Method for continuous production of a prepolymer based on phenol resins, oxazolines and epoxides

摘要

Continuous preparation (M1) of a prepolymer composition (P1) involves: combining a phenolic resin component, oxazoline component and epoxide component, in presence of a catalyst, in an extruder. The phenolic resin component and oxazoline component are supplied to the extruder in a stream A; at least one catalyst selected from Lewis adduct of boron trifluoride or aluminum trichloride, arylsulfonic acid, alkylsulfonic acid, latent arylsulfonic acid, and latent alkylsulfonic acid, is supplied to the extruder as stream B; and the epoxide component is supplied to extruder in a stream C. Continuous preparation (M1) of a prepolymer composition (P1) involves: combining a phenolic resin component, an oxazoline component and epoxide component, in the presence of a catalyst, in an extruder. The phenolic resin component and oxazoline component are supplied to the extruder in a stream A, and at least one catalyst selected from a Lewis adduct of boron trifluoride or aluminum trichloride, arylsulfonic acid, alkylsulfonic acid, a latent arylsulfonic acid, and latent alkylsulfonic acid, is supplied to the extruder as stream B, and the epoxide component is supplied to the extruder in a stream C. An infeed of the stream A, relative to an extrusion direction, is before an infeed of the stream C, where the streams A, B and C are combined at 120-200[deg] C with a residence time of 3 seconds to 15 minutes in the extruder to form a product, and then discharging the product from the extruder and cooling to less than 45[deg] C within 30-60 seconds. Independent claims are included for the following: (1) a prepolymer (P1) obtained by the process (M1); (2) a composition comprising the prepolymer (P1); (3) producing impregnated reinforcing fibers involving: dissolving the prepolymer (P1) in 2-butanone and impregnating at least one reinforcing fiber selected from a glass fiber and a carbon fiber with the dissolved prepolymer, and curing the impregnated reinforcing fiber; and (4) a powder for producing prepregs, comprising: the prepolymer (P1) and at least one additional component.