Document xjk8m0qo6m6O1LKoK5v7R0Q01
FILE NAME: General Electric (GE)
DATE: 1975 Nov 25 DOC#: GE195
DOCUMENT DESCRIPTION: US Patent - Asbestos-Free Heat-Resistant Phenolic Molding Composition
United States Patent [19]
Barker et al.
[54] ASBESTOS-FREE HEAT-RESISTANT TMHOELRDMINOGSECTOTMAPBOLSEITPIHOENNOL-ALDEHYDE
[75] Inventors: PR.icFhlaorrdenHti.neB,aPrkitetsrf,ieDldal,tobno;thForafnk Mass.
[73] Assignee: General Electric Company, Pittsfield, Mass.
[22] Filed: June 12, 1974 [21] Appl. No.: 478,785
[[5521]] UIn.tS..CCll.2...............................................................................2..6..0../.1..C7.028;L2610/0/328 [58] Field of Search.................................26Q/17.2, 38
[56]
References Cited
UNITED STATES PATENTS
3,567,667 3/1971 Rumbold.......................... 260/17,2
nn 3,922,241
[45] Nov. 25, 1975
33,,685183,,735506 45//11997742 LTiseuvkrueimeotnat!.e.t...a..l..................................... 226600//32.85 OTHER PUBLICATIONS
C--hFeimlle. rA,"bsYt.a6ts8e:n1k1o54e0tfa, l". Structural Material-Resins
APsrismisatarnytEExxaamminineerr----DEodnwaaldrdEW. Cozoadjbaerry AMt.toPranpeuyg, aAgent, or Firm--William F. Mufatti; Donald
[57]
ABSTRACT
pAonsiatisobnesctooms fprreies,inhgeaint raedsmistiaxntutrpeh, eanpohliecnmoloicldrinesgincoamnd alufliolsleerfciboemrsb.ination of aluminum silicate, talc and cel
6 Claims, No Drawings
1
3,922,241
2
ASBESTOS-FREE HEAT-RESISTANT
invTehnetiopnheins oplriceferreasibnlyeampphloeyneodl-ailndethheydperarecstiinceanodf tchains
THERMOMSOELTDTIANBGLECOPMHEPONOSILT-IAOLNDEHYDE
bacetianngyfprohmenolels-asltdheahnydoeneremsionlewthoicmhoirseptrheapnaroendebmy orlee
This invention relates to an asbestos free, heat resis 5 otifonans taoldperhoyvdideepaerremsionl.eIoflfepsshethnaonl uonndeemr coelertoafinancoanlddei
tmanixttuprheeanoplhicenmoloicldriensgincaonmdpaofsiiltlieorncocmombipnraistiinong oinf aaldu hayndoevioslaucs.edT,htehenorevsoilnacsorepsriondiuscgeedneisraclolmy mthoentlyypceatlhleadt
minum silicate, talc and cellulose fibers.
can be finely ground and requires blending thereof with
BACKGROUND OF THE INVENTION
10 taentreaxmteirnnealincroorsdsleirnktiongpraogveindtesaucthhearsmhoesxeatmtaebtlheyrleensien
Phenolic molding compositions have been available
which can be advanced to an infusible state upon expo sure to elevated temperatures. While any external
ffoilrlemr.aTnhyeyaeasbrsesatnods aisreusgeednearsaallyreminafdoercwinitghfiabnerasobresatsoas 15 cferrorsesdlinekxitnergnaagl ecnrotscslainnkbinegeamgepnlot yisedhehxearmeient,hythleeneptreet
mreoinldfoinrgcincgomfiplloesri.tiTonhewaitshbeisntcorseapsreodvimdeeschtahneicphl,enthoelirc rpalomyiende.hGereenienratollyp,rtehpeaprreetfhererendovroalnagceiosf0a.l5d-e0h.9ydme oemles
mal and electrical properties. However, the use of as bestos filled phenolics provides a hazard to those ex
tmhoelreesofthpeerreomf.oWlehoilfe pahneynoalldaenhdydperecfaenrabbelyem0.p6lo-y0e.8d
poTsehde stotanthdiasrtdypfoerodfirmecatteerxiaplo.sure to asbestos fibers is 20 ahledreehinydsue,chbuatsyrfaolldmeahlyddeeh,yfduer,fupraarladfeohrymdael,deethcy.,dteh,eapcreet
ctiloenarallySdaefteatyileadnbdyHtheaeltDhepAadrmtmineinsttroaftiLonab(oOr'SsHOAcc).upEaf fheyrdree.d aldehyde to be employed herein is formalde
fteucrtesooff epxhpeonsoulirce mtooplderinsogncnoeml ipnovuonlvdedininwthhiechmaranwufaacs- 25 peWr mheonle eomf pphloeynionlg, amoonree-stthagane roensien mis oplreodoufcaedldwehhyidche
biselsetsossoibsvhiaonudsliesdthoerhperaolctheshseadzairsdwteollpdereslionnenaetledin. sWhohpast ccaantiobne aodfvealnevceadtetdo taenminpfeursaitbulreesst.aTtehbeyothnee-msteargeearpepsliin
tmhoatldmedolpdaratssb.estos material and finish or machine the wachtiicnhg mcaonrebetheamnpolnoeyemdohleeroefinanisaoldneehpydreeppaerredmboyleroef
wiItnh aosrbdeesrtotso, tchoemdpelvyelowpitmhenOtSoHfAasbsteasntodsa-rfrdese dpehaelninog 30 tphheenporlefaernrdedpraelfdeerhaybdlye i1s.1fo-r3m.0almdeohleysdet.hereof. Again,
lic molding compositions which comply with the OSHA law is needed. However, there are properties problems
In addition, it has also been observed that when using a phenolformaldehyde novolac, favorable molding
amsosoldciinagtedcomwpitohsiteiloimnsi.naTtwinog oafsbtheestokseyfrpormopeprhtieensoelifc- 35 cthhoa-roarcttheorisctoincsteanrteoofbletasisntehdanw7h0enwtehigehntopveorlcaecnthoasf tohre
fecTthede haeraetdriemsiesntasinocnea,lmsteacbhialintyicaanl danhdeaetlercetrsiisctaalnpcer.op ttoatinalednowvhoelanc tchoemoprotshitoi-oonr.thOoptciomnutemntreissulatrsouarned o5b0
etirotniess mouf stthebenoant -laesabstesetoqsuipvhaleennotlitcomthoeldainsbgecsotoms-pcoosni
weight percent, by the balance of the novolac consists of ortho-para and para-para linkages.
ttahieninnognc-aosmbpesotsoitsiocnosm. pAodsditiitoionnsamllyu,stthbee meqoludiavbailleitnyt. toof 40 meBtyhytlheenseebvriadrgioinugs bteytpweesenofthlienkpahgeen,olitnuisclmeieaanndt ctahne
tisheusaesdbfeosrtoass-bfiellsetdoscaonmdpnoosnit-iaosnbse.sStoinscceomthpeossaitmioensm, othlde be represented by the following formulas:
snhorni-naksabgeestoofs bcootmh ptyopseitsiosnhsoushldoubledsinmoitlacrh.aInngsehonrotr,mthael 45
opTerhaetinoonn-parsobceesdtousrefsil,leart cleoamstbiinnaatiodneloetfetrhioeuinsssteannstei.n
vention satisfies this criteria.
A.
OH
OH
DESCRIPTION OF THE INVENTION
50
ch2
sisTtahnetipnhveennotiloicnmisodldirinecgtecdomtopoasnitaiosbnecsotoms-pfrrieseinhgeiant arde maluixmtuinreu,maspilhiceantoel,ictarlcesainndancedllaulofislleerfibceorms.bination of 55 usTedhewfiitlhlerthceomphbeinnoaltiiconreosfinthperoinvsitdaenstainmveonldtiionng wcohmen ortho-ortho linkage pasobsietsitoons hfailvleindgphheeantorleicsisrteasnint pcroompeprotsieitsiobne.ttAerlstoh,anheaant gdreefaletcetriounsintgemthpeerfailtluerrecoamndbindaiteiolenctorifcthsetriennsgttahnt airne 60 B . tvieonntaiollny, inwpaltaecre oabf saosrbpetsitoons, inarpcherneosliisctarnecsein,s. tAendsdilie strength, flexural strength, flexural modulus, compres stiievse ostfreanpgthhe,nIozloicd irmespinacwt iatnhdtdhreopfilblearllciommpbaicntaptrioonpeor-f 65 tfhileledinpsthaenntoliincv, reenstiinoncoamrepocsoitmiopna.rable to an asbestos
3,922,241
ortho-para linkage
OH
fcleonutrotof afsobrmestaos5f0ib/5e0rsmainxdtur1e5. wTehieghbtlepnedrciesntthoenf wcoomod 5 spuofufincdieendt itno amseclrtetwheexretrsuind.eTrhaet maboolutetn2m20ixFturwehiischadis
ovranpceeldletthfroorumg.h the screw and extruded into granular
EXAMPLE II
j0 ExampIe Iis repeated except that a filler combination
ocefn1t4owfetiaglhctapnedrc8enwteailguhmt ipneurmcesnitlicoaftec,el1lu5lwoseeigfhibtepreris
used in place of the asbestos.
Each of the materials so prepared in Examples I and
15 tIiIoanr,e sHuebajtectDedeflteocttihoenfo(llAowSTinMg teDst-s6:4W8)a,terDiAelbescotrrpic
4St9r5e)n,gthTe(nAsSilTe MStDre-n1g4t9h), (AArScTRMesisDta-n6c5e1)(,ASFTleMxurDa-l
The individual components of the combination of fill 20 SDt-r7e9n0gt)h, C(AomSTprMessDiv-e79S0tr),enFgltehxu(rAaSl TMModDul-u6s95()A, SITzoMd
aernsdocfeltlhueloisnestfaibnetrisnavreenctioomn,mie.er.c,iaallluymaivnaailsaiblilceaitne,vtaarlic tIemstpascptec(AimSeTnMs aDre-2m56oAld)edanfdrotmhecDornovpenBtaiollnIaml pmaoctld. iAnlgl
ous forms and grades. The combination of fillers can be methods. The results are tabulated as follows:
employed in an weight percent.
amount of Preferably
from about 15 to about 50 the filler combination con
25
TABLE I
stailiincsatfer,ofmroamboaubtou5tt5o taobaobuotu2t02w0ewigehigthpteprecrecnetnatloumf tianlac Test
1E1xample IExample
laonsde ffriobmersa.bSoauitd5wtoeigahbtoupter1c0enwtesigbhetinpgerbcaensetdofonceltlhue 30 WDHieaeatlteercDtAreifcblesScottrireopnntgio(thTn(^,6,0at2c42p6sh4.r.2)p5siC) ,st.
03.820 03.520 360 350
weight of the molding composition. The composition of this invention is prepared by
Arc Resistant (sec) VPM ) Tensile Strength (psi)
7108000 8108000
methods well known to those skilled in the art. For ex ample, the individual ingredients are mixed together in
FFlleexxuurraall SMtroednugltuhs ((ppssii)) Compressive Strength (psi)
11X201000" 11X20100*0 23000 27000
a suitable vessel and then fed directly hopper of a screw extruder or roll mill.
to
the
feed
35
IDzroodplmBaplal cItm(fpt-alcbt/i(ni.n.noVttclhb). weight)
.1310 .1333
It should be noted that the phenolic resin composi
etinotnsadodf itthiviseincvoemnptioounncdasn,wahnidchgeanreeranlloyrmdoa,llhyavuesepdreisn such compositions in addition to the composition of
moDldimedenpsaiornt atlo mstaabiniltiatiyn ritesfedrismetonsitohnes wabitihliitny roeaf sothne
this invention. Included among these other additives are fillers such as wood flour, calcium carbonate, glass
able limits under a wide variety of ambient conditions; pitairst ipsaartcicoumlaprolyneinmtpinoratadnetvwicheeonr tahsesemmoblldyewdhpichhenmoulisct
fibers, etc. and any combination of these or other known fillers employed in the phenolic molding com
reTlyhoisnpcrloopseertpyarwt atsoleevraalnucaetsedfofrorsutchceescsofmulpoopseitriaotnisono.f
position as well as such acid, etc. In a preferred
additives as coal, lime, stearic embodiment of the instant in
45
cEoxmamprpelsessioInanmdoIlId.eTdhe1Vtezsitn.mXol3diinng.sr, eicntathnigsuclaarseb, owxeerse,
vcoennttaioinn,litmhee icnomampoousinttiosnofoffrotmhe4intosta1n0twineivgehnttpioenrcmenaty. %Va iinn.. daneedpl,Awinit.h(cbrootstsosmec)t.ions of 0.100 in. (walls) and
In yet another preferred embodiment the composition of the instant invention may contain coal in amounts of
50
weDreimtreancskioendsovinerbaotphertihode
olefn1g5thdaaynsdatwriodotmh tdeimrepcteiroan
from 5 to 15 weight percent.
ture, 150F, 200F and 250F.
PREFERRED EMBODIMENT OF THE INVENTION The results are tabulated as follows:
moTrheeclfeoalrlolywtihnegperxinacmipplleeasnadrperasectticfeorotfhthtios inilvluesnttriaotne to those skilled in the art and unless otherwise speci
TABLE II
afireed,pawrhtseroer pparretcsenotragpeesrcbeyntwageiegshta.re mentioned, they Temperature
Example II*
ExaIm* ple
EXAMPLE I
R15o0o"mF Temperature(75F) 200F
01..14 2.3
021...263
A phenol-formaldehyde resin is prepared by reacting 250F
2.9
3.4
tahbeouptre0s.7enmceoloefsaonf faocridmacladtaehlyysdt,ewphericmh oislesuobf spehqeuneonltliyn These numbers indicate dimensional change of length m mils per inch.
neutralized, to form a novolac. The novolac is ground to a
fine
particle
size
with
65
tioTnhaendredsuieltlescitnriTc asbtrleenIgtdhemweornestsriganteifitchaanttlhyeaimt pdreoflveecd
abbaoseudt o1n6 twheeiwghetighpterocfenntovooflahce. xamethylenetetramine
with the composition of Example II whereas water ab sorption, arc resistance, tensile strength, flexural
The resin mixture is then blended with 38 weight per- strength, flexural modulus, compressive strength, Izod
5 3,922,241
6
impact and drop ball impact data of Example I were sentially of in admixture, a phenol-aldehyde resin and a
cthoamtpaatrhaibglheerwtitehmpEexraamtuprlees tIhI.eTcaobmlepoIsIitidoenmoonf sEtrxaatmes floilsleerficboemrsb;isnaaidtiofinlleorfcaolmumbiinnuatmionsilpicraetsee,nttailncaannadmceolulunt
ple II exhibits less overall change in dimension than the composition of Example I. Therefore, the filler combi
5
of from about 15 to about 50 weight percent based on the weight of the molding composition.
nation of the instant invention provides a phenolic 2. The composition as defined in claim 2 wherein the
tmieosldthinagncaomcopmospiotisoitnioonf ccoomntpaainrianbgleaasbndesbtoest.ter proper aalbuomutin5umto asbiloicuatt2e0iws epigrhestepnetrcienntanbasaemdoounnttheofwefrigohmt
theExaalummpilneumII wsialiscarteep, etaaltcedanudsicneglluvlaorsyeinfgibearms.oTunhtesroef 10 of3t.hTehmeoclodminpgocsoitmiopnoassitdioenfi.ned in claim 1 wherein the
sults obtained were similar to those set forth in Tables I and II.
twaelcigihstprpeesrecnetnitn abnasaemd oounnttohfefrwomeigahbtouotf 5thtoe amboouldtin20g
prOesbevnitouinsvlye,ntoitohnerarmeopdoisfsicibalteioinnstahnedlivghartiaotfiothnes oabf otvhee
composition. 15 4. The composition as defined in claim 1 wherein the
ctehaacnhgiensgsm. aIyt bies, mtahdeerefinorteh,e tpoarbtieculuanrdeemrsbtoooddimethnatst c5etlolualobsoeutfib1e0rws eairgehpt rpeesrecnetnitnbaanseadmoonutnhteowf efrigohmt oabf othuet
described which are within the full intended scope of the invention as defined by the appended claims.
mo5l.dTinhge ccoommppoossiittiioonn. as defined in claim 1 which con
What is claimed is:
tains lime. 20 6. The composition as defined in claim 1 which con
1. An asbestos-free, heat-resistant thermosettable phenol-aldehyde molding composition consisting es-
tains coal.
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