[0001] In some aspects, this invention relates generally to a method of making a (particulate) epoxy resin. The method uses a dispersion promoting agent whose solubility in water decreases with increasing temperature.

[0002] Commercially-produced epoxy resins are usually made by either (A) reacting a bisphenol (e.g. bisphenol A) and a low molecular weight liquid epoxy resin at high temperature or (B) directly by condensation of a bisphenol and epichlorohydrin in an aqueous slurry. In both alternatives it is difficult to heat or cool the reaction mixture through the reactor walls. Effective agitation is also a problem due to the viscous nature of the reaction mixtures. Further, for route (A) the necessary high temperature may lead to undesired side reactions and catalyst deactivation. Additional drawbacks for route (B) include the necessary salt removal, resin separation/recovery and difficulties in attaining a relatively high molecular weight product.

[0003] U.S. Patent No. 3,296,157 to Brojer et al., the teachings of which are incorporated herein by reference, discloses a method of manufacturing epoxy resins having a softening point of 50 ⁰ C to 160 ⁰ C. Brojer et al. reacts a bisphenol with a compound such as epichlorohydrin in the presence of aqueous caustic alkali and a water-soluble organic polymer in an amount which is effective to form a protective colloid, thereby obtaining the thus formed resin as a suspension of stirrable beads. As specific examples of water- soluble organic polymers Brojer et al. mentions polyvinyl alcohol and the sodium salt of carboxymethylcellulose.

[0004] British Patent (GB) 1,088,496 teaches a process for producing a condensation product from a dihydric phenolic compound and an epihalohydrin using an alkaline condensation agent in the presence of an emulsifier and/or a protective colloid and in the presence of a solvent miscible with water and water.

[0005] In some aspects, this invention is a method of making an epoxy resin by condensation of at least one polyphenolic compound and at least one condensation compound selected from epichlorohydrin, l,3-dichloro-2-propanol, and homologs thereof in water that is free of added organic solvent at an elevated temperature and in the presence of one or more catalysts. The method comprises carrying out the condensation in the presence of at least one dispersion promoting agent whose solubility in water decreases with increasing temperature. The water is preferably free of added organic solvent, whether the organic solvent is miscible with water or not. More preferably, the water contains no added solvent that is miscible with water (e.g. a lower alcohol with from 1 to 3 carbon atoms or a ketone). In other words, no organic solvent is added to water to form an aqueous phase for use in the above method. An organic solvent may interfere with the effects of the dispersion promoting agents. An organic solvent may also increase the cost of volatile removal and waste stream treatment.

[0006] In some variations, the aforementioned method may comprise (i) forming, at a temperature below the elevated temperature, of a dispersion of the at least one condensation compound in water that is free of added organic solvent, which dispersion comprises, in addition to water, the at least one polyphenolic compound, the catalyst, and the at least one dispersion promoting agent and (ii) heating such dispersion to the elevated temperature.

[0007] In some variations, the aforementioned method may comprise (i) forming, at a temperature below the elevated temperature, a dispersion of the epichlorohydrin in an aqueous alkali hydroxide solution which comprises water (with no added organic solvent), the at least one polyphenol and the at least one dispersion promoting agent and (ii) heating such dispersion to the elevated temperature.

[0008] In some aspects, this invention also includes an epoxy resin that results from various methods and variations thereof presented herein. The epoxy resin is preferably a particulate material with an as-formed average particle size within a range of from 10 nanometers (nm) to 1000 micrometers (μm), more preferably from 10 μm to 500 μm. The epoxy resin preferably has a number average molecular weight (Mn) of from 1500 grams per mole (g/M) to 3000 g/M and/or a weight average molecular weight (Mw) of from 3000 g/M to 7000 g/M.

[0009] Unless otherwise stated, a reference to a compound or component includes the compound or component by itself, as well as in combination with other compounds or components, such as mixtures of compounds.

[0010] Recitation of numerical ranges within this specification equates to a disclosure of all numerical values and ranges within that range as well as end points of such range. For example, if a range is from 1 to 50, it includes, for example, 1, 7, 34, 46.1, 23.7, or any other value or range within the range.

[0011] Examples of suitable polyphenolic compounds include bisphenols (diphenols). In addition, substances with a higher number of phenolic hydroxy groups per molecule than two (2), (e.g., novolac resins, especially preferably low molecular weight novolac resins) may also be employed, either alone or in combination with one or more bisphenols. In addition, non-phenolic polyhydroxy compounds such as l,4-bis(hydroxymethyl)benzene, 1 ,3-bis(hydroxymethyl)benzene, 1 ,4-bis(hydroxymethyl)-cyclohexane, 1,3- bis(hydroxymethyl)cyclohexane hexanediol, and cyclohexanediol, may also be present in the reaction mixture. One or more bisphenols usually accounts for at least (>) 30 wt%, preferably > 50 wt%, more preferably > 70 wt%, and still more preferably > 90 wt%, based upon total weight of polyphenolic compounds present in the reaction mixture.

[0012] Examples of suitable bisphenols include bisphenol A, brominated bisphenol A, bisphenol F, bisphenol K (4,4'-dihydroxybenzophenone), bisphenol S (4,4'- dihydroxyphenyl sulfone), hydroquinone, resorcinol and 1,1-cyclohexanebisphenol. Bisphenol A is a preferred bisphenol for use in the present invention.

[0013] Suitable condensation compounds include at least one of epichlorohydrin, 1,3- dichloro-2-propanol, epihalohydrin and homologs of these compounds, with epichlorohydrin being a preferred condensation compound. Other condensation compounds such as diepoxy compounds (e.g., cyclooctene diepoxide, divinylbenzene diepoxide, 1,7-octadiene diepoxide, 1,3-butadiene diepoxide, 1,5-hexadiene diepoxide, and the diepoxide of 4-cyclohexenecarboxylate 4-cyclohexenylmethyl ester); as well as glycidyl ether derivatives of novolacs such as phenol novolac, cresol novolac and bisphenol A novolac may also be present. Epichlorohydrin usually accounts for > 30 wt%, preferably > 50 wt%, more preferably > 70 wt%, and still more preferably > 90 wt% of all condensation compounds present in the reaction mixture.

[0014] The reaction mixture includes the one or more condensation compounds in a concentration of > 10 wt%, preferably > 15 wt%, more preferably > 20 wt%, and still more preferably > 30 wt%, but usually no higher than (<) 90 wt%, preferably < 70 wt%, more preferably < 50 wt%, and still more preferably < 40 wt%, based on total reaction mixture (condensation compound, polyphenolic compound, water, dispersion promoting agent, and catalyst) weight.

[0015] The condensation compound and the polyphenolic compound are preferably present in concentrations such that a ratio of (a) number of epoxy groups (and/or groups equivalent thereto) of the at least one condensation compound to (b) number of (phenolic) hydroxy groups of at least one polyphenolic compound in an initial reaction mixture is preferably > 0.5:1, more preferably > 0.6:1, still more preferably > 0.65:1 and even more preferably > 0.7:1, but preferably < 5:1, more preferably < 2.5:1, still more preferably < 1.5:1, even more preferably < 1.25:1, and yet more preferably < 1:1. Using, as an example, epichlorohydrin as the condensation compound and Bisphenol A as the polyphenolic compound, epichlorohydrin has one epoxy group and Bisphenol A has two hydroxy groups, which provides a ratio of 0.5:1.

[0016] If one chooses to express content of the condensation compound and the polyphenolic compound molar ratio basis, the compounds are present in a ratio of the former to the latter within a range of from 1:1 to 10:1, preferably from 1:1 to 1.3:1.

[0017] Any compound capable of catalyzing a condensation reaction of the condensation compound and the polyphenolic compound in water can be used as the catalyst. Non- limiting examples include inorganic compounds that dissolve in water to form an alkaline solution, e.g. oxides and hydroxides of metals such as lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), zinc (Zn) and aluminum (Al). Preferred catalysts include oxides and hydroxides of alkali metals (especially Li, Na and K) and alkaline earth metals (especially Mg and Ca) . The catalyst is more preferably sodium hydroxide (NaOH) or potassium hydroxide (KOH), with NaOH being especially preferred.

[0018] Typically employ the one or more catalysts in an amount such that the molar ratio of catalyst(s) such as NaOH or KOH to epoxy (and/or equivalent) groups of the condensation compound(s) is not higher than (10 : 1), e.g., not higher than (5 : 1), not higher than (3 : 1), not higher than (2 : 1) or not higher than (1.5 : 1), but not lower than (0.5 : 1), e.g., not lower than (0.7 : 1), not lower than (0. 9 : 1), or not lower than (1 : 1). [0019] The catalyst and the condensation compound are present in amounts that provide a molar ratio of catalyst to condensation compound epoxy groups (and/or groups equivalent thereto) of from 10 :1 to 0.7 : 1, preferably from 1.5:1 to 1:1.

[0020] The dispersion promoting agent is a (usually polymeric) compound whose solubility in water decreases with increasing temperature. In other words, solubility of the dispersion promoting agent in an amount of water may, for example, be significantly higher at 20 ⁰ C than its solubility in the same amount of water at 50 ⁰ C, e.g., by a factor of

> 1.5, preferably > 2, more preferably > 3, still more preferably > 4, even more preferably

> 5, yet more preferably > 10, and further more preferably > 20, or even higher.

[0021] Examples of suitable dispersion promoting agents, which may be used singly or in combination, include cellulose ethers and in particular, cellulose ethers which are substantially free of functional groups which are different from ether and hydroxy groups. Specific examples of such cellulose ethers include cellulose ethers which comprise one to four carbon atoms (C _1-4 ) alkyl and/or C _1-4 hydroxyalkyl groups such as, methylcellulose, ethylcellulose, propylcellulose, hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose and hydroxypropylmethylcellulose. Preferred dispersion promoting agents include hydroxyalkylcellulose materials such as hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose and hydroxypropylmethylcellulose.

[0022] The dispersion promoting agents used in various aspects and variations of this appear to differ from polymers specifically mentioned in U.S. Patent No. 3,296,157, i.e., polyvinyl alcohol (PVA) and the sodium salt of carboxymethylcellulose (CMC), in that solubility of the latter polymers does not decrease with increasing temperature. The dispersion promoting agents described herein, i.e. those with a decreasing solubility in water with increasing temperature, appear to be absorbed at an interfacial area between an organic phase (comprising, e.g., epichlorohydrin) and a water phase (that contains no added organic solvent and comprises, e.g., a polyphenolic compound which is dissolved by means of the caustic catalyst) and, upon heating the reaction mixture, have a tendency to precipitate at the interfacial area, possibly due to their decreased solubility at the elevated temperature employed. This precipitation results in the formation of a protective polymer film which prevents the agglomeration of the epoxy resin which is being formed both at the interfacial area and inside dispersed droplets. Absent agglomeration, there appear to be minimal difficulties in mixing, mass and heat transfer as well as washing, neutralizing and resin recovery. Another potential advantage associated with the use of the dispersion promoting agents described herein is an ability to obtain higher epoxy resin molecular weights than one can obtain without such dispersion promoting agents.

[0023] The dispersion promoting agent(s) is present in a concentration that is preferably > 0.02 wt%, more preferably > 0.05 wt%, and still more preferably > 0.1 wt%, but preferably < 2 wt%, more preferably < 1 %, and still more preferably < 0.5 % by weight, each based on the total weight of dispersion promoting agent, polyphenolic compound(s) and the condensation compound(s)

[0024] The reaction mixture may contain one or more additional substances that differ from a polyphenolic compound, a condensation compound, a catalyst and a dispersion promoting agent. Non-limiting examples of such substances include dispersants and emulsifiers such as quaternized or hydrophobic ally modified cellulose ethers, water soluble polyethylene glycol copolymers, water soluble polyethylene glycols with functional end group, water soluble polyethylene oxide copolymers, and inorganic salts such as, e.g., carbonates, phosphates, and sulfates of alkaline earth metals (for example, calcium phosphate (Ca ₃ PO ₄ ), magnesium carbonate (MgCO ₃ ), calcium carbonate (CaCO ₃ ), barium carbonate (BaCO ₃ ) and calcium sulfate (CaSO ₄ )). These substances will usually be employed, if at all, in a concentration which is > 0.02 wt%, preferably > 0.05 wt%, and more preferably > 0.1 wt%, but < 2 wt%, preferably < 1 wt %, more preferably < 0.5 wt%, each based on the total weight of polyphenolic compounds and condensation compounds present in the reaction mixture.

[0025] The elevated (reaction) temperature is preferably > 30 degrees centigrade ( ⁰ C), more preferably > 40 ⁰ C, still more preferably > 50 ⁰ C, even more preferably > 60 ⁰ C, and yet more preferably > 70 ⁰ C. The elevated temperature is preferably < 150 ⁰ C, more preferably < 140 ⁰ C, and still more preferably < 130 ⁰ C.

[0026] Typically practice the method of this invention at atmospheric pressure, but superatmo spheric pressure (e. g. up to five (5) atmospheres (490.33 kilopascals) may also be used. [0027] Epoxy resin recovery employs standard procedures such as separation from the reaction mixture (e.g., by filtration), washing/neutralizing and drying. A non-limiting example of a suitable neutralizing agent (for neutralizing excess catalyst) is sodium hypophosphate (NaH ₂ PO ₄ ) in, for example, a 25 % water solution.

[0028] The epoxy resin preferably has a particle size distribution where > 98 % of the particles (and preferably up to 100 % of the particles) have an as-formed particle size (diameter) > 10 nm, more preferably > 20 nm, but < 1000 μm, preferably < 900 μm, or and more preferably < 800 μm. Alternatively, the particles preferably have an average particle size > 10 μm, more preferably > 50 μm, and preferably < 500 μm, more preferably < 300 μm, and still more preferably < 200 μm. Measure particle size distribution by, for example, using a Beckman Coulter dynamic image analyzer with RapidVue 2.006 software.

[0029] The epoxy resin has an average molecular weight that can vary over a wide range. The number average molecular weight (Mn) is preferably > 1500, more preferably > 1800, and still more preferably > 2000, but preferably < 4000, more preferably < 3000, and still more preferably < 2500. The weight average molecular weight (Mw) is preferably > 3000, more preferably > 3500, still more preferably > 4000, even more preferably > 4500, and yet more preferably > 5000, but preferably < 7000, more preferably < 6500, and still more preferably < 6000. Skilled artisans recognize that molecular weight is a dimensionless number even though some express molecular weights in terms of Daltons or grams per mole.

Example (Ex) 1

[0030] To a IL round bottom flask equipped with an overhead stirring apparatus, a cooling condenser and a heating mantle, add 300 grams (g) of deionized water, 28.1 g of 50% NaOH, and 64.1 g of Bisphenol A to form a reaction mixture. Heat the reaction mixture, with agitation at a rate of 570 revolutions per minute (rpm), to 50 ⁰ C under a continuous nitrogen purge. After the Bisphenol A completely dissolves, cool the reaction mixture (flask contents) to 40 ⁰ C, then add 75 g of a 0.33% hydroxypropylmethylcellulose (HPMC) (Methocel®F75M, The Dow Chemical Company, a 2% water solution is 75,000 centipoises (75,000 millipascal seconds (mPa-s))) water solution to the flask. Agitate the flask contents for five (5) minutes (min.), then add 32.5 g of epichlorohydrin to the flask. Heat the flask contents (organic phase and water phase), with stirring, to 95°C and maintain that temperature for 160 minutes. Cool flask contents 70 ⁰ C, then drain the flask of its contents, and wash the flask with 350 g of deionized water 3 times, adding the wash to the flask contents. Neutralize excess NaOH in the resin with 25% NaH ₂ PO ₄ solution, then separate resultant epoxy resin powder filtration and vacuum dry the powder at room temperature overnight. The dried powder has an average particle size of 100 μm.

Ex 2

[0031] Replicate Ex 1 with changes. Increase the amount of 50% NaOH to 30.8 g and decrease the amount of HPMC solution to 60 g. The dried powder (white) has an average particle size of 250 μm, a Mn of 1970 and a Mw of 3970.

Ex 3

[0032] Replicate Ex 1 with changes. Increase the amounts of deionized water and 50%

NaOH respectively to 350 g and 32.4 g. Mix 32.5 g of epichlorohydrin with 37.5 g of the

0.33% HPMC solution in a first beaker, then add beaker contents to the flask in place of the 75 g of HPMC solution. In a second beaker, dissolve 0.64 g of a cationic hydroxyethyl cellulose (HEC) in 10 g of water and add the second beaker contents to the flask after the first flask contents addition. Reduce the time at 95°C to 120 minutes. The dried powder (white) has an average particle size of 338 μm, a Mn of 1920 and a Mw of

3520.

Ex 4

[0033] Replicate Ex 3 with changes. In the first beaker, mix 32.5 g of epichlorohydrin with 5 g of a 2% solution of a different HPMC (METHOCEL™ F50, The Dow Chemical

Company, viscosity of a 2% water solution is 50 centipoises (50 mPa-s)) and an additional 75g water. The dried powder (white) has an average particle size of 423 μm, a

Mn of 1850 and a Mw of 3490.

Ex 5

[0034] Replicate Ex 4, but reduce the amount of the cationic HEC to 0.48 g. The dried powder (white) has an average particle size of 448 μm, a Mn of 1860 and a Mw of 3500.

Ex 6

[0035] Replicate Ex 4, but use a different cellulose ether (HPMC) (METHOCEL™

KlOO, The Dow Chemical Company, viscosity of a 2% water solution is 100 centipoises (100 mPa-s ). The dried powder (white) has an average particle size of 338 μm, a Mn of 2070 and a Mw of 3900.

Ex 7

[0036] Replicate Ex 6, but reduce the amount of the cationic HEC to 0.48 g. The dried powder (white) has an average particle size of 438 μm, a Mn of 2130 and a Mw of 3880. Ex 8

[0037] Replicate Ex 6, but reduce the amount of the cationic HEC to 0.36 g. The dried powder (white) has an average particle size of 407 μm, a Mn of 1980 and a Mw of 3480.

[0038] Ex 1 through Ex 8 above show that use of a dispersion promoting agent that has a decreasing solubility with increasing temperature helps produce a relative large particle size epoxy resin that is easily recovered and has a reasonably uniform particle size. By way of contrast Ex 9 (comparative) and Ex 10 (comparative) show that Na-CMC and a polyethylene glycol, respectively, provide low product recovery (90% loss in Ex 9) or large coagulates that are not readily recovered via filtration and washing (Ex 10).

Ex 9 (Comparative)

[0039] Replicate Ex 1 with changes. Reduce deionized water addition to 250 g and increase the temperature used for Bisphenol A dissolution to 56°C. Substitute 6 grams of 1% water solution of a sodium salt of carboxymethyl cellulose (Na-CMC) for the HPMC solution. Addition of the Na-CMC solution prompts formation of a white dispersion. Filtration, as in Ex 1, yields only 6 g of fine white powder, the majority (approximately 90 wt%) of the product being a very fine white powder that rapidly clogs the filter. The powder that passes through the filter has an average particle size of 240 μm, a Mn of 1320 and a Mw of 2960.

Ex 10 (Comparative)

[0040] Replicate Ex 1, but substitute 0.48 g of a polyethylene glycol (MPEG 4000, The Dow Chemical Company) for the HPMC. During heating, an initially formed dispersion collapses into large coagulates. Abort this example without product recovery. Similar results follow with substitution of other glycols for the MPEG 4000. Ex 11 (Comparative)

[0041] Replicate Ex 1, but substitute 0.48 g of an ethylene oxide propylene oxide block copolymer (ATSURF™ 108) for the HPMC. During heating, an initially formed dispersion collapses into large coagulates. Abort this example without product recovery.