In-situ alkylphenol-aldehyde resins
View Patent ↗The invention relates to an in-situ process for preparing an alkylphenol-aldehyde resin. The process comprises the step of providing a raw alkylphenol composition. The raw alkylphenol composition comprises one or more alkylphenol compounds and at least about 1 wt % phenol. Each alkylphenol compound has one or more alkyl substituents. The raw alkylphenol composition is reacted directly, without pre-purification, with one or more aldehydes to form an in-situ alkylphenol-aldehyde resin. The invention also relates to an in-situ alkylphenol-aldehyde resin formed from the in-situ process, and its use in a tackifier composition and rubber composition. The tackifier composition and rubber composition containing the in-situ alkylphenol-aldehyde resin show, inter alia, improved tack performance.
1. An in-situ process for preparing an alkylphenol-aldehyde resin, comprising:
providing a raw alkylphenol composition comprising:
one or more alkylphenol compounds, each compound having one or more alkyl substituents, and
phenol;
reacting, without pre-purification, the raw alkylphenol composition directly with one or more aldehydes to form an in-situ alkylphenol-aldehyde resin; and
wherein the alkylphenol composition comprises:
about 50 to about 85 wt % para-tert-alkylphenol,
about 5 to about 10 wt % phenol,
about 7 to about 14 wt % di-tert-alkylphenol,
0 to about 3 wt % ortho-tert-alkylphenol, and
0 to about 1 wt % tri-tert-alkylphenol.
2. The process of claim 1 , wherein the alkylphenol composition includes para-tert-butylphenol.
3. The process of claim 1 , wherein the alkylphenol composition comprises para-tert-butylphenol, phenol, di-tert-butylphenol, and optionally tri-tert-butylphenol and ortho-tert-butylphenol.
4. The process of claim 1 , wherein the alkylphenol composition comprises:
about 50 to about 85 wt % para-tert-butylphenol,
about 5 to about 10 wt % phenol,
about 7 to about 14 wt % di-tert-butylphenol,
0 to about 3 wt % ortho-tert-butylphenol, and
0 to about 1 wt % tri-tert-butylphenol.
5. The process of claim 1 , wherein the aldehyde is formaldehyde.
6. The process of claim 1 , wherein the alkylphenol composition includes para-tert-butyl phenol and para-tert-octylphenol.
7. The process of claim 1 , wherein the alkylphenol composition comprises para-tert-butylphenol, para-tert-octylphenol, phenol, di-tert-octylphenol, and optionally ortho-tert-octylphenol and tri-tert-octylphenol.
8. The process of claim 1 , wherein the alkylphenol composition comprises para-tert-butylphenol, phenol, di-tert-butylphenol, optionally tri-tert-butylphenol and ortho-tert-butylphenol, para-tert-octylphenol, di-tert-octylphenol, and optionally ortho-tert-octylphenol and tri-tert-octylphenol.
9. The process of claim 1 , further comprising the step of reacting the alkylphenol-aldehyde resin with an amine, forming an amine-modified alkylphenol-aldehyde resin.
10. The process of claim 9 , further comprising the step of reacting the amine-modified alkylphenol-aldehyde resin with an epoxide or a chemical reagent for stabilizing the amine moiety in the alkylphenol-aldehyde resin.
11. The process of claim 9 , further comprising the step of reacting the amine-modified alkylphenol-aldehyde resin with a salicylic acid.
12. The process of claim 11 , wherein the amine is morpholine.