Synthesis of Phenol Formaldehyde Resin with Paraformaldehyde and Formalin

Abstract

Phenol and formaldehyde are the well-known raw materials used in synthesizing Phenol Formaldehyde (PF) resin. PF resin has been used extensively in various applications including molding and composite laminate industries. This study focused on the synthesizing PF resin using formalin and/or paraformaldehyde for laminate application and assess the physical properties, mechanical properties and fracture toughness of the resins. The density, dynamic viscosity, solid content, gel time, flexural properties, tensile properties and fracture toughness of the synthesized resins were evaluated upon varying the formalin content from 0% to 40% (w/w) in the synthesis process. The result shows that addition of 40% w/w formalin in the PF resin synthesis had increased the fracture toughness and decreased the flexural strength and modulus properties of PF by 97.14% and 97.60% respectively. The tensile stress value was also reduced by 67.80% when the 40% w/w of formalin was added. However, the PF resins that produced by adding formalin up to 20% w/w in the PF resin synthesis, still maintained their flexural and tensile properties within the acceptable range required by EN438 standard for decorative high-pressure laminate (HPL) application. This work shows that paraformaldehyde enhanced the mechanical properties of PF laminate resin compared to formalin.