Process for producing a dispersed novolac resin and use in a binder system for thermal insulation
First Claim
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1. A process for producing a dispersed particulate novolac resin comprising the steps in the following order of:
- (a) reacting a phenol with an aldehyde in the presence of a catalyst under acidic conditions to produce a novolac resin;
(b) heating the novolac resin to remove water, unreacted phenol, and other volatile organic materials from the resulting novolac and to produce a molten novolac resin;
(c) cooling the molten novolac resin to a point where water can be added;
(d) adding about 10-30 wt % of water based on the total novolac resin solids and, optionally, a surfactant, to the molten resin, the water being added in an amount sufficient to produce a water-in-oil emulsion;
(e) adding a protective colloid to the emulsion in an amount sufficient to stabilize the dispersed particulate novolac resin; and
(f) adding additional water and agitating to produce the dispersed particulate novolac resin, wherein the particulate novolac resin has a particle size of 0.1μ
to 20μ
.
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Abstract
An aqueous dispersion of small particles of a phenol/formaldehyde novolac resin, referred to as a dispersed novolac resin, useful for example as a binder in preparing glass fiber insulation. The dispersed novolac resin is produced by preparing a molten novolac resin, cooling, adding water and optionally a surfactant and then adding a protective colloid. Additional water is added to provide the desired dispersion.
70 Citations
11 Claims
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1. A process for producing a dispersed particulate novolac resin comprising the steps in the following order of:
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(a) reacting a phenol with an aldehyde in the presence of a catalyst under acidic conditions to produce a novolac resin; (b) heating the novolac resin to remove water, unreacted phenol, and other volatile organic materials from the resulting novolac and to produce a molten novolac resin; (c) cooling the molten novolac resin to a point where water can be added; (d) adding about 10-30 wt % of water based on the total novolac resin solids and, optionally, a surfactant, to the molten resin, the water being added in an amount sufficient to produce a water-in-oil emulsion; (e) adding a protective colloid to the emulsion in an amount sufficient to stabilize the dispersed particulate novolac resin; and (f) adding additional water and agitating to produce the dispersed particulate novolac resin, wherein the particulate novolac resin has a particle size of 0.1μ
to 20μ
. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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Specification