Process for the production of phenol silicate compounds and their condensation products

Claim 2

The process for the production of phenol silicate compounds and their resinous products by the following steps: (a) mixing about equal parts by weight of silicic acid and a phenol compound; (b) adding an alkali catalyst equal to 1 to 10% by weight of silicic acid and phenol compound; (c) heating said mixture to just below the boiling point of the phenol compound for 15 to 100 minutes while agitating, thereby (d) producing a granular phenol silicate compound.

Claim 3

The method of claim 1 wherein the silicic acid is selected from the group consisting of air dried silicic acid gel, moist silicic acid gel, orthosilicic acid, metasilicic acid, polysilicoformic acid, orthosilicoformic acid, silicoformic acid, monosilandiol and mixtures thereof.

Claim 4

The method of claim 1 wherein the phenol compound is selected from the group consisting of phenol, p-cresol, o-cresol, m-cresol, cresylic acid, xylenols, resorcinol, cashew-nut shell liquids, anocordol, p-tert-butyl phenol, cardol, anacardic acid, Bisphenol A, creosote oil, 2,6-dimethylphenol, and mixtures thereof.

Claim 5

The method of claim 1 wherein the alkali catalyst is selected from the group consisting of sodium carbonate, potassium hydroxide, sodium hydroxide, potassium carbonate, sodium metasilicate and mixtures thereof.

Claim 6

The method of claim 1 including the further steps of: (a) adding an aldehyde in the ratio of 0.5 to 3 mols to each mol of the phenol compound; (b) heating said mixture to 70° to 110° C. for 20 to 80 minutes while agitating, thereby (c) producing a poly(aldehyde phenol silicate) resin.

Claim 7

The method of claim 5 wherein the aldehyde is selected from the group consisting of formaldehyde, acetaldehyde, butylaldehyde, acrolein, paraformaldehyde, furfural, and mixtures thereof.

Claim 8

The method of claim 5 including the further step of adding an acid catalyst until the pH is 4 to 6 following step (a) and before step (b).

Claim 9

The method of claim 7 wherein the acid catalyst is selected from the group consisting of sulfuric acid, hydrochloric acid, acetic acid, formic acid, oxalic acid, aromatic sulfonic acid, sodium hydrogen sulfate and mixtures thereof.

Claim 10

The method of claim 1 wherein the phenol compound is phenol.

Claim 11

The method of claim 5 wherein the aldehyde is formaldehyde in an aqueous solution.

Claim 12

The process for the production of phenol silicate compounds and their resinous products by the following steps: (a) providing silicic acid selected from the group consisting of air dried silicic acid gel, moist silicic acid gel, orthosilicic acid, metasilicic acid, polysilicoformic acid, orthosilicoformic acid, silicoformic acid, monosilandiol and mixtures thereof; (b) providing a phenol compound selected from the group consisting of phenol, p-cresol, o-cresol, m-cresol, cresylic acid, xylenols, resorcinol, cashew nut shell liquids, anacordol, p-tert-butyl phenol, p-tert-amyl phenol, p-phenyl cardol, anacardic acid, Bisphenol A, cresote oil, 2,6-dimethylphenol and mixtures thereof; (c) mixing said silicic acid and phenol compound in about equal parts by weight; d. adding an alkali catalyst selected from the group consisting of sodium carbonate, potassium carbonate, sodium hydroxide, potassium hydroxide, and mixtures thereof, equal to 1 to 10% by weight of silicic acid and phenol compounds; (d) (e) adding an aldehyde to said mixture ratio of 0.5 to 3 mols to each mol of the phenol compound, and the aldehyde is selected from the group consisting of formaldehyde in an aqueous solution, acetaldehyde, butylaldehyde, acrolein, paraformaldehyde, furfural, and mixtures thereof; (f) heating said mixture to 70° to 110° C. for 20 to 80 minutes while agitating, thereby (g) producing a poly(aldehyde phenol silicate) resin.

Claim 13

The process for the production of phenol silicate compounds and their resinous products by the following steps: (a) providing silicic acid selected from the group consisting of air dried silicic acid gel, moist silicic acid gel, orthosilicic acid, metasilicic acid, polysilicoformic acid, orthosilicoformic acid, silicoformic acid, monosilandiol and mixtures thereof; (b) providing a phenol compound selected from the group consisting of phenol, p-cresol, o-cresol, m-cresol, cresylic acid, xylenols, resorcinol, cashew nut shell liquids, anacordol, p-tert-butyl phenol, p-tert-amyl phenol, p-phenyl cardol, anacardic acid, Bisphenol A, cresote oil, 2,6-dimethylphenol and mixtures thereof; (c) mixing said silicic acid and phenol compound in about equal parts by weight; d. adding an alkali catalyst selected from the group consisting of sodium carbonate, potassium carbonate, sodium hydroxide, potassium hydroxide, and mixtures thereof, equal to 1 to 10% by weight of silicic acid and phenol compounds; (d) (e) adding an aldehyde to said mixture ratio of 0.5 to 3 mols to each mol of the phenol compound, and the aldehyde is selected from the group consisting of formaldehyde in an aqueous solution, acetaldehyde, butylaldehyde, acrolein, paraformaldehyde, furfural, and mixtures thereof; (f) heating said mixture to 70° to 110° C. for 20 to 80 minutes while agitating, thereby (g) producing a poly(aldehyde phenol silicate) resin.

Claim 15

The method of claim 1 wherein the silicic acid is selected from the group consisting of air dried silicic acid gel, moist silicic acid gel, orthosilicic acid and metasilicic acid.

Claim 16

The method of claim 1 wherein the alkali catalyst is an alkali metal carbonate selected from the group consisting of sodium carbonate and potassium carbonate.

Claim 17

The method of claim 11 wherein the silicic acid is selected from the group consisting of air dried silicic acid gel, moist silicic acid gel, orthosilicic acid and metasilicic acid.

Claim 18

The method of claim 11 wherein the alkali catalyst is an alkali metal carbonate selected from the group consisting of sodium carbonate and potassium carbonate.