Rosen phenolic resins and uses related thereto
View Patent ↗Rosin modified phenolic resins are prepared by reacting together resin acid, fatty acid, tri- or higher-functional phenolic compound and aldehyde. The fatty acid may be Monomer (derived from the fatty acid dimerization process). The reaction mixture may optionally include a,l3-olefinically unsaturated carbonyl compounds and/or polyol. The resin may be dissolved in a solvent to form a varnish. The resin may be used as a component of printing inks, e.g., inks for lithographic or gravure printing.
1. A process for preparing a resin, the process comprising reacting reactants at elevated temperature, the reactants comprising fatty acid, wherein at least 10 wt. % of the fatty acid is monomer fatty acid derived from acidic clay polymerization of tall oil fatty acid (Monomer), resin acid, aldehyde, polyol, polyester and phenolic compound that is at least trifunctional with respect to reactivity with aldehyde, where the phenolic compound that is at least trifunctional constitutes at least 25 wt % of all phenolic compounds used to form the resin.
2. The process of claim 1 wherein phenol constitutes at least 55 wt % of the phenolic compounds.
3. The process of claim 1 wherein 10 wt. % to 100 wt. % of the fatty acid is Monomer.
4. The process of claim 3 wherein at least 25 wt. % of the fatty acid is Monomer.
5. The process of claim 1 wherein the aldehyde constitutes up to 40 wt % of the reactants.
6. The process of claim 5 wherein the aldehyde constitutes 5-15 wt % of the reactants.
7. The process of claim 1 wherein phenolic compound(s) constitute up to 50 wt % of the reactants.
8. The process of claim 7 wherein phenolic compound(s) constitute 5-15 wt % of the reactants.
9. The process of claim 1 wherein the aldehyde comprises formaldehyde.
10. The process of claim 1 wherein the polyol constitutes up to 15 wt % of the components.
11. The process of claim 10 wherein the polyol comprises pentaerythritol.
12. The process of claim 1 wherein the reactants further comprise an α,β-olefinically unsaturated carbonyl compound.
13. The process of claim 12 wherein the α,β-olefinically unsaturated carbonyl compound constitutes up to 8 wt % of the components.
14. The process of claim 13 wherein the α,β-olefinically unsaturated carbonyl compound comprises maleic anhydride.
15. The process of claim 1 wherein the resin is self-gelling in mineral oil at resin:mineral oil weight ratio of 1:1.5.
16. The process of claim 1 wherein the resin is completely soluble in mineral oil at 10% solids at 180° C.
17. The process of claim 1 wherein the resin has a softening point in excess of 120° C.
18. The process of claim 1 wherein a 45 wt % solution of the resin in a hydrocarbon solvent has a flow viscosity at 25° C. of 0.1 to 150 Pascal-seconds.
19. The process of claim 1 wherein the resin is suitable for use as a lithographic ink resin.
20. The process of claim 1 wherein the resin is suitable for use as a gravure ink resin.
21. The process of claim 1 wherein azeotropic distillation is not used to remove water from the resin.
22. The process of claim 1 wherein an inert organic solvent capable of azeotropic distillation of water at the elevated temperature is not used as an entraining agent for azeotropic distillation of water.
23. A varnish comprising a resin prepared by the process of claim 1 and a solvent.
24. A process for preparing a resin, the process comprising reacting reactants at elevated temperature, the reactants comprising resin acid, fatty acid, wherein at least 10 wt. % of the fatty acid consists essentially of monomer fatty acid derived from acidic clay polymerization of tall oil fatty acid (Monomer), aldehyde, and phenolic compound that is at least trifunctional with respect to reactivity with aldehyde, where the Monomer contributes at least 5% of the weight of the listed reactants, and the resin has a softening point of at least 105.degree.C, and wherein the phenolic compound that is at least trifunctional constitutes at least 25 wt % of all phenolic compounds used to form the resin.
25. The process of claim 24 wherein the resin has a softening point of at least 120° C.
26. The process of claim 24 wherein 10 wt. % to 100 wt. % of the fatty acid is Monomer.
27. The process of claim 26 wherein at least 25 wt. % of the fatty acid is Monomer.
28. The process of claim 24 wherein phenolic compound that is at least trifunctional with respect to reactivity with aldehyde constitutes at least 5 wt % of all phenolic compounds present among the reactants.
29. The process of claim 24 wherein phenolic compound that is at least trifunctional with respect to reactivity with aldehyde constitutes at least 10 wt % of all phenolic compounds present among the reactants.
30. A resin prepared by the process of claim 1 .
31. The process of claim 3 wherein at least 45 wt. % of the fatty acid is Monomer.
32. The process of claim 3 wherein at least 65 wt. % of the fatty acid is Monomer.
33. The process of claim 3 wherein at least 75 wt. % of the fatty acid is Monomer.
34. The process of claim 26 wherein at least 45 wt. % of the fatty acid is Monomer.
35. The process of claim 26 wherein at least 65 wt. % of the fatty acid is Monomer.
36. The process of claim 26 wherein at least 75 wt. % of the fatty acid is Monomer.
37. A resin prepared the by process of claim 24 .