Process for the manufacture of dispersions of thermosetting phenolic resin reaction products

Claim 2

A SUBSTITUTED PHENOL SELECTED FROM THE GROUP CONSISTING OF A. A SUBSTITUTED PHENOL HAVING ONE PHENOLIC HYDROXYL GROUP AND FROM 1 TO 4 SUBSTITUENTS ON THE PHENOL NUCLEUS AND HAVING AT LEAST ONE RING CARBON ATOM OF THE PHENOL AVAILABLE FOR REACTION WITH FORMALDEHYDE, AND WHICH SUBSTITUTED PHENOL HAS A SPEED OF TION OF THE UNSUBSTITUTED PHENOL, AND B. A DIHYDROXYPHENYLALKANE OF THE GENERAL FORMULA

Claim 3

PROCESS FOR THE MANUFACTURE OF A WATER-DILUTABLE, AQUEOUS DISPERSION OF A THERMOSETTING REACTION PRODUCT CONTAINING AN EMULSIFIER AND A PROTECTIVE COLLOID WHICH COMPRISES A. WARMING AN AQUEOUS MIXTURE OF

Claim 4

PROCESS FOR THE MANUFACTURE OF A WATER-DILUTABLE, AQUEOUS DISPERSION OF A THERMOSETTING REACTION PRODUCT CONTAINING AN EMULSIFIER AND A PROTECTIVE COLLOID WHICH COMPRISES A. WARMING AN AQUEOUS MIXTURE OF

Claim 5

Process of claim 1 wherein the substituted phenol (1) (A) is used, and such substituted phenol is made by heating to about 150* to 160*C a mixture of phenol and a styrene compound in excess phenol as the solvent in the presence of about 2 to about 5% by weight of oxalic acid, relative to the total amount of phenol and styrene compound, until the reaction mixture contains at least 95% by weight of an equimolar phenol-styrene reaction product.

Claim 6

phenol,

Claim 7

phenol,

Claim 8

formaldehyde or a formaldehyde donor,

Claim 9

formaldehyde or a formaldehyde donor,

Claim 10

FORMALDEHYDE OR A FORMALDEHYDE DONOR,

Claim 11

FORMALDEHYDE OR A FORMALDEHYDE DONOR,

Claim 12

Process of claim 1 wherein the substituted phenol component (1) is of the (A) type and is selected from the group consisting of m-cresol, 3,4-dimethylphenol, 3,5-dimethylphenol, 2,5-dimethylphenol, m-ethylphenol, m-propylphenol, m-butylphenol, n-butylphenol, p-tert-butylphenol, o-n-propenylphenol, o-isopropenylphenol, p-n-propenylphenol p-isopropenylphenol, o-allylphenol, p-allylphenol, o-phenylphenol, p-phenylphenol, o- Alpha -phenylethylphenol, p- Alpha -phenylethylphenol, o- Beta -phenylethylphenol, p- Beta -phenylethylphenol, o- Alpha -phenylisopropylphenol, p- Alpha -phenylisopropylphenol, o- Beta -phenylisopropylphenol, P- Beta -phenylisopropylphenol, and ethylene/phenol substituted phenol reaction products which boil at from 230* to 260*C and of which substituted phenol reaction product 60 to 70% of which dissolves in an alkaline solution, and mixtures thereof.

Claim 13

Process of claim 1 wherein the substituted phenol (1) is a dihydroxyphenylalkane of formula (1) (B).

Claim 14

a basic nitrogen compound selected from the group consisting of ammonia, primary amines and secondary amines,

Claim 15

a basic nitrogen compound selected from the group consisting of ammonia, primary amines and secondary amines,

Claim 16

A BASIC NITROGEN COMPOUND SELECTED FROM THE GROUP CONSISTING OF AMMONIA, PRIMARY AMINES AND SECONDARY AMINES,

Claim 17

A BASIC NITROGEN COMPOUND SELECTED FROM THE GROUP CONSISTING OF AMMONIA, PRIMARY AMINES AND SECONDARY AMINES,

Claim 18

A NON-IONIC,EMULSIFIER WHICH IS COMPATIBLE WITH PHENOLIC RESIN,

Claim 19

A NON-IONIC,EMULSIFIER WHICH IS COMPATIBLE WITH PHENOLIC RESIN,

Claim 20

Process of claim 1 wherein water is added to the mixture during the stirring and cooling step.

Claim 21

a non-ionic emulsifier which is compatible with phenolic resin,

Claim 22

a non-ionic emulsifier which is compatible with phenolic resin,

Claim 23

polyvinyl alcohol, and

Claim 24

polyvinyl alcohol, and

Claim 25

Product produced by the process of claim 1.

Claim 26

POLYVINYL ALCOHOL, AND

Claim 27

POLYVINYL ALCOHOL, AND

Claim 28

HYDROXYETHYLCELLULOSE, UNTIL A SAMPLE OF THE REACTION MIXTURE HAS A B-TIME OF 30 SECONDS TO 10 MINUTES AT 160*C, AND B. WHILE STIRRING, COOLING THE MIXTURE FROM STEP (A), SAID PRECESS BEING FURTHER CHARACTERIZED IN THET THE MIXTURE CONTAINS TH SUBSTITUTED PHENOL (1) AND THE PHENOL (2) IN A RATIO SUCH THAT THE AVERAGE FUNCTIONALITY OF THE SUM OF THESE PHENOLIC COMPOUNDS (1) AND (2) RELATIVE TO FORMALDEHYDE IS BETWEEN 2.1 AND 2.8, AND THE AMOUNT OF FORMALDEHYDE (3) IN THE MIXTURE IS SO CHOSEN THAT THE MOLAR RATIO OF THE TOTAL SUM OF FORMALDEHYDE (3) TO THE SUM OF THE PHENOLIC COMPONENTS (1) AND (2) RANGES FROM ABOUT 1.0 AND 1.4 TO 1, THE CONTENT OF THE BASIC NITROGEN COMPONENT (4) IN THE MIXTURE RAGES FROM ABOUT 5 TO 50 MOL PERCENT RELATIVE TO THE TOTAL WEIGHT OF THE PHENOLIC COMPONENTS (1) AND (2), THE CONTENT OF THE NON-IONIC EMULSIFIER (5) IN THE MIXTURE FROM ABOUT 1.0 AND 1.4 TO 1, WEIGHT OF THE PHENOLS (1) AND (2), THE WEIGHT RATIO OF POLYVINYL ALCOHOL (6) RELATIVE TO THE HYDROXYETHYL CELLULOSE (7) RANGING FROM ABOUT 2 TO 1 TO 4 TO 1, AND THE SUM OF THE WEIGHTS OF THE POLYVINYL ALCOHOL (6) AND HYDROXYETHYL CELLULOSE (7) IN THE MIXTURE RANGING FROM ABOUT 5 TO ABOUT 25% BY WEIGHT RELATIVE TO THE TOTAL WEIGHT OF THE PHENOL COMPONENTS, THE AMOUNT OF WATER IN THE MIXTURE, INCLUDING ADDED WATER AND WATER OF REACTION, RANGING FROM 30 TO 60% BY WEIGHT, RELATIVE TO THE WEIGHT OF THE TOTAL MIXTURE.

Claim 29

HYDROXYETHYLCELLULOSE, UNTIL A SAMPLE OF THE REACTION MIXTURE HAS A B-TIME OF 30 SECONDS TO 10 MINUTES AT 160*C, AND B. WHILE STIRRING, COOLING THE MIXTURE FROM STEP (A), SAID PRECESS BEING FURTHER CHARACTERIZED IN THET THE MIXTURE CONTAINS TH SUBSTITUTED PHENOL (1) AND THE PHENOL (2) IN A RATIO SUCH THAT THE AVERAGE FUNCTIONALITY OF THE SUM OF THESE PHENOLIC COMPOUNDS (1) AND (2) RELATIVE TO FORMALDEHYDE IS BETWEEN 2.1 AND 2.8, AND THE AMOUNT OF FORMALDEHYDE (3) IN THE MIXTURE IS SO CHOSEN THAT THE MOLAR RATIO OF THE TOTAL SUM OF FORMALDEHYDE (3) TO THE SUM OF THE PHENOLIC COMPONENTS (1) AND (2) RANGES FROM ABOUT 1.0 AND 1.4 TO 1, THE CONTENT OF THE BASIC NITROGEN COMPONENT (4) IN THE MIXTURE RAGES FROM ABOUT 5 TO 50 MOL PERCENT RELATIVE TO THE TOTAL WEIGHT OF THE PHENOLIC COMPONENTS (1) AND (2), THE CONTENT OF THE NON-IONIC EMULSIFIER (5) IN THE MIXTURE FROM ABOUT 1.0 AND 1.4 TO 1, WEIGHT OF THE PHENOLS (1) AND (2), THE WEIGHT RATIO OF POLYVINYL ALCOHOL (6) RELATIVE TO THE HYDROXYETHYL CELLULOSE (7) RANGING FROM ABOUT 2 TO 1 TO 4 TO 1, AND THE SUM OF THE WEIGHTS OF THE POLYVINYL ALCOHOL (6) AND HYDROXYETHYL CELLULOSE (7) IN THE MIXTURE RANGING FROM ABOUT 5 TO ABOUT 25% BY WEIGHT RELATIVE TO THE TOTAL WEIGHT OF THE PHENOL COMPONENTS, THE AMOUNT OF WATER IN THE MIXTURE, INCLUDING ADDED WATER AND WATER OF REACTION, RANGING FROM 30 TO 60% BY WEIGHT, RELATIVE TO THE WEIGHT OF THE TOTAL MIXTURE.

Claim 30

Product produced by the process of claim 2.

Claim 31

hydroxyethylcellulose, until a sample of the reaction mixture has a B-time of 30 seconds to 10 minutes at 160*C, and b. while stirring, cooling the mixture from step (a), said process being further characterized in that the mixture contains the substituted phenol (1) and the phenol (2) in a ratio such that the average functionality of the sum of these phenolic compounds (1) and (2) relative to formaldehyde is between 2.1 and 2.8, and the amount of formaldehyde (3) in the mixture is so chosen that the molar ratio of the total sum of formaldehyde (3) to the sum of the phenolic components (1) and (2) ranges from about 1.0 and 1.4 to 1, the content of the basic nitrogen component (4) in the mixture ranges from about 5 to 50 mol percent relative to the total weight of the phenolic components (1) and (2), the content of the non-ionic emulsifier (5) in the mixture ranging from 5 to 25% by weight relative to the total weight of the phenols (1 ) and (2), the weight ratio of polyvinyl alcohol (6) relative to the hydroxyethyl cellulose (7) ranging from about 2 to 1 to 4 to 1, and the sum of the weights of the polyvinyl alcohol (6) and hydroxyethyl cellulose (7) in the mixture ranging from about 5 to about 25% by weight relative to the total weight of the phenol components, the amount of water in the mixture, including added water and water of reaction, ranging from 30 to 60% by weight, relative to the weight of the total mixture.

Claim 32

hydroxyethylcellulose, until a sample of the reaction mixture has a B-time of 30 seconds to 10 minutes at 160*C, and b. while stirring, cooling the mixture from step (a), said process being further characterized in that the mixture contains the substituted phenol (1) and the phenol (2) in a ratio such that the average functionality of the sum of these phenolic compounds (1) and (2) relative to formaldehyde is between 2.1 and 2.8, and the amount of formaldehyde (3) in the mixture is so chosen that the molar ratio of the total sum of formaldehyde (3) to the sum of the phenolic components (1) and (2) ranges from about 1.0 and 1.4 to 1, the content of the basic nitrogen component (4) in the mixture ranges from about 5 to 50 mol percent relative to the total weight of the phenolic components (1) and (2), the content of the non-ionic emulsifier (5) in the mixture ranging from 5 to 25% by weight relative to the total weight of the phenols (1 ) and (2), the weight ratio of polyvinyl alcohol (6) relative to the hydroxyethyl cellulose (7) ranging from about 2 to 1 to 4 to 1, and the sum of the weights of the polyvinyl alcohol (6) and hydroxyethyl cellulose (7) in the mixture ranging from about 5 to about 25% by weight relative to the total weight of the phenol components, the amount of water in the mixture, including added water and water of reaction, ranging from 30 to 60% by weight, relative to the weight of the total mixture.