Novolac alkylphenol resin formed with fatty acid
View Patent ↗The invention relates to novolac alkylphenol resins having a low level of free alkylphenol, a method for the production thereof, and the use thereof as tackifying resins and reinforcing resins for rubbers. The resins may be used advantageously in the production of tires.
1. A novolac alkylphenol resin comprising 2-20% by weight, based on the weight of the alkylphenol, of at least one saturated or unsaturated fatty acid, wherein the resin has a rate of residual alkylphenol of less than 2% and a softening point temperature between 85-105° C.
2. The resin of claim 1 , wherein the rate of residual alkylphenol is less than or equal to 1.5%.
3. The resin of claim 2 , wherein the rate of residual alkylphenol is less than or equal to 1%.
4. The resin of claim 1 , wherein the softening point temperature is between 95-105° C.
5. The resin of claim 1 , wherein the amount of fatty acid ranges from 5-10% by weight, based on the weight of the alkylphenol.
6. The resins of claim 1 , wherein the alkylphenols comprise phenols alkylated by a C 6 -C 10 hydrocarbon in the para position of the phenol group.
7. The resin of claim 6 , wherein the alkylphenol is para-tertiary octylphenol.
8. The resin of claim 1 , wherein up to 30% of the total mass of the phenols of the resin is selected from the group consisting of phenol, resorcinol, cardanol, dialkylphenols, xylenols 2,4-ditertiary octylphenol, 2,6-ditertiary octylphenol, and combinations thereof.
9. The resins of claim 1 , wherein the fatty acid is a saturated mono-carboxylic acid or a mono-olefinic acid having at least 8 carbon atoms.
10. The resin of claim 9 , wherein the fatty acid is a saturated fatty acids having 8 to 32 carbon atoms, or a synthetic or natural mixture of fatty acids obtained by saponification of vegetable oils or animal fats.
11. The resin of claim 10 , wherein the fatty acid is stearic acid.
12. A process for preparing a novolac alkylphenol resin, comprising:
(a) reacting an alkylphenol with an aldehyde to form a first resin, wherein the molar ratio of the alkylphenol:aldehyde is at least 0.9:1.0, and
(b) mixing the first resin with from 2-20% by weight, base on the weight of the alkylphenol, of at least one saturated or unsaturated fatty acid in a melted state,
to form a novolac alkylphenol resin, wherein the novolac alkylphenol resin has a residual alkylphenol of less than 2% and a softening point temperature between 85-105° C.
13. The method of claim 12 , wherein the rate of residual alkylphenol is less than or equal to 1.5%.
14. The method of claim 13 , wherein the rate of residual alkylphenol is less than or equal to 1%.
15. The method of claim 12 , wherein the softening point temperature is between 95-105° C.
16. The method of claim 12 , wherein the amount of fatty acid ranges from 5-10% by weight, based on the weight of the alkylphenol.
17. The process of claim 12 , wherein the aldehyde comprises formol.
18. A process for the preparing a novolac alkylphenol resin, comprising condensing an aldehyde and an alkylphenol in the presence of from 2-20% by weight based on the weight of the alkylphenol, of at least one saturated or unsaturated fatty acid at a temperature of less than or equal to 200° C., to form a novolac alkylphenol resin,
wherein the novolac alkylphenol resin has a residual alkylphenol of less than 2% and a softening point temperature between 85-105° C.
19. The method of claim 18 , wherein the rate of residual alkylphenol is less than or equal to 1.5%.
20. The method of claim 19 , wherein the rate of residual alkylphenol is less than or equal to 1%.
21. The method of claim 18 , wherein the softening point temperature is between 95-105° C.
22. The method of claim 18 , wherein the amount of fatty acid ranges from 5-10% by weight, based on the weight of the alkylphenol.
23. The process of claim 18 , wherein the aldehyde comprises formol.
24. The process of claim 18 , wherein the condensing temperature is less than or equal to 180° C.
25. The process of claim 24 , wherein the temperature is less than or equal to 160° C.
26. The process of claim 18 , wherein the process is conducted in a batch or continuous process.