Phenolic resins, also known as phenol-formaldehyde resins, are synthetic polymers that are produced from the reaction of phenol or substituted phenol with formaldehyde. They were first developed in the late 19th century and find uses in many industrial and consumer goods due to their good electrical properties, heat and abrasion resistance, and moldability.
Chemistry of Phenolic Resins
Phenol and formaldehyde undergo a polycondensation reaction to form Phenolic Resins. The reactions mainly involve hydroxymethylation of phenol rings followed by condensation of the hydroxymethylated phenol intermediates. The hydroxymethylation reaction produces methylol phenols such as bismethylol phenol. These intermediates then polymerize through methylene (CH2) bridge linkages forming three-dimensional crosslinked thermosetting networks.
The polymerization process can be alkali-catalyzed or acid-catalyzed. Alkali-catalyzed ("novolac") resins are thermoplastic before curing but become thermosetting after the addition of hexamethylenetetramine or formaldehyde. Acid-catalyzed ("resole") phenolic resins are heat-reactive and thermosetting as produced. Varying the reactants, reaction conditions, and curing methods allows control over properties of the final products.
Applications of Phenolic Resins
Due to their heat resistance, mechanical strength, moldability, and electrical insulation properties, phenolic resins find wide usage across many industries:
- Molding Compounds - Used for making electrical insulators, small appliance parts, and automotive components that require heat and wear resistance. Good dimensional stability under heat.
- Laminates - Used to produce decorative surfacing materials, toilet seats, and electrical switchgear panels. Phenolic-coated papers provide heat, abrasion, and chemical resistance.
- Wood Adhesives - Durable bonds are formed for making plywood, particle board, fiberboard. Adhesives bond well even under wet conditions.
- Insulation - Phenolic foams are used for thermal and acoustic insulation in appliances, construction, and industrial uses. Rigid fiber insulation boards are also produced.
- Friction Materials - Phenolic novolacs are binders for brake and clutch linings/pads used in automobiles due to their heat resistance.
- Foundry and Refractory Binders - Used to make cores and molds that need high heat resistance during metal casting processes.
- Abrasives - Phenolic resins are used to bond and coat abrasives in products like sandpaper, grinding wheels, and honing sticks.
- Coatings - Durable coatings are produced for flooring, metallic substrates, and roofing due to corrosion and wear resistance.
Advantages of Phenolic Resins
The key advantages offered by phenolic resins stem from their chemical structure and performance properties:
- High mechanical strength and hardness coupled with flexibility impart impact and abrasion resistance.
- Good thermal stability - phenolic resins can withstand temperatures up to 150°C without softening. The crosslinked structure provides heat resistance.
- Electrical insulation properties make them suitable for applications involving dielectric materials.
- Molded phenolic resins exhibit dimensional stability and do not readily change shape with variations in temperature, pressure or humidity.
- Chemical resistance to alkalis, dilute acids, oils and solvents. Not readily attacked except by oxidizing acids.
- Low smoke emission and minimal toxicity in case of fire, imparting fire safety.
- Excellent adhesive properties for bonding various materials like wood, metals etc. due to reactivity of functional groups.
- Economical cost and wide commercial availability.
Future Outlook
The phenolic resins market is projected to grow steadily driven by their expanding use in construction and automotive sectors. Ongoing research aims to develop phenolic resins with enhanced properties like flexibility, scratch/solvent resistance for newer applications in coatings, composites and high-performance adhesives. Bio-based phenolic resins from lignin are also being developed to reduce dependence on non-renewable phenol. With their versatile properties and performance advantages, phenolic resins will continue playing an important role as industrial thermoset materials.
Get more insights on Phenolic Resins
Global phenolic resins market size was valued at USD 9.30 billion in 2015 and is expected to grow at an estimated CAGR of 5.4% from 2016 to 2022.
Technological advancements have fostered the development of unique heat shields with ablative phenolics for aerospace applications, leading to greater market share in recent years.Development of lignin and corn-based renewable feedstock have also presented new growth avenues in the industry.
Increasing awareness regarding resource conservation and the implementation of stringent sustainability standards has positively impacted green materials demand, encouraging manufacturers to integrate such raw materials into their products.Download FREE Sample of this Report @ https://www.grandresearchstore.com/report-sample/global-phenolic-resins-2019-2023-676Novolac emerged as the dominant product segment, occupying nearly 50% of the volume share in 2015.
These resins are increasingly being designed for use as hardeners or curing agents in epoxy applications to meet the demand for laminates, adhesives, molding materials, and coatings.
The segment is expected to grow at around 5.2% CAGR from 2016 to 2025.Key companies operating in the industry are BASF SE, Momentive Specialty Chemicals, Sumitomo Bakelite Co. Ltd., Georgia-Pacific Chemicals, and Kolon Industries Inc. Other major participants may be listed as Owens Corning, Arclin Inc., Olympic Panel Products LLC, Ashland Inc., DIC Corporation, and Hexcel CorporationPhenolic Resins Report by Material, Application, and Geography Global Forecast to 2023 is a professional and comprehensive research report on the world?s major regional market conditions, focusing on the main regions (North America, Europe and Asia-Pacific) and the main countries (United States, Germany, United Kingdom, Japan, South Korea and China).The report firstly introduced the Phenolic Resins basics: definitions, classifications, applications and market overview; product specifications; manufacturing processes; cost structures, raw materials and so on.
Then it analyzed the world?s main region market conditions, including the product price, profit, capacity, production, supply, demand and market growth rate and forecast etc.
