PHENOLIC RESINS

PROF. PRAKASH MAHANWAR

HEAD, DEPT.OF POLYMER TECHNOLOGY &

DEPT. OF SURFACE COATINGS

INSTITUTE OF CHEMICAL TECHNOLOGY

MATUNGA, MUMBAI-400 019
Phenolic resins are the oldest commercially
manufactured synthetic polymer. They were first
'invented' by Leo Hendrik Baekland in 1907. He
was the one to develop an economical method to
convert these resins to moldable formulations which
were transformed by heat and pressure to hard and
resistant molded parts.
Why Phenolic Resins??

Phenolic resins are distinguished by broad array of

application areas amongst Thermosetting and
Thermoplastic resins.

They are relatively inexpensive and highly versatile

having vital role in construction, automotive, electrical,
and appliance industries.

They are irreplaceable materials for selective high

technology applications offering high reliability under
severe circumstances.
 Continued…

Prominent features of Phenolic Resins are:

- Excellent thermal behavior
-High Strength level
-Long thermal and mechanical stability.
-Excellent fire, smoke,and low toxicity
characteristics.
-Excellent electrical and thermal insulating
capabilities.
-Excellent cost performance characteristics.
 Market scenario

According to the Chemical Economics the global
market for Phenolic resins had reached 2.46 million
tonnes by 1997 (on a 100% resin weight basis) with
39% of demand in NAFTA, 24% in Europe, 5% in
Japan and the balance of 33% in other regions in
2005 where as in 2008 the rate of increase in
worldwide market was 8-12% than 2005.
world consumption of Phenolic resins
 Basic Chemistry

Phenolic resins are obtained by step growth polymerization of

difunctional monomers (aldehydes) with monomers of functionality
greater than 2 (Viz, Phenol, substituted Phenols or combination of
phenols).
Key factors in the design of the desired phenolic resin are:
- Molar ratio of F to P
- Mode of catalysis: Acid, base, metal salt, enzyme.
-Liquid, Solid, dispersion
-Thermoplastics or thermosetting
Low to medium Mw are considered as “ Reactive intermediates which
can be cured or undergo various transformation reactions via reactive
hydroxyl group viz, Epoxy,allyl, cyanate or form new ring structure.

REACTION OF PHENOLAND ALDEHYDE UNDER ACIDIC OR BASIC

CATALYST ARE EXOTHERMIC REACTIONS ( SIDE REACTIONS DUE
TO EXOTHERM NEEDS TO BE AVOIDED)
 PHENOLIC RESINS

THERMOPLASTIC RESINS NOVOLAC RESINS THERMOSETTING RESINS RESOL

FIP< 1 RESINS
MONOMERS:
FIP>1
A. Phenol- OH

OH OH OH OH

CH 3
CH 3 C CH 3 (CH 2 ) 7 CH 3

CH 3

PHENOL CRESOL p-t-BUTYL p-OCTYL p-PHENYL

(o/m/p) PHENOL PHENOL PHENOL

OH OH OH
CH 3

HO C OH
OH
CH 3
C 15 H 27
(CH 2)8
CH 3

p-NONYL RESORCINOL CARDANOL BISPHENOL 'A'

PHENOL
RAW MATERIAL AND CATALYST

- Phenol, o,m,p-Cresol, p-tert Butylphenol, p-tert Octylphenol,

p-Tert Nonylphenol, (2,3), (2,4), (2,5), (2,6), (3,4), (3,5) –
Xylenol, Resorcinol, Bisphenol A, Bisphenol-F, CNSL, BNSL ,
etc.

- Formaldehyde, Acetaldehyde, Propionaldehyde, n-
butyraldehyde, Isobutyraldehyde, Glyoxal, Furfural, etc.

Catalyst:
-Acid: Organic Acids and Mineral acids
-Base: NaOH, KOH
-Metal salts
-Enzymes
Contd.

Mode of catalysis and molar ratio of F to P decides the type and property of
Phenolic resin.

Mode of Catalysis dictates the overall property of Resin.

Depending on type of catalyst and ratio:

Base catalyst: Resol, F/P >1, Liquid, solid, solution/limited stability

Acid Catalyst: : Novolak, F/p <1, Solid, stable

Metal Salts: Resol/Novolak, F/P >1, Liquid/Solid , Varying stability

Enzymes: Pseudo Novolak, No ( CH2O), Solid, stable.

Phenols of lower functionality are used to incorporate special properties in the resin.

Formaldehyde is preferred because of its high reactivity and freedom from side
reactions
VARYING F/P RATIO, TYPE OF CATALYST ONE CAN TAILOR THE PRODUCT WITH:
- Required Melting Range
- Required Molecular weight
- Required functional groups available for modifications.

Three reaction sequences must be considered:

1. Formaldehyde addition to phenol.
2. Chain growth or prepolymer formation.
3. Cross linking or curing reaction.
 PHENOLIC RESIN PROCESSSES

PHENOL PHENOL (EXCESS)

+ +
FORMALDEHYDE (EXCESS) FORMALDEHYDE
+ +
BASIC CATALYST ACIDIC CATALYST

RESOLES NOVOLAC
(THERMOSETTING RESINS) (THERMOSETTING
RESINS)

RESITE CURED RESINS

ONE STAGE PROCESS TWO STAGE PROCESS

 Phenolic Resin Chemistry

Formaldehyde Reactions
-Monomers react with formaldehyde under different
conditions to make different products
-Reacting under acid conditions yields thermoplastic
resins (Novolaks)
-Reacting under base conditions yields reactive resins
(Resoles)
-Resole resins can be used for curing of elastomers
Curing Of Resin

Complex polymer with multiple reactive sites (resole resin)

Undergoes multiple reactions simultaneously

Activated by halogens (resinous, elastomeric,or metallic salts)

Requires zinc source for best results

 Two prepolymers types are obtained depending
on pH

Type of phenolic resin Novolac Resols

Type of reaction Electrophilic aromatic Nucleophilic

substitution mechanism

Medium (pH) Acidic medium(1-5) Alkaline medium(>7)

Molar ratio P/F 1:0.80 1:1 to 1:3
Type of polymer Linear or slightly Branched
branched

Characteristic property Low MW, soluble and Insoluble and infusible

permanently fusible
Varients and their Effect
General Ratio: p,p’:o,p’:o,o’1:2:1

Catalyst:

F/P Ratio : Softening Range

4-6 pH With Divalent metal salts as
catalyst: High Ortho (57-58%: o-o,
1:065 : 60-70
40-42%: o-p and 2-3% p-p)

1:075 : 70-75

Oxalic Acid: (25-26%: o-o, 48-50%: o-
p and 25-30% p-p)
1:085 : 80-100

Phosphoric Acid: (23-25%: o-o, 50-
52%: o-p and 25-30% p-p)

Sulphuric Acid : (25-26%: o-o, 45-

50%: o-p and 25-30% p-p)
Batch Calculations: Novolak

100 gm batch of Novolak:
Phenol + Formaline----
100 gm Novolak Resin +n Water
1 n ( Mole wt of Phenol) + 0.8 n ( Mol wt of HCHO)= 100 gm+ 18xn gms
94n + 0.8n x 30 = 100+18n
94n + 24n =100
100n = 100
n=1
Quantity of 100% pure Phenol= 94 x1.18gms
Assume 96% pure Phenol
Actual weight of Phenol = 97.91 gms
Quantity of 100% pure formaldehyde= 24 gms
Assume 35% solution of Formaldehyde
Actual weight of Formaldehyde = 68.57
Catalyst ( Oxylic Acid) 1.5% mole on Phenol = 0.944 gms
Actual weight of Oxalic Acid = H00C-COOH.2H2O ( Mole wt 126 , Eq Wt. 63)
Resol

100 gm batch of Resol:
Phenol + Formaline----
100 gm Resol Resin + 1n Water
1 n ( Mole wt of Phenol) + 1.5 n ( Mol wt of HCHO)= 100 gm+ 18n gms
94n + 1.5n x 30 = 100+18n
94n + 45n =100+18n
121n = 100
n = 0.826
Quantity of 100% pure Phenol= 77.644 gms
Assume 96% pure Phenol
Actual weight of Phenol = 80.88 gms
Quantity of 100% pure formaldehyde= 24.7 gms
Assume 35% solution of Formaldehyde
Actual weight of Formaldehyde = 70.8gm
Catalyst ( NaOH) 1.5% mole on Phenol = 1.21 gms
Actual weight of NaOH = ( Mole wt 40 , Eq. Wt. 40)
Steps in Resin Manufacture (Bettleheim and Nihlberg)

Warming up time;

Ripening, the time at condensation temperature before the time

starts to precipitates;

Post ripening, the time is held at condensation temperature after

resin separates from the aqueous phase;

End Point Check: Alcohol Solubility, Free Phenol Content, and

Gelation time

Distillation;

Concentration, the period the resin is held under vacuum and heated
to advanced to the desired viscosity;

Cooling.
Chek Points

A. Free Formalin:
Sample+ Acetone+25ml, 10% Hydroxylamine Hydrochloride +
Bromophenol Blue V/s 0.1N NaOH (Yellow to Violet)
% Free Formalin= ( B-S) X NX 3.003
-----------------------
W
B. Free Phenol:
Sample ( distillate)+ 25 ml Brominating Solution+ 10 ml of 10%
KI V/s 0.1N Sodium Thisulphate using Starch solution ( Blue
to) Colorless
% Free Phenol= ( B-S) x 0.001566x100xV
--------------------------------
V
Different types of phenolic resins
There are two types of phenolic resin - Novolac and Resol
Where Novolac is two stage compound. And Resol is one stage
compound.
 Phenolic resin Modifications

Use of phenol derivatives like alkyl phenols.

Etherification of the methylol group or phenolic hydroxyl group.

Reaction with unsaturated compounds like reactions with rosins.

Physical modification such as mixing with vinyl resins or rubber.

Reaction with epoxide compounds or poly isocyanates.

Reaction with inorganic acids or inorganic compounds.

Different Modification of Phenolic Resin
Epoxy Modification:
The resulting products exhibit high strength, strong adhesion,
excellent dielectric properties and improved oxidation resistance.

CH 2 -Cl
O + O-CH 2 -CH-CH2-0-
OH

CH 2 CH 2 CH 2
O O O
CH CH CH

CH 2 CH 2 CH 2
O O O

CH 2 CH 2

n
 Condition for preparation of epoxy phenolic resin
1. Ratio of Resol to epoxy resin : 15:85 and 40:60

2. Epoxy equivalent weight : more than 1500

3. Transition temperature : about 750C

4. Stoved temperature : over 1800C

5. Curing catalyst : phosphoric acid or organic

phosphates

Chemistry : The hydroxy methyl groups of the Resol react with the
hydroxyl groups of the epoxy resin in addition to the reaction of the
phenolic hydroxyl groups with the epoxide groups to form cured,
flexible coatings.
Properties:
Combination of resols with epoxy resins are of high suitability in the
production of stoving enamels which are cured at above 2000C to give
chemical resistant, highly elastic and firmly adhering coatings.

Applications:
1. Used in marine anti-fouling paints in combination with chlorinated rubber.

2. Used in interior and exterior coatings for packaging, drums and cans.

3. Coating of panels for containers and packages for storage and packaging
of food stuffs and other products.

*Epoxies made with Bis F, a Bis F and Novolac mixture, or Novolac resin

exhibit greatly improved chemical and heat resistance compared to the much

more common Bis A epoxies*

2. Diisocyanates

Fast curing.

Used as Single component polyurethane coating.

Used as crosslinkers in polyester powder
coatings.

Suceptible to thermal dissociation.
 Urea, melamine Modification
OH OH O
O
CH2 OH -H2O CH2-NH-C-NH2
+ H2N-C-NH2

Application in particle boards, plywood, mineral fibre bonding, foundry

resins and laminates.

Improvement of flame retardant property.

 Using Imide precursors
O O
OH OH
NH2 O NH-C- C COR

COOCH2 CH2 OH
COOH

Improvement in higher temperature characteristics of phenolics

Rosin acid-modified phenolic resins

They render oil solubility to Phenolic resin, good through drying of the
film, high hardness, good gloss high chemical resistance and high
abrasion resistance

Rosin modified phenolic resins are used in printing inks, in oil lacquers
and in additives to alkyd paints because of their good compatibility with
natural oils in which they improve the drying and gloss.

They are used in primers, Anticorrosive Coatings, as fillers, Putties.

Phenol Ester Resins

In these resins, the phenolic hydroxyl group is esterfied.

These are important for the plastic sector.

Phenolic resins are combined with saturated polyesters in order to
improve their flexibility

Phenol Ether Resins

In these resins, phenolic hydroxyl group is etherified.

These include
1. Epoxy-Novolacs.
2. Allyl ether resols.
3. Water soluble binder system.
4. Phenol ethers with the ether group as polymer linking member.
 Alkyl phenol resins

Starting material : para and ortho substituted phenols

Suitable for boiling down with unsaturated fatty oils imparting

hardness and resistance properties to these systems at a
temperature of 240-2600C

Ratio of oil to resin : > 2:1

Applications

Oil and heat reactive resins.

Tackifiers for rubber processing.

Marine varnishes.

Glazes.

Adhesives
Alkyl phenol resin dispersions
The boiling of thermoplastic alkyl phenol resins with oils gives rise to

products which can be dispersed in aliphatic or aromatic hydrocarbons.

Properties
1. Good adhesion.
2. Abrasion resistance.
3. Good water resistance.

Applications
1. Anticorrosion primers.
2. Quick drying road marking paints.
3. Protective coating on metals.
Boron-modified phenolic resins
-The prepared BPR is intended for use as the innermost lining in a multilayer

composite for tank armor and related future applications.

-The usage of borates in enhancing flame retardancy of phenolic resin

paraformald triphenyl borate

ehyde (PF) (TPB)
Silicon modified resin

The addition of silicon compounds for improval of thermal resistance of
phenol formaldehyde resins was recommended by E.G. Rochow way
back in 1941.

The modification is performed by chemical reaction of silicones or
siloxanes containing reactive groups with phenolic compounds or by a
mixture of components.

The addition of silanes as adhesion promoters is widespread. Example:
mineral wool mats, foundry sands, silica microsphere composites.

HX
Si X

OH
R
+ R Si O + ROH
Si OR

H2O
Si OH
Phosphorus modified resin

These resins are obtained by esterification of novolacs with phosphoric
acids or by reaction with phosphorus oxychlorides.

These exhibit excellent heat resistance in oxidizing media.

Outstanding flame resistance.

OH OH

CH2 CH2 O P O
+
Cl P Cl O
2HCl CH2
CH2
O
Heavy metal modified resins

Heat and flame resistant resisns are obtained by reaction of
phenol or phenolic resins with

Metal halides like molybdenum trichloride, titanium tetrachloride,
zirconium oxy chloride, tungsten hexa chloride

Metal alcoholates like aluminium trimethoxide, titanium
tetramethoxide.

Metal organic compounds (acetyl acetonates).
Applications
1. Manufacturing of high temperature resistant phenolic resins.
2. Deeply coloured resins due to the presence of ionic bound metal.
Example : phenol reacted with titanium tetramethoxide gives red
coloured titanium modified resins
Nitrogen modified resins

Some polycondensation products of formaldehyde with aromatic amines
are characterized by significant stability.

The most thermo stable materials are polycondensation compounds of
formaldehyde with p-amino phenol.

Example : p-amino benzyl alcohol undergoes polycondensation by loss of
water.
Application
1. Production of laminates and molding compounds for electrical applications
2. High tracking resistance and favourable elecrical properties.
3. Used to modify wood and mineral fiber binder and foundry resins

H2 N CH2 OH NH NH CH2 NH
Sulfur modified resins

Direct reaction of phenols and sulfur occurs in presence of
alkaline catalyst at 1300C -2300C.

The simplest compound resulting from this reaction in dihydroxy
diphenyl polysulfide which can be further reacted with
formaldehyde or crosslinked with resols.
Applications
1. Manufacturing of resins with high plasticity.
2. High water solubility.
 Vegetable Oil Modified Phenolic Resin

The phenol-added vegetable oil is react with an aldehyde to form
a vegetable oil-modified phenolic resin.

A laminate produced by impregnating paper with the vegetable

oil-modified phenolic resin and laminating and moulding the
impregnated paper is excellent in low temperature punching
quality and electrical properties and is free from low molecular
weight components oozing out the surface of the laminate.

Tung Oil-modified Phenolic Resin

A Linseed Oil-modified Phenolic Resin by using a Lewis Acid

 APPLICATIONS
#Automotive industry
- Tires as tackifire and reinforcing agent
- Friction and clutch facings
- Sound insulation felts

#Building and Construction industry

- Composites
- Insulation foam
- Grinding wheels and abrasive paper
 APPLICATIONS
# Metallurgical industry
- Foundry casting
- Refractory materials

# Paper industry
- Carbonless Copy paper
- Paper impregnation

#Electronical
- Coating of capacitators, resistors
- Electrical laminates
Surface Coating Application of Phenolic resins
Effective properties of Phenolic coatings

High metal adhesion.

Low water vapour/ oxygen transmission.

Excellent chemical and abrasion resistance.

Moderately high temperature characteristics.

Curing temperature range – 160 to 2000c.

Crosslinking at room temperature promoted by acids or pre reaction

with drying oils.

Unmodified phenolic resins result in brittle coatings due to structural

rigidity of cured resin.
Types of Phenolic Coatings

Automotive Coatings

Metal container coatings

Marine paints
Automotive coatings

Modern automotive enamel topcoat is acrylic resin crosslinked with
MF resins

Vehicles like maleic anhydride, epoxy ester, alkyd and acrylic resins
are crosslinked with phenolic resins for better corrosion resistance
and throwing power of the coating.

Additional flexibility is provided by alkylphenols.

The automotive under coat is applied by electrodeposition(ED) or a

variation of the “dip” operations.

Suitable crosslinking agents for cationic electrodeposition system

include MF,UF, blocked isocyanates and phenolic resins to produce
well cured coatings.
Metal container coatings

Metal containers like steel, chromium plated steel, tin plate,
aluminium or aluminium alloys are coated phenolic/epoxy resin
system.

Phenolic resins are used for pails, drums, collapsible tubes,aerosol

cans and for the interior/exterior food containers.

Food stuffs containing sulphur cause black stains on the metal.

Phenolics coatings offer excellent resistance to corrosion, chemicals

and sulfur staining compounds.
Marine coatings

Marine paints are important for all phases of marine construction,

vessels and currently offshore oil platforms

Shop primer- the most successful ones are based on phenolic

resin/polyvinyl butyral combination, zinc dust or aluminium/ epoxy
resin combination or zinc silicate.

For ship repairing, primer coat based on polyvinyl butyral/ phenolic

resin/ phosphoric acid.

Second coat consists of oil and rosin modified phenolic resins having
anti corrosive property.
Other Applications
Foam for floral arrangements
Adhesives
Floor Polish
can Coating
Toll manufacturing

Printing Ink
THANKS************
TIME
to
WORK & ENJOY