Title of Invention

AN IMPROVED PROCESS FOR THE PREPARATION OF AQUEOUS EMULSION FROM CASHEW NUT SHELL LIQUID/CARDANOL BASED RESINS

Abstract The present invention relates to a process for the preparation of aqueous emulsion from cashew nut shell liquid/cardanol based resins. As the aqueous emulsion of cashewnut shell liquid /cardanol resins particularly of their applications as adhesives are in the plywood and lamination sectors. The emulsion can substitute phenol-formaldehyde, urea formaldehyde resins used in such industries. The process of the present invention has essentially the following steps: reacting CNSL / cardanol with phosphorus pentoxide at ambient temperature for 4 hrs. under stirring and cooling (the temperature rises due to heat of reaction) it down to 90 °C when cold water is added under stirring followed by the addition of emulsifying agent at room temperature and stirring till emulsification is complete.
Full Text The present invention relates to a process for the preparation of aqueous emulsion from
cashewnut shell liquid / cardanol based resins. As the aqueous emulsion of cashewnut shell liquid / cardanol resins particularly of their applications as adhesives are in the plywood and lamination sectors, the industries to which the invention applies are plywood industries, laminating industries, adhesive industries. The process of the present invention is also applicable in the plastics and composite industries as aqueous emulsion can substitute phenol - formaldehyde, urea formaldehyde resins used in such industries.
A number of CNSL / cardanol resins such as CNSL -formaldehyde resin, phosphorylated
CNSL prepolymer, phosphorylated cardanol prepolymer, CNSL -furfural resin, bromoderivative
of phosphorylated CNSL prepolymer are known, but they are water insoluble and find
difficulty for use in plywood and related industries where the requirement is the supply of resin
in the aqueous emulsion form. Reference may be made to Cashew nut Shell Liquid Patents
U.S.,Vol.1 and UK, Indian and Japan, Vol.2, June, Cashew Export Promotion Council,
Eranakulam, 1964; Cashew Nut Shell Liquid- Extraction and Uses- a Survey of World Patents
upto 1976, Cashew Export Promotion Council, Eranakulam, 1978; Indian Cashew Nut Shell
Liquid- A Versatile Industrial Raw Material of Great Promise- Regional research laboratory,
Trivandrum and Cashew Export Promotion Council, Ernakulam., 1983, C. K. S. Pillai, V. S.
Prasad, J. D. Sudha, S. C. Bera
and A. R. R. Menon, J. Appl. Polym. Sci., 41, 2487 (1990); A. R. R. Menon, C. K. S. Pillai, J. D. Sudha and A.G. Mathew, J. Scient. Ind.Res., 44, 324 (1985); J. H. P. Thyman, Chem. Soc .Rev.,8, 499, (1979); W.Knop and A.Sheib, Chemistry Applications of Phenolic Resins, Springer Verlag, Berlin, 1979. Resins such as CNSL -formaldehyde resin and phosphorylated CNSL prepolymer have, however, give positive values when tested for their adhesive behaviour using

standard tests such as lap shear tests. Unfortunately, these tests were conducted using a
non-aqueous solvent and therefore, the use of the resin as a subtitute for aqueous resins such" as phenol - formaldehyde resins and urea - formaldehyde resins in plywood and laminating industries were hampered by the requirement of non-aqoueous solvent for CNSL resisn. Lap shear tests of CNSL -formaldehyde resin and phosphorylated CNSL prepolymer (PCNSL) gave values of the order of 60 - 70 N / Cm2 and 400±20N / Cm2 respectively which indicate that the latter can be used as an adhesive subtituting even polyviny alcohol based adhesives whose lap shear strength is of the order of 500 N / Cm2. Additionally, the development of aqueous PCNSL resin would be commercially of great interest as its production cost will be in range range of Rs. 30-40 whereas Fevicol cost Rs. 290/ Kg. So, it would be commercially a geart advantage if aqueous PCNSL emulsion system is developed and marketed.
The main object of the present invention is to provide a process for the preparation of aqueous emulsions from cashewnut shell liquid / cardanol based resins useful as adhesives / binder resins.
Yet another object of the present invention is to provide a process for the preparation of aqueous emulsion from cashewnut shell liquid / cardanol based resins for use in plywood and laminating industries as adhesive binder which can be used in place of water based adhesive binders such as phenol-formaldehyde resin, urea formaldehyde - resins etc.
Yet another object of the present invention is to provide a process for the preparation of aqueous emulsion from cashewnut shell liquid / cardanol based resins for use as adhesive binders in place of conventional water based adhesives.

Still another object of the present invention is to provide a process for the preparatiort of aqueous emulsion from cashewnut shell liquid / cardanol such as phosphorylated cashewnut shell liquid prepolymer based resins for use as binder resins in place of conventional water based resins such as such as phenol-formaldehyde resin used in the manufacture of composite materials.
In our patent No. 176069 (1157/DEL/88) we have described and claimed a process for the preparation of phosphorylated cashewnut shell liquid prepolymer. In this patent, phosphorylation is described to be carried out by the reaction of orthophosphoric acid at 160 -170 °C under vacuum. This process has, thus, certain disadvantages such as use of vacuum and high temperature.
The present invention has a number of advantages in the technique of phosphorylation over the previous method (patent No. 176069 (1157/DEL/88)). The present invention uses phosphorus pentoxide instead of orthophosphoric acid. The reaction is carried out at ambient temperature instead of at high temperature of the earlier process. It also does not require the use of vacuum as against the earlier process which requires vacuum.
The main finding underlying the present invention is our observation that CNSL resins such as phosphorylated CNSL prepolymer obtained by the phosphorylation of CNSL has been found to give aqueous emulsions on treatment with emusifying agents such as carboxymethyl cellulose, polyvinyl alcohol, sodium laurylsulphate, ammonium dodecylsulphate, etc. The emulsions are stable at room temperature and develop adhesive property on curing with curing agents such as hexamine, formaldehyde, paraformaldehyde etc. On testing between two wood

pieces, the lap shear strength, a measure of adhesive property, obtained was in the range of 400
± 20 N / cm2 in comparison to 230 N / cm2 of phenolformaldehye resin and to 500 N / cm2 for adhesives available in the market such as Fevicol indicating that the aqueous emulsion obtained from phosphorylated CNSL prepolymer functions better than phenol-formaldehyde resin and is close to that of Fevicol®.
The process of the present invention has essentially the following steps: reacting CNSL / cardanol with phosphorus pentoxide at ambient temperature for 4 hrs. under stirring and cooling (the temperature rises due to heat of reaction) it down to 90 °C when cold water is added under stirring followed by the addition of emulsifying agent at room temperature and stirring till emulsification is complete.
Accordingly, the present invention provides an improved process for the preparation of aqueous emulsion from cashew nut shell liquid/cardanol based resins which comprises: adding cashewnut shell liquid /cardanol based resins such as herein described in a reactor, adding phosphorous pentoxide 20 to 25 % by wt. of CNSL/Cardanol based resin under stirring at room temperature, stirring the reaction mixture for a period of 3 to 5 hrs., cooling to a temperature below 90 deg.C, adding water in the range of 25 to 60 % by wt. of CNSL/Cardanol based resin, adding emulsifying agent 0.06 to 0.1 % such as herein described under stirring to obtain the desired aqueous emulsion.
In the process of the present invention, CNSL / cardanol is reacted with phosphorus pentoxide at ambient temperature under stirring and cooling it (the temperature rises due to heat of reaction) down to 90 °C when cold water is added under stirring till emulsification is complete. The emulsion can be tested by mixing with hexamine, paraformaldehyde or formaldehyde between two wood pieces and hot pressed to an adhesive block.

The resin used for emulsification may be phosphorylated CNSL prepolymer, CNSL-
formaldehyde resin, phosphorylated cardanol prepolymer, CNSL -furfiiral resin, bromoderivative of phosphorylated CNSL prepolymer or any related resins. The phosphorylating agent may be such as orthophosphoric acid, phosphorus pentoxide etc.
The emulsifying agent used may be such as carboxymethyl cellulose, polyvinyl alcohol, sodium lauryl sulphate, ammonium lauryl sulphate, ammonium dodecylsulphate, sodium dodecylsulphate.
The aqueous phase may be added below a temperature of 90°C.
The curing agent used may be such as paraformaldehyde, hexamine, formaldehyde.
The invention is described in detail in the following examples which are provided by way of illustration only and should not be construed to limit the scope of the invention..
Example 1.
30 Kg of cashewnut shell liquid, was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 7.25 Kg of phosphorous pentoxide was added portion wise over a period of 1 hr under stirring and stirring continued for another 4 hrs. 18 Kg of water was added under stirring. When the temperature has come down to ambient temperature, 37 gm of sodium dodecyl sulphate is added and stirring continued for another one hr. The emulsion is ready for use.

Example2.
30 Kg of cardanol was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 7.25 Kg of phosphorous pentoxide was added portion wise over a period of 1 hr under stirring and stirring continued for another 4 hrs. 12.5Kg of water was added under stirring. When the temperature has come down to ambient temperature, 37 gm of sodium dodecyl sulphate is added and stirring continued for another one hr. The emulsion is ready for use.
Example3.
15 Kg of cashewnut shell liquid, was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc.3.65 Kg of phosphorous pentoxide was added portion wise over a period of 1 hr under stirring and stirring continued for another 4 hrs. 6 Kg of water was added under stirring. When the temperature has come down to ambient temperature, 18gm of sodium dodecyl sulphate is added and stirring continued for another one hr. The emulsion is ready for use.
Example4
15 Kg of cashewnut shell liquid, was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc.3.65 Kg of phosphorous pentoxide was added portion wise over a period of 1 hr under stirring and stirring continued for another 4 hrs. 6 Kg of water was added under stirring. When the temperature has come down to ambient temperature,

18gm of polyvinyl alcohol is added and stirring continued for another one hr. The emulsion is ready for use. Example 5.
15 Kg of cardanol was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 3.65 Kg of phosphorous pentoxide was added portion wise over a period of 1 hr under stirring and stirring continued for another 4 hrs. 6Kg of water was added under stirring. When the temperature has come down to ambient temperature, 18 gm of sodium dodecyl sulphate is added and stirring continued for another one hr. The emulsion is ready for use.
Example 6 .
18 Kg of CNSL- formaldehyde resin was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 4.5 Kg water was added under stirring .18 gm of carboxy methyl cellulose is added and stirring continued for another one hr. The emulsion is ready for use.
Example7
20 Kg of CNSL- furfural resin was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 5 Kg water was added under stirring .20 gm of ammonium lauryl sulphate is added and stirring continued for another one hr. The emulsion is ready for use.

Examples .
20 Kg of bromo derivative of phosphorylated CNSL prepolymer resin was weighed into a polymerisation reactor fitted with an agitator, cooling facility, temperature sensor etc. 5 Kg water was added under stirring. 20 gm of poly vinyl alcohol is added and stirring continued for another one hr. The emulsion is ready for use.



We Claim:
1. An improved process for the preparation of aqueous emulsion from cashew nut
shell liquid/cardanol based resins which comprises: adding cashewnut shell liquid /cardanol based resins such as herein described in a reactor, adding phosphorous pentoxide 20 to 25 % by wt. of CNSL/Cardanol based resin under stirring at room temperature, stirring the reaction mixture for a period of 3 to 5 hrs., cooling to a temperature below 90 deg.C, adding water in the range of 25 to 60 % by wt. of CNSL/Cardanol based resin, adding emulsifying agent 0.06 to 0.1 % such as herein described under stirring to obtain the desired aqueous emulsion.
2. An improved process as claimed in claim 1 wherein the resin used is selected from
phosphorylated CNSL prepolymer, CNSL-furfural resin, CNSL-formaldehyde resin, phosphorylated cardanol prepolymer, bromoderivative of phosphorylated CNSL prepolymer.
3. An improved process as claimed in claims 1 and 2 wherein the emulsifying agent
is selected from sodium dodecylsulphate, ammonium dodecylsulphate, carboxymethylcellulose, ammoniumlauryl sulphate, sodium lauryl sulphate, polyvinyl alcohol.
4. An improved process for the preparation of aqueous emulsion from cashew nut
shell liquid/cardanol based resins substantially as herein described with reference to the examples.

Documents:

1152-del-1999-abstract.pdf

1152-del-1999-claims.pdf

1152-del-1999-correspondence-others.pdf

1152-del-1999-correspondence-po.pdf

1152-del-1999-description (complete).pdf

1152-del-1999-form-1.pdf

1152-del-1999-form-19.pdf

1152-del-1999-form-2.pdf


Patent Number 215578
Indian Patent Application Number 1152/DEL/1999
PG Journal Number 11/2008
Publication Date 14-Mar-2008
Grant Date 27-Feb-2008
Date of Filing 26-Aug-1999
Name of Patentee COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH
Applicant Address RAFI MARG, NEW DELHI-110001
Inventors:
# Inventor's Name Inventor's Address
1 CHENNAKKATTU KRISHNA SADASIVAN PILLAI EMPLOYED AT REGIONAL RESEARCH LABORATORY (COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH), THIRUVANANTHAPURAM 695019, KERALA, INDIA.
2 JANARDANAN NAIR DEVAKIAMMA SUDHA EMPLOYED AT REGIONAL RESEARCH LABORATORY (COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH), THIRUVANANTHAPURAM 695019, KERALA, INDIA.
3 VADAKKETHONIPPURATHU SIVANKUTTY NAIR PRASAD EMPLOYED AT REGIONAL RESEARCH LABORATORY (COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH), THIRUVANANTHAPURAM 695019, KERALA, INDIA.
4 PADMANABHAN ANAN DAN EMPLOYED AT REGIONAL RESEARCH LABORATORY (COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH), THIRUVANANTHAPURAM 695019, KERALA, INDIA.
PCT International Classification Number A61K 9/34
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA