Document MMXoJd2bR2yQkaX72w6YrbovM
"INDEXED"
Q0: Dr* Ho H* Hopkins, WiJUa. '0-702.6
Mr. John Marshall, vaim. .d -7014 Mr. A. K, Burke, Wilsu D-0022
Mr. R. 0. lick, Mlm. 1-10448 Mr. J* B. Bullitt, lab,
Df Paul Robinson, Lab. sMr G. W, Kidder, Phila,
Philadelphia Laboratory August 7, 1946
SilEi Haw Materials 1010
Project P-146
M2M0MIDDB REPORT
BEIUfiS TB
L
BKHEiCi COW
NOT FOB CIKtMTiOM
IMPROVED METHODS Off VARNISH MANUFACTURE
a survey has been mad to determine if any of the synthetic varnish Ingredients now purchased as processed raw materials might be considered for synthesis by us from their ultimate components in . solution method varnish making equipment during the cooking cycle. The possible benefits of such a procedure include lower cost varnishes, simplification of raw materials, and greater leeway in varnish formu lation. The varnishes considered in the survey were all those with VC and VC prefixes which were produced in the quantity of 10,000 gallons or more in.any year from 1940 to 1945 inclusive. The number of varnishes in this category total 117 and their 1940 to 1945 production totals 16,100,000 gallons {see fable II). Inasmuch as the grand total of the VC and VG varnish produced in these years was 1?,600,000 gallons, the ones we are considering give an excellent cross section, for they represent 92$ of the total production in these
classes. Other varnish Glassifications, such as VD, VH, VK, VO, to.,
were not included because they are blends, alternates, or are mad from ultimate raw materials, The VB*s were not included because over 95$ of production is already on a natural material basis.
In fable I are listed all the synthetic raw materials used in the manufacture of varnish during the 1940-1945 period, fhese can be classified according to composition into four classesj (1) 100$ pheaolios, (2) modified phenolics, (3) maleic resins, and (4) ester gum types. An analysis of the varnishes made from these and from natural raw materials shows that approximately two-thirds of all varnish produced during the past six years was manufactured from th simplest raw materials available, which comprise natural oils, rosin, natural gums, litharge, lime, etc. The actual percentages obtained are tabulated below*
Haw Materials
natural Raw Materials 100$ Phenolios Modified Phenolios' Ester Gum Types Maleio Resins
64$ 13$
5$ 13$
g$
For convenience in discussing the possibilities of manu facturing varnishes which contain synthetios from their ultimate raw materials, we can divide the above synthetios into two broad classes; (1) 100$ and modified phenolic, and (2) ester gum and maleio types.
100$ and Modified Phenolios:
Several times in the past the Finishes Division Has contem plated manufacturing their own varnish resins in this class. Each time the decision has been in favor of our present practice. The reasons advanced have included the amount and type of new plant equipment required, the fact that our competitors are far ahead of us in the technical aspects, the field is well covered with patents, and we would in effect be competing with other Departments in the Company who sell phenolio and aldehydio raw materials to our compet itors. In order to manufacture phenolic varnishes from their ultimate raw materials, we must have a method which will nullify all or most of these reasons. Sorenson's method of producing aoylatad phenolic varnishes seems to fit the qualifications very well* It puts us ahead of competition technically, provides patent protect-ion, and requires only solution method equipment made of molybdenum stainless steel with a fractionating column. In addition, we would make only varnish fey this method, not varnish gums? so in no sens of the word would w be competing with phenolio gum manufacturers who buy their raw mater ials from other Departments in the Company.
Even though the aoylating method of producing phenolic varnishes look most attractive, there are other methods which may be used to make phenolic varnishes from raw materials which are intermediate between the present phenolio gums and the ultimate raw materials. These include the use of A stage phenolic liquids in making either 100$ or modified phenolio varnishes, and the use of heat reactive phenolic gums along with rosin or ester gum to make modified phenolio varnishes. These methods are less desirable than the aoylating method and should be investigated extensively only if that method does not give us everything we want.
Ester Rum and Maleic Types:
Given the right equipment and unlimited time, there is little doubt that any or all of these varnishes could b duplicated fey using the ultimate raw materials involved; that is, natural oils, oil aoids, polymerized and natural rosin, natural gums, pentaerythritol, maleic, glycerol, etc. However, it must fee remembered that each of these varnishes was formulated to do a certain Job or to duplicate or excel a competitive product in specific properties.
DUP030002822
3
If we tried to matoil tile constants and properties of each varnish and then evaluate it in pigmented products, a considerable length of time would be required, and there would be no assurance that subsequent formulas could be made by using these procedures. A better method would be to.perform sufficient laboratory work to set up the principles whereby the properties imparted by P.E. or xaaleio gums, for example, could be predicted; then us these principles in formulating new, and possibly better, tarnishes. This should out to a very small number the varnishes which would require duplication, and the actual job would be made much easier by the4principles evolved from the research program.
Consideration of the above leads us to believe that the following recommendations as to the future varnish program are in order.
1,. In the immediate future, plan on making all tarnishes from the same natural and synthetic raw materials we are now using. The program on making varnishes from ultimate, raw materials probably will not produce results on a plant scale for about two years.
2. All Engineering work on the manufacture of varnishes in solution method equipment should be done on present varnish formulas, and preference should be given to the largest volume items now made from the natural raw materials.
3. Plan to make all phenolic varnishes eventually by Sorenson's aoylating method. If we find it is impossible to make all phenolic varnishes by this method, w should investigate A stage resins as a more economical means of introducting the phenolic than that now used.
4, Initiate a laboratory research program to determine the principles of formulation whereby the properties imparted to varnishes by P.E. and maleic gums can be predicted and translated at will to the plant scale.
5, In designing solution method equipment which will be used for the manufacture of tarnishes, always consider the fact that the following various types of raw materials may be used;
ibi natural raw materials* 100$ or modified phenolic gums as purchased,
(o P.E. or maleic gums as purchased. (d) A stag liquid pheholios,
Sorenson's acylated phenolic varnishes, Basic raw materials like P.E,, maleic; glycerol, etc. Dehydrated or treated oils. Solid inorganic materials which must be added as
a dry powder or slurry.
PHILADELPHIA LABORATORY
PIS: PL
P. JP. SANDERS
DUP030002823
TABLE I
RAW MSRIALS WHICH MAY BE CQNSIESHED FOR SYNTHESIS IN THE VARNISH KETTia
COBB
' TYRE
APPROXIMATE COMPOSITION
5, Doras #175
"G-7 AmberoX 925
0-8. Run Congo
G-15 Bakelit BR-4036
G-l? Aaberoi K-12-A
G-X8 Balelit BR-254
0-20 Balelit BR-9432
0-28
BR-17000
0-3^
" BR-2963
0-43 Eater Gum
0-55 Fentalyn G
0-60 Bakelit XR-10282
0-70 Varoisa 250
0-77 Bakelit .BR-9434
0-83 Fentelyn A
0-89 Beokasite P-405
0-92 Pentalya 0
0-104 Amber! 890-D
0-105 Aaberoi 891-D
0-10 Run Congo
0-309 Amber! M-86
0-318 Super Beokaoite 1003
0-325 liquid Reedaox 455-B
G-32? Amber! F-7
0-320 Amber! BS-1
0-337 Bakelit BR-17700
0-34! Bakelit BR-11504
0-348 " XE-16689
0-608 Ester Gum
KO-2924 Poly Pal Ester Gum
H-156 Dehydrated Castor Oil
H-557 Kellin Oil
H-589 Vacuum Bodied DCO
VO-SOS0 Bodied DCO
VO-5159 35% IGF Oil
10Q% Phenolic.
PE ester of rosin modified with 3# maleic.
Fin melt.
100$ Phenolic.
Rosin modified with 25% phenolic.
100% Phenolic. MW
nw
*
Ester gam modified'with 25% phenolic. Glyceryl ester of rosin. PE ester of rosin modified with 3% maleic. 100% Phenolic.
nn n ft
PE ester of rosin.
B ester of Polypale rosin.
Rot?
ft
n
04% ester gum, 16% maleio.
ft r
it w
ft
Slack melt. Ester gum modified with. 20% phenolic, 100% Phenolic,
W ft
Ester gum modified with 20% phenolic.
ft ft
ft
R ft
ft
100% Phenolic.
Ester gum modified with 20% phenolic.
100% Phenolic* Oiyoeryl ester of rosin. Glyceryl ester f polymerized rosin.
.*
1,0, modified with 4% maleio.
L.O* modified with 35% OF,
DUP030002824
-5-
ML VARNISHES MUCH IN 1940-1945 INCLUSIVE
VARNISH CODE
VC-791
VC-805
VC-810
VC-829 VC-837 VC-861 VC-876 VG-880
VC-894 VC-950
VO-959 VC-966 VC-978 VC-1000 VC-1022 VC-1040 VC-1081 VC-1082
VC-1084 VC-1092
VC-1094 VC-1113 VC-1122 VC-1123
VC-1124 VC-1136 VC-1158
VC-1329
VC-1431 VC-1518
VC-1570 VC-1856
VC-1864 VC-1963 VC-2020
VC-4005
vc-4052 VC-5052 VC-5062 VC-5066
vo-5067 VO-5068 vc-5069 vc-5109 VC-5112
VC-5133 VC-5137
/TOTAI* PRODUCTION
1940*19455 GALLONS
389,000 827,000
792,000 18,000 31,000 29,000 78,000 68,000 86,000
3,826,000 23,000 18,000 33,000
125,000 180,000 111,000
585,000 57,000 80,000 18,000 32,000
171,000 141,000
68,000 13,000 37,000 17,000 984,000 87,000 33,000 12,000 31,000 45,000 24,000
34,000 21,000
150,000 205,000 107,000 135,000 1,217,000
96,000 32,000
229,000 14,000
50,000
16,000
AERIALS TOOH MAY BE C SYNTHESIS IN THE VARNI
G-105 0-327, G-328 or G-55 None
0-105 Non 0--36, 0--43 0-328 Non 0-43, H-156, H-589 None
0-105 0--43, 0--60 None G-15, 0-18 or 0-70 None
n
0-43,0--318 None
G-327 G-17, V0-5080 H-156 0-43 0-43, KO-2924, H-156 Non
H-557 0-43, KG-2924, H-156 Non
G-43 0-328 Non 0-608 0-328 G-328
0-327 None
n
0-43, H-156 0-7, 0-55, VO-5159 None 0-7, H-156 0-105, H-156 0-83 0-105 G-83, H-156 None
DUP030002825
TARNISH CODE
vo-5151 VO-5153 0-5153 0-5170 0-5176 0-5193 0-5194 0-5206 VO-5207 0-5208
0-5223 0-5228 0-5230 0-5232
0-5244 0-5253 0-5270 0-5272 VO-5274 0-5276
0-5277 0-5278 0-5283 0-5288 0-5529 0-7738 0-7767 0-7781 VC-8010
0-8013 0-8018 0-8032
0-8053 0-8056 0-8062 0-8070
0-8081
0-8099 0*8106
0-8116
0-8122 0-8125 0-8131 0-8370 0-8520 0-8810
0-234 VG-924
VG-955 G968
w
TOTAL PRODUCTION
1940*194? GALLONS
44.000 40.000 42,000
12,000 15,000
24,000 114,000
20,000
14,000
25,000
18,000 27.000 106,000 17.000 19,000 15.000 121,000 38.000
13.000
18,000 17.000 58.000
11,000
29,000 83,000 238,000 56,000 59,000 363,000 48,000
40,000 49,000 33,000 84,000 20,000 31,000 127,000 292,000 52,000 19,000 115,000 54,000 26,000 79,000 46,000
532,000 18,000
39,000 37,000
-6-
TABm II (coat'd)
MATERIALS TOOH MAI BE GONSI33SHSD FOR amassaIS IN THE VARNISH KETTLE
G-20 Non 1
G-7 G-43 G-89 G-20 G-18 G-20 G-83, H-I56 G-7, VO-5159 G-92 H-589, G-92
G-18
G-28 G-92 or G-89, H-I56 Non G-327, G-32S G-43 G-328 Non
G-83
vr--
Non G-18 Non
G-309 Non
G-327 G-43 None G-18 Non
w
w
w
to
G-337 Non
to to to to
H-156
Non to
n
G-105
DUP030002826
" -V"'";-
: ~w>
TARNISH GOES
TO-1097 TO~U56 VG-1264 VG-1430 TO-2065 TO-4295 YG-5015 YG-5047 VG-5128
TO-7634 TO-8399 0-979
TABLE II (oont'd)
TOfAT.
PHOBOCTION
1940-1.945
MATERI/iXS MilGH MAT BE CONSIDERED FOR
GALLONS
SYNTHESIS IN THE VARNISH KETTLE
67,000 16,000 99,000 239,000
59,000 44,000 66,000 22,000 94,000 37,000 42,000
18,000
,
No b
G-43 Non
\
G-83, 6--104 Non
G-5 6-77
0-3.27 ion
DUP030002827