Modified phenol-formaldehyde resole resins, methods of manufacture, methods of use, and articles formed therefrom

摘要

A method for the manufacture of a modified phenolic-aldehyde resin composition, comprises reacting a base with a phenolic compound to produce a phenolate medium; adding an aldehyde source to the phenolate medium wherein the initial mole ratio of aldehyde to phenolic compound is about 0.7:1 to about 1.4:1; heating the aldehyde source and phenolate medium for a time and at a temperature sufficient to yield an aldehyde-phenolate medium with a level of free aldehyde of less than about 0.5% of the total mass on a liquids basis; adding a urea-aldehyde condensate to the aldehyde-phenolate medium; and condensing the resulting urea-aldehyde-phenolate medium, wherein the modified phenolic-aldehyde resin composition is not infinitely dilutable in water. A modified phenolic-aldehyde resin prepared by this method is also disclosed, as are articles prepared therewith.