Phenol Formaldehyde Resin for Curtain Coating

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Solution Overview

Problem

Existing phenol formaldehyde resin formulations are not suitable for curtain coating due to inappropriate rheological properties and viscosity, leading to breaks in the curtain and defects in the coated product.

Innovation Solution

A phenol formaldehyde resin formulation with specific rheological and viscosity properties, including a formaldehyde to phenol molar ratio of 1.8:1 to 2.8:1, average molecular weight of 2500 to 4000 Da, and a solids content of 45 to 60 wt.%, allowing for controlled application by curtain coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional phenol formaldehyde resin formulations are used for curtain coating, then the coating process can be implemented, but the formulation fails to provide a homogeneous and continuous curtain due to inappropriate rheological properties and viscosity

Engineering Contradiction:

Improvecurtain continuityVSAvoidcoating uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent modifies the rheological parameters of the phenol formaldehyde resin formulation by adjusting viscosity and adding specific additives (such as polyethylene glycol and surfactants) to enable the formulation to form a stable, continuous curtain during the curtain coating process, resolving the contradiction between curtain continuity and coating uniformity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces intermediary substances (thickeners, surfactants, and rheology modifiers) that act as mediators between the resin formulation and the curtain coating process, enabling the formulation to achieve appropriate flow characteristics for curtain formation while maintaining coating uniformity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the amount of coating material is increased to prevent curtain breaks, then curtain continuity is improved, but the amount of coating applied to the substrate increases, eliminating the main advantage of curtain coating

Engineering Contradiction:

Improvecurtain continuityVSAvoidcoating material amount

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent changes the rheological parameters of the coating formulation to achieve optimal viscosity and flow characteristics that enable stable curtain formation at reduced material quantities, thereby maintaining curtain continuity while minimizing coating material consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates an optimized version of the conventional phenol formaldehyde resin formulation with modified rheological properties that replicates the desired coating performance at lower material quantities, effectively copying the benefits of curtain coating without the drawback of excessive material usage

Inventive Principle:

Principle #26Copying

3Productivity

If phenol formaldehyde resin is applied by curtain coating, then production rate is increased and coating material usage is reduced, but breaks in the curtain and defects in the coated product occur

Engineering Contradiction:

Improveproduction rateVSAvoidcoating quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent modifies the rheological parameters of the phenol formaldehyde resin formulation to achieve optimal viscosity and flow characteristics that enable stable curtain formation during high-speed curtain coating, thereby maintaining both high productivity and coating quality without breaks or defects

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces intermediary substances (rheology modifiers and surfactants) that mediate between the resin formulation and the curtain coating process, enabling the formulation to maintain stability and continuity at high production rates while preventing curtain breaks and coating defects

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4277951B1Phenol formaldehyde resin formulation and adhesive for curtain coating

Publication Date: 2025.04.30 FORESA TECH S L U

Figure 1~2

AI summary

The present invention relates to a phenol formaldehyde resin formulation, an adhesive comprising the same suitable for curtain coating, and a process for manufacturing the phenol formaldehyde resin formulation. The present invention also relates to a process for manufacturing a coated material by applying said adhesive by curtain coating, to coated products, in particular plywood, veneered board or laminated veneer lumber (LVL), obtainable or obtained by said process and to coated products, in particular plywood, veneered board or laminated veneer lumber (LVL), comprising the adhesive of the invention.