Phenolic epoxy system
View Patent ↗The embodiments described herein generally relate to methods and chemical compositions of phenolic epoxy systems. In one embodiment, a composition comprising a phenolic epoxy resin system includes an epoxy resin component and an alkoxylated phenol-aldehyde novolac resin.
1. A composition consisting essentially of:
an epoxy resin component; and
a partially alkoxylated phenol-aldehyde novolac resin, and
an optional curing agent, wherein the composition is a powder.
2. The composition of claim 1 , wherein the epoxy resin component comprises an epoxy group functionality equal or greater than 2.
3. The composition of claim 1 , wherein the composition consists essentially of:
from 20 wt. % to 70 wt. % of the epoxy resin component; and
from 30 wt. % to 80 wt. % of the partially alkoxylated phenol-aldehyde novolac resin; and
from 0 wt. % to 5 wt. % of the optional curing agent, wherein the total weight percent is 100 weight percent.
4. The composition of claim 1 , wherein the optional curing agent is selected from the group consisting of hexamethylenetetramine, oxazolidine, paraformaldehyde, trioxane, 2-methyl imidazole, imidazole, melamine, triethanol amine, tributyl amine, and combinations thereof.
5. The composition of claim 1 , wherein the optional curing agent is present in the composition and comprises from 0.1 wt. % to 5 wt. % of the composition.
6. A composition consisting essentially of:
an epoxy resin component; and
a partially alkoxylated phenol-aldehyde novolac resin, and
an optional curing agent, wherein the partially alkoxylated phenol-aldehyde novolac resin comprises a reaction product from components comprising:
a phenol-aldehyde novolac resin; and
an alkoxylation agent selected from the group consisting of an alkylene oxide, an alkylene carbonate, and a combination thereof; and
an optional alkoxylation catalyst, wherein a molar ratio of the alkoxylation agent to phenolic hydroxyl group reactive sites of the phenol-aldehyde novolac resin is from 0.1:1 to 0.9:1 to form the partially alkoxylated phenol-aldehyde novolac resin.
7. The composition of claim 6 , wherein the composition is a powder.
8. The composition of claim 6 , wherein 10% to 50% of the phenolic hydroxyl group reactive sites of the phenol-aldehyde novolac resin are alkoxylated, the reaction product comprises a hydroxyl group functionality equal or greater than 2, or a combination thereof.
9. The composition of claim 6 , wherein the reaction product comprises a reaction product from components comprising:
from 59 wt. % to 90 wt. % of the phenol-aldehyde novolac resin; and
from 10 wt. % to 41 wt. % of the alkoxylation agent; and
from 0 wt. % to 5 wt. % of the optional catalyst, wherein the total weight percent is 100 weight percent.
10. The composition of claim 9 , wherein the optional catalyst is present in the amount from 0.05 wt. % to 5 wt. %.
11. The composition of claim 6 , wherein the alkylene oxide comprises a compound selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, and combinations thereof and wherein the alkylene carbonate comprises a compound selected from the group consisting of ethylene carbonate, propylene carbonate, butylene carbonate, and combinations thereof.
12. The composition of claim 6 , wherein the composition is a liquid.
13. A process comprising:
reacting a phenol-aldehyde novolac resin and an alkoxylation agent selected from the group consisting of an alkylene oxide, an alkylene carbonate, and a combination thereof, and an optional alkoxylation catalyst to form a partially alkoxylated phenol-aldehyde novolac resin; and
mixing the partially alkoxylated phenol-aldehyde novolac resin and an epoxy resin component and an optional curing agent to form a composition consisting essentially of: the epoxy resin component and the partially alkoxylated phenol-aldehyde novolac resin, and optionally the curing agent, wherein:
the composition is a powder,
a molar ratio of the alkoxylation agent to phenolic hydroxyl group reactive sites of the phenol-aldehyde novolac resin is from 0.1:1 to 0.9:1 to form the partially alkoxylated phenol-aldehyde novolac resin, or
the composition is a powder and a molar ratio of the alkoxylation agent to phenolic hydroxyl group reactive sites of the phenol-aldehyde novolac resin is from 0.1:1 to 0.9:1 to form the partially alkoxylated phenol-aldehyde novolac resin.
14. The process of claim 13 , wherein the partially alkoxylated phenol-aldehyde novolac resin and the epoxy resin component are mixed at room temperature to form the composition.
15. The process of claim 13 , wherein the partially alkoxylated phenol-aldehyde novolac resin and the epoxy resin component are mixed by grinding, blending, or a combination thereof to form the composition.
16. The process of claim 13 , wherein mixing the partially alkoxylated phenol-aldehyde novolac resin and the epoxy resin component is performed in the presence of the curing agent.
17. The process of claim 13 , wherein 10% to 50% of the phenolic hydroxyl group reactive sites of the phenol-aldehyde novolac resin are alkoxylated and the partially alkoxylated phenol-aldehyde novolac resin comprises a hydroxyl group functionality equal or greater than 2.
18. The process of claim 13 , wherein reacting the phenol-aldehyde novolac resin and the alkoxylation agent is performed in the presence of the alkoxylation catalyst.
19. The process of claim 13 , wherein the composition is in liquid or solid form.
20. The process of claim 13 , further comprising applying the composition as a composite, a liquid coating, a hot melt adhesive, a molding powder, a powder coating, or combinations thereof.