Formaldehyde → Formaldehyde;phenol

Participants

Reaction Steps

In accordance with one embodiment, a calcium ion source is combined in an aqueous solution with phenol, wherein the phenol is provided in an amount relative to the calcium ion source sufficient to provide a phenol to calcium mole ratio (P:Ca) in the range of 35:1 to 70:1. An amount of formaldehyde, sufficient to establish a formaldehyde to phenol mole ratio (F:P) in the range of 0.6:1 to 1.6:1, is thereafter reacted, under an alkaline reaction condition, with the phenol in the aqueous solution. Following the initial reaction, an additional amount of formaldehyde is added to the aqueous solution, sufficient to establish a cumulative phenol to formaldehyde mole ratio (F:P) in the range of 1.5:1 to 2.6:1. In the presence of a base (alkaline catalyst), usually an inorganic base and especially an alkali metal hydroxide, sufficient to establish a total alkalinity in the aqueous solution in the range of 1.5 to 8 percent by weight, and usually a total alkalinity in the aqueous solution in the range of 3 to 6 percent by weight, the added formaldehyde reacts with species in the solution (the reaction product) to form a phenol-formaldehyde resole resin.

Provenance & Evidence