under the same conditions as in the second step of Example 1 to dissolve the water-containing lignin, thereby obtaining a second mixture.
• Example 7 (Example 7) 100 parts by weight of phenol was charged into a four-necked flask equipped with a stirrer, a cooling tube, and a thermometer. Then, the temperature of this phenol was adjusted to 60°C. Next, while stirring, 169.5 parts by weight of brown powdered hydrated lignin with a solid content of 59% by mass prepared in Example 1 was added in portions to obtain a first mixture. The quantitative ratio of phenol to water in the first mixture was phenol:water (mass ratio) of 1:0.7. (Second step) The first mixture obtained in the first step was treated under the same conditions as in the second step of Example 1 to dissolve the water-containing lignin, thereby obtaining a second mixture.
• the second mixture obtained in the second step was treated under the same conditions as in the third step of Example 1 to obtain a third mixture.
• the third mixture obtained in the third step was reacted at 60°C for 60 minutes, and further heated to 85°C and reacted for 80 minutes. Thereafter, it was rapidly cooled and adjusted to a desired viscosity by adding pure water. Thereafter, the mixture was passed through a 200 mesh filter to remove fibrous insoluble matter and lumpy insoluble matter, thereby obtaining a lignin-modified resol type phenolic resin.
• the nonvolatile content, water solubility, solution resin viscosity, free phenol content, and free formaldehyde content of the obtained lignin-modified phenolic resin are shown in Table 1.
• the lignin-modified resol type phenolic resin produced by the method of the example had a reduced content of unreacted free phenol and a reduced content of unreacted free formaldehyde.
• the reaction mixture obtained in the fourth step in the method of the example contained a small amount of insoluble matter as fibrous matter.
• the reaction mixture obtained in the fourth step in the method of the comparative example contained fibrous insoluble matter and lumpy insoluble matter.
• the reaction time in the fourth step could be shortened.
• Example 5 in which the first mixture was subjected to distillation dehydration treatment, it was possible to obtain a third mixture that was uniformly dissolved even when cashew shell oil was mixed in the third step.

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