Novel alkylphenol resins and a method of preparing thereof

Patent metadata

Field	Value
Publication number	US-2020369821-A1
Application number	US-202016992848-A
Country	US
Kind code	A1
Filing date	Aug 13, 2020
Priority date	Oct 29, 2015
Publication date	Nov 26, 2020
Grant date	—

Abstract

Compositions, methods, and resins using alkyl aldehydes and phenols are provided herein. In one embodiment, a composition comprising an alkylphenol resin can be prepared by condensing at least one phenolic monomer selected from the group consisting of phenol, cresol, resorcinol, xylenol, ethyl phenol, alkylresorcinols, and combinations thereof; and at least one alkyl aldehyde having from 5 to 12 carbon atom alkyl groups. The alkylphenol resins of the application are free of octylphenol or nonylphenol monomers. In one embodiment, the alkylphenol resins may be prepared using formaldehyde, and alternatively, in another embodiment, the alkylphenol resins may be prepared without the use of formaldehyde. The process to make these new alternative alkylphenol resins is a cost effective process and easy to scale-up.

First claim

What is claimed is:

1 . A method of forming a composition, comprising:
making a resole alkylphenol resin comprising:
reacting at least one phenolic monomer selected from the group consisting of phenol, cresol, resorcinol, xylenol, ethyl phenol, alkylresorcinols, and combinations thereof and at least one alkyl aldehyde having from 5 to 12 carbon atom alkyl groups in the presence of an acid catalyst, and optionally, an organic solvent that forms an azeotrope with water;
adding a base catalyst and formaldehyde;
reacting the at least one phenolic monomer, the at least one alkyl aldehyde, and the formaldehyde in the presence of the base catalyst; and
performing a reflux or azeotropic distillation process.

2 . The method of claim 1 , wherein the alkylphenol resin acts as a tackifier.

3 . The method of claim 1 , wherein the alkyl aldehyde is selected from the group consisting of 3,5,5-trimethyl hexanal, nonanal, 2-ethyl hexanal, and combinations thereof.

4 . The method of claim 1 , wherein the alkyl resorcinols comprise dihydroxy benzenes having one or two alkyl chains present on a ring.

5 . The method of claim 4 , wherein the alkyl chains comprise from 1 to 3 carbons.

6 . The method of claim 1 , wherein the alkylphenol resin is present in the composition in the range of from 1 to 10 parts per hundred rubber,

7 . The method of claim 1 , wherein the ratio of at least one alkyl aldehyde to at least one phenolic monomer and is from 0.5 to 1.0.

8 . The method of claim 1 , wherein the performing a reflux or azeotropic distillation process comprises a temperature from 100° C. to 140° C.

9 . The method of claim 1 , further comprising providing a solvent with the phenolic monomer.

Assignees

• Hexion Inc

Inventors

• Reddy Ashok T
• Willman Justyne Marie

Classifications

• C08G8/10 Primary

  with phenol · CPC title

• C08G8/04 Primary

  of aldehydes · CPC title

• C08L61/06

  of aldehydes with phenols · CPC title

• C08G8/20

  with polyhydric phenols · CPC title

• C08K5/09

  Carboxylic acids; Metal salts thereof; Anhydrides thereof · CPC title