Polypropylene–phenol formaldehyde‐based compatibilizers. I. Preparation and characterization

This work deals with the synthesis of a new type of compatibilizer suitable for blends or alloys of polypropylene and engineering polymers having aromatic residues or functionality complimentary to hydroxyl. Polypropylene–phenol formaldehyde graft copolymers from thermoplastic phenol formaldehyde (PF) resins and functionalized polypropylene (f‐PP) were synthesized by reactive extrusion. The content of PF in the graft copolymer was determined by reaction variables like type and density of functionality on PP, molecular weight of PF, and viscosity ratio of f‐PP and PF. The results showed that the viscosity ratio is of primary importance for such reactive processing. Also, type and concentration of the functional groups were important variables. The glycidyl methacrylate functionality resulted in higher conversions than did PP‐g‐maleic anhydride within the available reaction times. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 347–354, 2000     

Introduction of long-chain branches in linear polyethylene by light cross-linking with 1,3-benzenedisulfonyl azide

Metallocene synthesised HDPE with M_w=82,000 and M_n=40,000 was modified with small amounts of 1,3-benzenedisulfonyl azide by reactive extrusion at 200 °C with the purpose to form long-chain branches. At the processing temperature the two azide groups decompose to nitrenes that work as cross-linkers for PE. Cross-linking occurs primarily by insertion of singlet nitrenes into CH bonds. Size exclusion chromatography revealed that the modification resulted in the formation of a long-chain branched (LCB) high molecular weight fraction. The LCB was detectable with SEC for concentrations above 100 ppm corresponding to approximately 0.03–0.04 branch points pr 10⁴ carbon. No signs of the formation of low molecular species due to chain scission were observed. Dynamical mechanical analysis and shear creep test showed sign of long chain branching at concentrations down to the same limit as SEC (100 ppm). These signs were thermorheological complexity, increased zero shear viscosity, increased shear thinning and increased recovery compliance. The cross-linking efficiency of 1,3-BDSA were estimated to 40–60% from comparison of SEC data with random cross-linking theory and traditional SEC-LCB analyses.     

Influence of Resin Molecular Weight on Curing and Thermal Degradation of Plywood Made From Phenolic Prepreg Palm Veneers

The present work evaluates curing and the thermal behavior of different molecular weight phenol formaldehyde (PF) resins used to prepare PF prepreg oil palm stem veneers. The physical properties (solid contents, gelation time, pH, and viscosity) of PF resins were determined. The molecular weight of resins was characterized by gel permeation chromatography, whilst thermal properties were determined by differential scanning calorimetry and thermogravimetric analyses. The average molecular weight of PF resins were 526 g/mole (low), 1889 g/mole (medium), and 5178 g/mole (control - commercial). Among the resins, medium (MMwPF) gives better thermal stability with a retained weight of 48.9% at 300°C. High (Commercial PF) had a low decomposition temperature (109.3°C) which occurred within 11 min. Both low (LMwPF) and MMwPF started to melt at ≥120°C. Based on strength and shear values, phenolic prepreg palm veneers can be prepared using either low or medium molecular weight PF but with varying results. In all cases, the mechanical properties of palm plywood made from PF prepreg veneers were superior to those made from PF-bonded plywood using the commercial process.     

Effect of synthesis parameters on thermal behavior of phenol–formaldehyde resol resin

Differential scanning calorimetry (DSC) was used to investigate the influence of resin synthesis parameters on the thermal behavior of low molecular weight phenol–formaldehyde (PF) resol resins prepared with different formaldehyde/phenol (F/P) molar ratios, different sodium hydroxide/phenol (NaOH/P) molar ratios, and different catalysts. As the F/P molar ratio increased, the molecular weight and activation energy increased while the gel time, peak temperature, resin pH, and nonvolatile solids content decreased. By contrast, the molecular weight, gel time, resin pH, resin solids content, and peak temperature increased with an increasing NaOH/P molar ratio. However, the activation energy decreased with an increasing NaOH/P molar ratio. The polydispersity increased with both F/P and NaOH/P ratios. Calcium hydroxide gave a faster curing resin compared to sodium and potassium hydroxides. All DSC thermograms of this study showed just a single exothermic peak for the resins that were used. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 1415–1424, 2002     

Bark extractives-based phenol–formaldehyde resins from beetle-infested lodgepole pine

In this study, phenol–formaldehyde (PF) resins derived from the bark extractives were synthesized and characterized. Bark of lodgepole pine (Pinus contorta Dougl.) infested by mountain pine beetle (Dendroctonus ponderosae Hopkins) was first extracted with 1% NaOH. The bark extractives with and without acid-neutralization were then dried to the solid state. The neutralized and non-neutralized extractives were used to partially replace petroleum-based phenol for synthesizing the bark extractives-PF resins. In comparison with a commercial PF resin and a laboratory made PF resin (Lab PF), the bark extractive-PF resins were found to have higher molecular weights, higher viscosities, and shorter gel times. Acid neutralization of the bark extractives increased the molecular weight of the extractives and modified the performance and curing behavior of the resulting bark extractive-PF resins. Bark extractive-PF resins (BEPF) showed a similar level of post-cured thermal stability to that of the lab PF at higher temperatures, but they differed significantly from that of the commercial PF resin. The bark extractive-PF resins made from both neutralized and non-neutralized extractives at 30% replacement of phenol (by weight) exhibited similar dry and wet bond strengths to the commercial PF resin. At 50% substitution level, BEPF had dry and wet bond strengths similar to the lab PF resin. Our findings suggest that alkaline extractives from mountain pine beetle-infested lodgepole pine bark are suitable for partially substituting phenol in the synthesis of phenolic resin for use in wood adhesives.     

Use of organosolv lignin in phenol–formaldehyde resins for particleboard production: I. Organosolv lignin modified resins

This paper describes the work considering the potential for partially replacing phenol with organosolv lignin in phenol–formaldehyde resin used as an adhesive in the production of particleboard. Lignin-based resins were synthesised with organosolv lignin using various percentages of lignin replacement for phenol. The lignin was introduced to the resin in two different ways. The first method was the replacement of a certain percentage of phenol (5–40%) with lignin (as supplied) directly into resins. In the second method, lignin was modified by phenolation prior to resin manufacture. Different degrees of phenol substitution (20–30%) were investigated for the production of lignin-based resins. The physical properties of the formulated resins were measured and compared to commercial PF resin.     

Reactive extrusion vs. batch preparation of starch–g–polyacrylonitrile

Acrylonitrile (AN) was graft polymerized onto unmodified cornstarch by a continuous reactive extrusion process and, for comparison, by a typical batch reaction process. The effect of AN/starch weight ratios, level of ceric ammonium nitrate (CAN) initiator, starch in water concentration, reaction temperature, reaction time, and extruder screw speed in the reactive extrusion process was studied. Add-on, reaction efficiency, grafting frequency, weight average molecular weight (MW) and MW distribution of polyacrylonitrile (PAN), and water absorbency of the saponified copolymers were determined. Processing times in the twin-screw extruder (ZSK) were 2–3 min, and total reaction time was about 7 min before reaction of the extruded material was terminated, compared to a reaction time of 2 h used in the typical batch procedure. The continuous reactive extrusion process was found to be a rapid and efficient means of preparing St-g-PAN with high add-on (% PAN of the grafted product). For example, 42% add-on was achieved within the 7-min reaction period using an AN/starch weight ratio of 1.0 (3.5% CAN, starch weight basis), as compared to 38–49% for the 2-h batch process (0.75–1.5 AN/starch ratio). Percentages of homopolymer of the copolymers were low for both extrusion and batch processes. Grafting frequencies were substantially higher while MWs were significantly lower for grafts from the extrusion process. Water absorbency of the saponified St–g–PAN products was somewhat greater for the products prepared by the batch process.     

Phenol–urea–formaldehyde resin co-polymer synthesis and its influence on Elaeis palm trunk plywood mechanical performance evaluated by 13C NMR and MALDI-TOF mass spectrometry

This study evaluated a new method of producing phenol–urea–formaldehyde (PUF) adhesives formulated differently under actual “in-situ” resin synthesis conditions. This was carried out by co-polymerizing urea formaldehyde (UF) resin with phenol–formaldehyde resin in the core layer of low molecular weight (LMW) phenol–formaldehyde (PF) resin treated Elaeis palm trunk veneers during the gluing process of Elaeis palm plywood. Matrix assisted laser desorption Ionization time of flight (MALDI-TOF) mass spectrometry (MS) illustrated and confirmed a series number of the phenol–urea co-condensates repeating unit in the prepared PUF resins which corroborated well with its mechanical properties (modulus of elasticity and modulus of rupture), bonding quality (dry test and weather boil proof or WBP test) and physical properties. A series of PF, UF and PUF resins oligomers forming repeating units up to 1833 Da were identified. Besides that, the solid state ¹³Carbon nuclear magnetic resonance (NMR) interpretation identified that the signal at 44–45 ppm and 54–55 ppm corresponding to methylene bridges were co-condensated in between phenol and urea in the PUF resin system. The ¹³C NMR investigation showed that the synthesis process of PUF resin contained no free formaldehyde elements. Furthermore, the proportion of urea and methylolureas in the mixture to synthesis PUF resin were sufficient and incorporated well into the formulation by reacting with LMWPF units to form co-condensed methylene bridges. This study showed a new and useful method to synthesize PUF resin during the gluing process of manufactured Elaeis palm plywood which can also enhance the performance of Elaeis palm plywood panels for structural instead of utility grade applications.     

Polypropylene–phenol formaldehyde‐based compatibilizers. II. Application in PP/PA6 75/25 (wt/wt) blends

A new class of compatibilizers suitable for blends or alloys of polypropylene and engineering polymers having aromatic residues or functionality complimentary to hydroxyl were evaluated in blends of isotatctic polypropylene (PP) and polyamide 6 (PA6). The compatibilizer consisted of a PP part with a phenol formaldehyde (PF) polymer grafted onto it. In this study, various combinations of the polymer parameter of each compatibilizer building block were examined. Based on the same loading, the compatibilizer with low molecular weight PP and high content of high molecular weight PF was observed to be the most efficient. A compatibilizer content of up to 7.5% by weight gave significant reduction in the average particle size of the dispersed PA phase. Similarly, corresponding improvements in the mechanical properties were observed as the average particle size was reduced. For some of the blends, more than additive improvement in the mechanical properties were achieved. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 355–360, 2000     

Effects of recycled fiber addition on high‐density fiberboard for laminated flooring bonded with phenol‐formaldehyde resin adhesive

The effects of old corrugated cardboard (OCC) fiber addition on high‐density fiberboard (HDF) were investigated in this study. A phenol‐formaldehyde (PF) resin was synthesized in the laboratory with resin solids at 50% content as an HDF binder. The physical characteristics and molecular weight of the PF resin are described herein. The laboratory HDFs were made using the OCC fiber based on 0, 20, 40, and 60% oven‐dry weight addition with the laboratory‐synthesized PF resin. The HDFs were tested for physical strength and dimensional stability properties according to the procedure of ASTM D 1037‐99. Evaluation of the HDFs manufactured using the PF resin showed that the internal bond and bending strength properties were decreased gradually with increasing OCC fiber content. Overall, the OCC fiber can be used at a content of 40% in the substitution of raw materials for HDF manufacture. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Effects of urea and curing catalysts added to the strand board core‐layer binder phenol–formaldehyde resin

Effects of adding urea to the strand board core‐layer phenol–formaldehyde (PF) resin were investigated in conjunction with cure‐accelerating catalysts. Ten percent urea based on the liquid resin weight was added at the beginning, at three different middle stages of polymerization, and at the end of PF resin synthesis. No significant cocondensation between the urea and PF resin components occurred as identified by ¹³C NMR analyses, which corroborated well with the curing and strand board bonding performance test results. The various urea addition methods resulted in resins that slightly differ in the various tests due to the urea's temporary holding capacity of formaldehyde. The preferred method of urea addition was found to do it in the later part of PF resin synthesis for convenience, consistency, and slightly better overall performance. Some cure‐accelerating catalysts were shown to reduce the thickness swelling of strand boards. This study showed the usefulness of adding some urea to strand board core‐layer binder PF resins of replacing higher cost phenolic components with lower cost urea. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Reactive extrusion of polystyrene/polyethylene blends

The feasibility of inducing beneficial changes to polystyrene/polyethylene (PS/PE) blends via reactive extrusion processes is considered. Experiments have been conducted on 50:50 wt.% PS/PE blends that were treated with different levels of dicumyl peroxide and triallyl isocyanurate coupling agent. Both a low molecular weight and a high molecular weight blend series have been investigated. A “more reactive” polystyrene was synthesized by incorporation of a minor amount of ortho-vinylbenzaldehyde. Blends containing this modified polystyrene were subjected to identical processing' conditions on a counter-rotating twin screw extruder. Examination of the tensile properties of the extrusion products suggested that a judicious level of peroxide and coupling agent additives would be beneficial to the ultimate physical properties. The quantity of styrenic phase becoming chemically grafted to the polyethylene matrix was influenced most strongly by the level of the chosen coupling agent. As determined by scanning electron microscopy, the phase morphologies of the tensile test fracture surfaces were strongly dependent upon the reaction extrusion process; those extruded blends that had been exposed to the additive pre-treatment displayed substantially finer microstructure. The enthalpy of fusion of the polyethylene melting endotherm was likewise influenced by both the presence or absence of the additives as well as the molecular weight nature of the blend series.     

Modification of polystyrene by reactive extrusion with peroxide and trimethylolpropane triacrylate

Polystyrene (PS) was modified by reactive extrusion with trimethylolpropane triacrylate (TMPTA) and dicumyl peroxide (DCP). The coupling reaction caused by TMPTA increased the molecular weight of PS, and this coupling reaction was enhanced in the presence of DCP at high TMPTA/DCP ratio. The rheological properties of the extrudate were examined. The impact strength of PS improved as the molecular weight increased by the coupling reaction. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 1672–1679, 2004     

木质素改性高耐磨酚醛树脂的制备及性能研究

利用酶解木质素(EHL)和腰果壳油(CNSL)改性热塑性酚醛树脂,讨论了不同酚醛摩尔比、CNSL用量和1,4-丁二醇对改性树脂性能的影响。研究表明,木质素及腰果壳油双改性的酚醛树脂耐热性能优于腰果壳油改性的酚醛树脂。改性后酚醛树脂基摩擦材料具有良好的摩擦磨损性能,更适合作为摩擦材料的树脂基体。     

Preparation and characterization of microencapsulated polythiol

Microcapsules containing curing agent for epoxy were successfully prepared by in situ polymerization with poly(melamine–formaldehyde) (PMF) as the shell material and high-activity polythiol (pentaerythritol tetrakis (3-mercaptopropionate), PETMP) as the core substance. Having been encapsulated, the core material PETMP had the same activity as its raw version. The synthesis approach was so improved that the consumption of polythiol was reduced to a low level. By carefully analyzing the influencing factors including catalyst concentration, reaction time, reaction temperature, feeding weight ratio of core/shell monomers, dispersion rate and emulsifier content, the optimum synthetic conditions were found out. The results indicated that not only core content and size of the microcapsules but also thickness and strength of the shell wall can be readily adjusted by the proposed technical route. The relatively thin shell wall (0.2 μm) assured sufficient core content even if the microcapsules were very small (1–10 μm). The polythiol-loaded microcapsules proved to be qualified for acting as the mate of epoxy in making two-part microencapsulated healing agent of self-healing composites.     

Engineering Plastics from Lignin. IX. Phenolic Resin Synthesis and Characterization

The performance of phenol-formaldehyde (PF) resins, formulated with lignin derivatives previously synthesized as phenolic resin prepolymers, was evaluated by thermal analysis of the curing process, and by a hard maple shear block test. At 54 and 60% phenol replacement levels, respectively, kraft (KL) and steam explosion lignin (SEL)-based resoles exhibited cure behavior very similar to a standard PF resin. Acid hydrolysis lignin gelled prematurely, and was found to be incompatible with the normal synthesis procedure. Differential scanning calorimetry (DSC) was used to compare kinetic parameters for the curing process of neat and lignin derived phenolic resins. Activation energies and cure rates determined by DSC showed no difference between adhesives. High lignin contents had no inhibitory effect on resin cure. Shear strength properties were evaluated in a compression test, and results illustrate that both lignin-based resins have acceptable strength properties, both in a dry and accelerated aging test. Of the lignins tested, kraft lignin consistently demonstrated superior performance as a pre-polymer in phenolic adhesives. This was attributed to differences in the chemical structure of the two lignins, which had been found to vary in terms of their reactivity with formaldehyde and phenol. KL had been noted to be more amenable to derivatization with formaldehyde and phenol, hence its ability to crosslink with a phenol-formaldehyde fraction during resin synthesis was increased. Positive structural features in KL are a high phenolic guaiacyl (3-methoxy, 4-hydroxy phenyl) content, low carbon-to-carbon bonding between aromatic rings, high solubility in alkali, and a higher number average molecular weight than SEL.     

Synthesis of aromatic polyketones by using biphenylene monomers

Bisfunctional biphenylene monomers were designed, synthesized, and inspected as building blocks for aromatic polyketone synthesis. Starting from 2,2′-dimethoxybiphenylene (1), a highly activated acyl-acceptant biphenylene monomer affording high molecular weight polyketones, two types of biphenylene monomers were developed: 5,5′-bis(3[4]-chlorobenzoyl)-2,2′-dimethoxybiphenylenes (6) which readily gave the corresponding polyketones by nickel-catalyzed aromatic coupling polymerization and 2,2′-bis(trifluoromethyl)-4,4′-biphenylenedicarboxylic acid (27) which reacted with biphenylene 1 in P₂O₅---CH₃SO₃H to give the corresponding fluorinated aromatic polyketone, selectively. The related model reactions for both monomer synthesis and polymerization were also investigated.     

A study on new polymerization technology of styrene

The classic polymerization technology of polystyrene is a high‐cost and nonfriendly environmental technology. Furthermore, the weight‐average molecular weight of polystyrene is hard to enhance up to 400,000 in the classic polymerization technology. The disadvantages limit the growth rate of polystyrene. The solution for increasing the growth rate of polystyrene lies in new technology. The reactive extrusion process of polystyrene was studied in detail and the whole reactive extrusion process of polystyrene was obtained. By means of controlling the flow rate of styrene and the initiator and the screw rotational speed, samples of polystyrene with different molecular weights were synthesized by the twin‐screw extruder. The properties of synthesized polystyrene with different molecular weights were studied; the mechanic properties of polystyrene will increase with an increase of the weight average molecular weight of polystyrene. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 85: 2130–2135, 2002     

Role of fabrication route and sintering on wear and mechanical properties of liquid-phase-sintered alumina

Liquid-phase-sintered Al₂O₃ (LPS) fabricated by slip casting, tape casting, isopressing, uniaxial pressing, piston and auger extrusion showed substantial differences in wear due to differences in morphology as observed in image analyses of SEM micrographs. The abrasive wear was low in the case of uniaxial pressing and high in the case of tape casting in the ‘dry sand and rubber wheel’ test. The wear surface of the tape cast specimen exhibited extensive microcracking possibly due to orientation of Al₂O₃ platelet (major face) parallel to the abraded surface whereas some degree of perpendicular orientation in extruded surface resulted in lower wear loss. In wet-milling wear test, the isopressed balls of a 95–97 wt% LPS derived from reactive powder (<1 μm) showed 25% lower wear loss than that of the extruded balls of a 91–94 wt% LPS derived from coarse powder (70–100 μm). Sintering at a lower temperature with longer duration and batch milling of the composition in between 12 and 16 h resulted in low wear loss. Flexural strength also improved by longer sintering time but did not show any improvement by increasing milling time. However, the variation in flexural strength was minimized by isopressing the extruded specimen. A high indentation fracture toughness at 49.03 N test load was associated with (i) large elongated reinforcement grains in a fine-grained microstructure with overall elongated morphology and (ii) with an intergranular fracture.     

棉秆焦油替代苯酚合成酚醛树脂胶粘剂的研究

采用气/质联用仪(GC/MS)对棉秆焦油的成分进行了分析,确定了62种化合物,其中酚类化合物的相对含量为25.755%。用棉秆焦油部分替代苯酚合成酚醛树脂(PF)胶粘剂,并对其性能进行了研究。实验结果表明,棉秆焦油替代量对所合成的PF胶粘剂的粘度和胶合强度等性能影响较大;当m(棉秆焦油)=25g(即苯酚替代量达到19.2%)时,所制得的PF胶粘剂的粘度适中、w(游离甲醛)<0.5%,具有较高的胶合强度,并且胶合强度达到GB/T9846-2004标准中对Ⅰ类胶合板的要求。由于棉秆焦油的加入降低了PF胶粘剂的成本,因此,该PF胶粘剂具有良好的应用前景。