METHOD FOR PREPARING PHENOL-FORMALDEHYDE RESINS, RESIN MATERIALS AND METHOD FOR PREPARING RESIN MOLDING MATERIALS
A method for preparing a phenol-formaldehyde resin is provided. The method includes extracting a biomass pyrolysis oil to obtain a first phenolic mixture, and polymerizing the first phenolic mixture to form a phenol-formaldehyde resin solution under an aldehyde, an alcohol and an alkaline catalyst. The disclosure also provides a resin material prepared from the phenol-formaldehyde resin. The disclosure further provides a method for preparing a resin molding material.
1 . A method for preparing a phenol-formaldehyde resin, comprising the following steps:
extracting a biomass pyrolysis oil to obtain a first phenolic mixture; and
polymerizing the first phenolic mixture to form a phenol-formaldehyde resin solution under an aldehyde, an alcohol and an alkaline catalyst.
2 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the first phenolic mixture comprises at least two of phenol, 2-cresol, 4-cresol, 3-cresol, guaiacol, 2,6-dimethyl phenol, 2,4-dimethyl phenol, 4-ethyl phenol, m-ethyl phenol, 2-methoxy-4-methyl phenol, 1,2-benzenediol, 3,4-xylenol, 4-ethyl-m-cresol, 3-methoxy catechol, 3-methyl pyrocatechol, 1,4-benzenediol, 4-ethyl guaiacol, 4-methyl catechol, 4-vinyl-2-methoxy phenol, 2-methyl-1,4-benzenediol, 2,6-dimethoxy phenol, 2-methoxy-4-propyl phenol, isoeugenol, 2-methoxy-4-propyl phenol, 2,6-dimethoxy-4-allyl phenol, 3-allyl-6-methoxy phenol or the like.
3 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the biomass pyrolysis oil is extracted by an extractant, the extractant is ethyl acetate, propyl acetate, butyl acetate, methyl isopropyl ketone (MIPK), methyl isobutyl ketone (MIBK), methyl i-amyl ketone (MIAK), ethyl ethyl ketone (EEK) or toluene.
4 . The method for preparing a phenol-formaldehyde resin as claimed in claim 3 , wherein the extractant further comprises a second phenolic compound.
5 . The method for preparing a phenol-formaldehyde resin as claimed in claim 4 , wherein the second phenolic compound comprises phenol, 2-cresol, 4-cresol, 3-cresol, guaiacol, 2,6-dimethyl phenol, 2,4-dimethyl phenol, 4-ethyl phenol, m-ethyl phenol, 2-methoxy-4-methyl phenol, 1,2-benzenediol, 3,4-xylenol, 4-ethyl-m-cresol, 3-methoxy catechol, 3-methyl pyrocatechol, 1,4-benzenediol, 4-ethyl guaiacol, 4-methyl catechol, 4-vinyl-2-methoxy phenol, 2-methyl-1,4-benzenediol, 2,6-dimethoxy phenol, 2-methoxy-4-propyl phenol, isoeugenol, 2-methoxy-4-propyl phenol, 2,6-dimethoxy-4-allyl phenol, 3-allyl-6-methoxy phenol or the like, or a combination thereof.
6 . The method for preparing a phenol-formaldehyde resin as claimed in claim 4 , wherein the second phenolic compound and the biomass pyrolysis oil have a weight ratio of 0.1:1-1:1.
7 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the aldehyde is formaldehyde, glycolaldehyde, propanal, m-hydroxybenzaldehyde, vanillin, 2,3-dihydroxy benzaldehyde, m-hydroxy benzaldehyde or 5-methyl-2-furfural.
8 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the aldehyde and the first phenolic mixture have a weight ratio of 0.1:1-1:1.
9 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the alcohol is ethanol, methanol, n-propanol, isopropanol, n-butanol, isobutanol, n-pentanol, n-hexanol or t-butanol.
10 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , wherein the alcohol and the first phenolic mixture have a weight ratio of 0.1:1-10:1.
11 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , further comprising adding a third phenolic compound to polymerize the first phenolic mixture under the aldehyde, the alcohol and the alkaline catalyst.
12 . The method for preparing a phenol-formaldehyde resin as claimed in claim 11 , wherein the third phenolic compound comprises phenol, 2-cresol, 4-cresol, 3-cresol, guaiacol, 2,6-dimethyl phenol, 2,4-dimethyl phenol, 4-ethyl phenol, m-ethyl phenol, 2-methoxy-4-methyl phenol, 1,2-benzenediol, 3,4-xylenol, 4-ethyl-m-cresol, 3-methoxy catechol, 3-methyl pyrocatechol, 1,4-benzenediol, 4-ethyl guaiacol, 4-methyl catechol, 4-vinyl-2-methoxy phenol, 2-methyl-1,4-benzenediol, 2,6-dimethoxy phenol, 2-methoxy-4-propyl phenol, isoeugenol, 2-methoxy-4-propyl phenol, 2,6-dimethoxy-4-allyl phenol, 3-allyl-6-methoxy phenol or the like, or a combination thereof.
13 . The method for preparing a phenol-formaldehyde resin as claimed in claim 11 , wherein the third phenolic compound and the first phenolic mixture have a weight ratio of 0.5:1-2:1.
14 . The method for preparing a phenol-formaldehyde resin as claimed in claim 4 , further comprising adding a fourth phenolic compound to polymerize the first phenolic mixture under the aldehyde, the alcohol and the alkaline catalyst.
15 . The method for preparing a phenol-formaldehyde resin as claimed in claim 14 , wherein the fourth phenolic compound comprises phenol, 2-cresol, 4-cresol, 3-cresol, guaiacol, 2,6-dimethyl phenol, 2,4-dimethyl phenol, 4-ethyl phenol, m-ethyl phenol, 2-methoxy-4-methyl phenol, 1,2-benzenediol, 3,4-xylenol, 4-ethyl-m-cresol, 3-methoxy catechol, 3-methyl pyrocatechol, 1,4-benzenediol, 4-ethyl guaiacol, 4-methyl catechol, 4-vinyl-2-methoxy phenol, 2-methyl-1,4-benzenediol, 2,6-dimethoxy phenol, 2-methoxy-4-propyl phenol, isoeugenol, 2-methoxy-4-propyl phenol, 2,6-dimethoxy-4-allyl phenol, 3-allyl-6-methoxy phenol or the like, or a combination thereof.
16 . The method for preparing a phenol-formaldehyde resin as claimed in claim 14 , wherein the fourth phenolic compound and the biomass pyrolysis oil have a weight ratio of 0.1:1-0.5:1.
17 . The method for preparing a phenol-formaldehyde resin as claimed in claim 1 , further comprising diluting the phenol-formaldehyde resin solution to form a phenol-formaldehyde resin diluent.
18 . The method for preparing a phenol-formaldehyde resin as claimed in claim 17 , wherein the phenol-formaldehyde resin solution is diluted with an alcohol.
19 . The method for preparing a phenol-formaldehyde resin as claimed in claim 17 , further comprising impregnating a matrix with the phenol-formaldehyde resin diluent to form a resin-impregnated material.
20 . The method for preparing a phenol-formaldehyde resin as claimed in claim 19 , further comprising hot-pressing the resin-impregnated material to form a resin molding material.
21 . A resin material, comprising:
a matrix impregnated with the phenol-formaldehyde resin diluent as claimed in claim 17 .
22 . A method for preparing a resin molding material, comprising the following steps:
providing a biomass pyrolysis oil extract;
polymerizing the biomass pyrolysis oil extract to form a stratified solution under an aldehyde, an alcohol and an alkaline catalyst, wherein the biomass pyrolysis oil extract is polymerized at 70-90° C. for 0.5-2 hours;
diluting an under-layer solution of the stratified solution with an alcohol to form a diluent;
impregnating a matrix with the diluent; and
drying, pulverizing and molding the matrix.