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Getting Into the Basics of Phenolic Resin - LabTech

Laboratories worldwide provide the high-tech environments that lab managers need to make groundbreaking discoveries and innovative solutions to the world’s most pressing problems. However, such work necessitates the use of high-quality lab tables and phenolic table top in each laboratory comprised of high-quality materials.

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Choosing the right material for your lab equipment is crucial when choosing your laboratory tables, and phenolic resins have proven to be the preferred choice of lab managers worldwide.

In this article, we will provide you with some of the basics of phenolic resin, including what it is, how it is manufactured, and why it makes for a durable choice for all types of lab tables.

Continue reading to learn more about phenolic resin and how LabTech Supply Company can provide you with high-quality science lab equipment that is built to last.

What Does Phenolic Resin Mean?

Phenolic resins (PF) are a class of polymers that are among the most versatile ever devised. Despite the fact that they were created at the dawn of the polymer era, they continued to be developed into more and more uses. They are also regarded as the first polymeric goods commercially made from simple low-molecular-weight chemicals.

Phenolic resin is a synthetic resin made from the polymerization of phenol (C6H5OH) and formaldehyde (CH2C=O). Repeating units of –[(C6H3OH)-CH2]- with methylene (-CH2-) connections linking carbon sites to the phenolic hydroxide group make up the polymer (-OH).

Depending on the circumstances employed to manufacture the polymer, phenolic resins are phenolic novolac resins and phenolic resole resins. To harden phenolic novolac resins, they are further treated with a cross-linker.

Chemical and water stability are high in both types, as is temperature stability above 300C or 572F. Some phenolics can endure temperatures of up to 550F. Condensation has proven to be a non-issue for many.

Phenolic resins can be considered the first commercially produced polymeric goods made from simple low-molecular-weight chemicals, as they were the first synthetic resins to be used at the time.

Phenolic resins are widely employed in the fabrication of circuit boards and are used in a variety of industrial items. These resins are commonly used to make billiard balls, chemically resistant worktops, circuit boards, and other panels due to their high hardness.

They can also be used for laminations and as a binding agent for items like brake pads. Coatings and adhesives are common uses for them as well.

Lightweight Composite Materials Processing

The phenolic resin contains p-t-Amylphenol, p-t-Butylphenol, p-Nonylphenol, mixed cresols, and cashew nutshell liquid and has low toxicity.

Phenolic resins are employed in structural composite materials because of their strong mechanical resistance, high heat resistance under load, and high impact resistance.

Because of their outstanding qualities and low cost, phenolic resins are commonly used to impregnate fiberglass, woven aramid, woven PBO (poly(p-Phenylene Benzobisoxazole)), and woven HMPE.

Phenolic Resins in Adhesive and Bonding Applications

In 1993, 916 million pounds of phenolic resins were sold in the adhesive and bonding industries—making this specific type of adhesive and bonding market the second largest outlet for phenolic resins.

The adhesive and bonding market may cover these applications because the phenolic resin is used as a bonding agent in composite wood and laminating applications.

In adhesive and bonding applications, phenolic resins include:

• Materials for insulating

• Wood that is fibrous and granular

• Shell molding and foundry

• Materials that cause friction

• Abrasives that are bonded and coated

Specialty Polymers and Polymer Processing

Adhesives made with phenolic resins and neoprene rubber have strong thermal stability or service temperatures up to 95C and hardness.

The structure of the phenolic resin has been linked to adhesive qualities, particularly tack strength and peel strength.

The systems are available as toluene or MEK-based solutions or films. Although formulations that cure at ambient temperature are available, most adhesive films cure at 90C to 250C in 15 to 30 minutes.

Metal, wood, and polymers are all commonly bonded with them.

Composites

Phenolic resins are made from formaldehyde and phenol. Under acidic conditions, phenol reacts with less than equimolar amounts of formaldehyde to produce novolac resins, which contain aromatic phenol units linked mostly by methylene bridges.

Novolac resins are heat resistant and can be cross-linked with formaldehyde donors like hexamethylenetetramine to cure them. On the other hand, resoles are the most extensively used phenolic resins for composites.

They are essentially hydroxymethyl functional phenols or polynuclear phenols and are made by reacting phenol with a greater than the equimolar amount of formaldehyde under alkaline circumstances.

They are low-viscosity materials that are easier to process than novolacs. Other phenols, such as cresols or bisphenol, can also be used to make phenolic resins.

Cured phenolic resins are difficult to ignite because of their great thermal stability and charring tendency during the breakdown. Methane, acetone, carbon monoxide, propanol, and propane are the most common volatile breakdown products.

Additive and reactive flame retardants can be employed in a few circumstances when phenolic resins require flame retardant treatment. Some of the reactive flame retardants utilized in phenolics include tetrabromobisphenol A, different organic phosphorus compounds, halogenated phenols, and aldehydes—e.g., p-Bromobenzaldehyde.

In addition, flame retardants, chlorine compounds like chloroparaffins, and different thermally stable aromatic bromine compounds are used. Synergists such as antimony trioxide are also commonly used.

Phosphorus compounds that have been halogenated, such as tris(2-chloroethyl) phosphate (TRCP), halogenated organic polyphosphates, calcium, and ammonium phosphates, are all acceptable.

Zinc and barium compounds of boric acid, as well as aluminum hydroxide, are frequently used. Compounds like aluminum chloride, antimony trioxide, and organic amides are used to reduce the afterglow of phenolic resins.

Fiber-Reinforced Laminates in Aerospace Engineering

Phenolic resins are ideal for high-temperature applications requiring parts to meet fire safety requirements. Phenolic resins are used in a variety of applications, including electronics, ballistics, mine ventilation, offshore water pipe systems, aircraft, rail, and mass transit.

Key characteristics of phenolic resins include:

• Low density or weight-efficient

• Low thermal conductivity

• Excellent corrosion and chemical resistance

• Improved design flexibility

• Cost-effective production of complex 3D structures

• Excellent fatigue and impact properties

• Improved acoustic performance

• Radar or sonar transparency

• Low maintenance

Environmentally Assisted Fatigue

Phenolic resins are produced between phenols and aldehydes, yielding either novolacs or resoles.

These are then heated in the case of resoles or cross-linked with curing chemicals in the case of novolacs. This results in chains with a lot of aromatic rings, each of which has a phenol group linked to it.

Phenolic resins are generally less expensive than epoxies and polyimides, have a good temperature resistance, and are less flammable. Their biggest disadvantage is their low toughness, which limits their applications to those requiring high heat and combustion resistance.

Phenolic Resins in Advanced Fiber-Reinforced Polymer (FRP) Composites

When compared to alternative polymeric matrices for fire-resistance applications, phenolic resins have shown improved fire, smoke, and toxicity (FST) qualities. The FST qualities of phenolic resins are critical in determining which materials to use in a variety of applications.

No other matrix material has the same FST performance at a comparable price. The phenolic resin’s self-ignition temperature is around 600C, and the limiting oxygen index is between 40% and 49%.

Phenolic composites are primarily employed in aviation for interior and mass transit like buses and trains industries—with interest in marine applications growing. Civil infrastructure, sporting items, and consumer products all use these composites on a regular basis.

When fire safety is the most important factor to consider when choosing building materials, phenolic composites have been the material of choice.

Phenolic composites do not support a flame due to the intrinsic qualities of the matrix, and when exposed to fire, they emit little or no smoke, which is less harmful than smoke produced by other composites, especially those containing specific halogenated flame retardants.

Flammability and Fire Resistance of Composites

Phenolic resins are made from formaldehyde and phenol. Under acidic conditions, phenol reacts with less than equimolar amounts of formaldehyde to produce so-called novolac resins, which contain aromatic phenol units linked mostly by methylene bridges.

Novolac resins are heat resistant and can be cross-linked with formaldehyde donors like hexamethylenetetramine to cure them. However, resoles made by reacting phenol with a greater than the equimolar quantity of formaldehyde under alkaline conditions—are the most extensively used phenolic resins for composites.

Resoles are hydroxymethyl functional phenols, also known as polynuclear phenols. They are low-viscosity materials that are easier to process than novolacs. Other phenols, such as cresols or bisphenols, can also be used to make phenolic resins.

Phenolics are particularly interesting in structural applications because of their intrinsic fire-resistance qualities, which result in limiting oxygen index (LOI) values of around 25, despite the fact that they tend to increase smoke generation. Because of the high level of inherent flame resistance, additional flame retarding is rarely required to achieve the required performance levels in composites.

Water and Phenolic Resins

However, their chief downsides are low toughness and a curing reaction that generates water. Water produced during curing can become trapped within the composite, and steam can be generated during a fire, causing harm to the material’s structure.

This evolution is supplemented chemically during the initial step of heat degradation, which could be due to phenol-phenol condensation. The released water aids in the oxidation of methylene groups to carbonyl bonds, which disintegrate further, releasing CO, CO2, and other volatile chemicals.

Water is not released until beyond 400C in heavily cross-linked materials, and breakdown begins above 500C. This was true for all of the phenolic resin samples tested by differential thermal analysis (DTA) and our own and others.

Flame Retardants and Phenolic Resins

Methane, acetone, carbon monoxide, propanol, and propane are the principal breakdown products, and the amount of char depends on the structure of phenol, initial cross-links, and tendency to cross-link during decomposition.

Additive and reactive flame retardants can be used to treat phenolic resin when it needs to become one. Some of the reactive flame retardants utilized in phenolics include tetrabromobisphenol A, different organic phosphorus compounds, halogenated phenols, and aldehydes like p-Bromobenzaldehyde.

Phosphorus can be added to the phenolic resin by a direct reaction with phosphorus oxychloride. Chemical reactions can also incorporate inorganic chemicals like boric acid into the phenolic resin.

As an additive flame retardant, chlorine compounds like chloroparaffins and different thermally stable aromatic bromine compounds can be used, and antimony trioxide is frequently added as a synergist. Halogenated phosphoric acid esters, such as tris(2-chloroethyl) phosphate, halogenated organic polyphosphates, calcium, and ammonium phosphates, are all suitable phosphorus compounds.

Zinc and barium compounds of boric acid, as well as aluminum hydroxide, are frequently used. Compounds like aluminum chloride, antimony trioxide, and organic amides are used to reduce the afterglow of phenolic resins.

Carbon Fiber Spinning

Other than activated carbon fibers (ACFs), phenolic resins can be used in a variety of applications. Circuit boards and molded items, such as laboratory counters and pool balls, as well as adhesives and coatings, friction linings, and oil well proppants, are the most common applications.

Versatile, inexpensive, heat and flame resistant, durable, strength and stiffness, low toxicity, and ease of processing are some of the fundamental qualities that have helped phenolic resin maintain its commercial viability. Apart from that, phenolics can be produced with superior acid, organic solvent, and water-resistant features to improve their properties.

The majority of phenolic-based CFs today are created from a phenol-formaldehyde thermosetting resin, which is made by combining phenol with formaldehyde in the presence of an acid catalyst.

The infusible fiber produced by formaldehyde curing a melt-spun novolac resin offers a 58% yield of CF at 700C, with a carbon content of 94.5% and a strength of 0.69 GPa when heat treated in an inert atmosphere.

Heat treatment at 1800C raises the carbon content to 99.96% while lowering the strength to 0.47 GPa. Clearly, phenolic resins as precursors for the production of CFs have been explored, but they have not been found to be commercially feasible.

Nonetheless, phenolic-based ACFs have a number of advantages over other ACFs and have gotten a lot of attention in the last two decades. To make ACFs, phenolic resins are melt-spun at a temperature over their softening point, stabilized with formaldehyde solution below the fibers’ melting point, carbonized at around 600C, and then activated with carbon dioxide greater than 850C or with steam less than 700C as an oxidizing agent.

Shop with LabTech Supply Company for All of Your Lab Equipment Needs

Like any other business or institution, science labs and lab tables evolve with time, which makes it even more vital to update your lab equipment to stay up with the diverse requirements of science laboratories.

Durable tables are in great demand in all types of laboratories, but determining what these tables are built of and what materials to examine before making a purchase can be difficult.

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Related links:
Synthesis of trioxane from formaldehyde catalyzed by [Ga, Al]

Despite the challenges, lab tables made of phenolic resin continue to be the preferred choice of lab managers worldwide. Are you interested in learning more about lab tables made from phenolic resins?

At LabTech Supply Company, we understand that our customers want fresh and inventive solutions to keep their laboratory up to date with today’s technology.

That is why we are proud to be a recognized leader in laboratory benches, furniture, workstations, and storage equipment, and proud to be your one-stop store for anything lab tables and phenolic table tops related.

To find out more about our vast selection of laboratory equipment and discover how we can help you improve your laboratory’s work environment today, you can visit our website or contact us at LabTech Supply Company today!

Phenolic Plywood Buyers Guide for 2023

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We, as a customer, prefer products that are high quality. Phenolic plywood is a popular and most trusted material used for cabinet-making as well as building other furniture and even fixtures in European countries.

Phenolic board is an engineered material that, unlike typical plywood, uses synthetic resin as its veneers. Contractors and builders use it usually for residential and commercial construction. It is used to build kitchen and bathroom cabinets as well as for flooring.

But is it truly better than other types of plywood?

Read the rest of the article. The article covers everything you need to know about phenolic plywood, including its perks, drawbacks, shelf life, and value.

What Is Phenolic Plywood?

Phenolic plywood is a wooden board commonly used in commercial and residential construction. It is an engineered material which means that they are created by combining and binding pieces of scrap wood, sawdust or wood fibers, as well as genuine wood using adhesives.

Essentially, phenolic plywood is a fusion of two different wood parts. Its main section or the “core” is made by piling a large number of thin planks of birchwood— often 13 to 15 layers for a ¾ sheet—and is combined by applying a high amount of pressure.

The core is then covered using a veneer which is the outer section. It is either made of birch and other types of wood or thick paper. However, unlike the material’s core, its veneers are soaked and coated in a synthetic resin called phenolic. The resin acts as a coat and, at the same time, as an adhesive which makes it superior compared to modern plastics.

Thus, it is named phenolic plywood.

What Is It Used For?

Phenolic-faced plywood has a wide range of uses. It is, however, commonly used in building fixtures, kitchen and bedroom cabinets, countertops, and other furniture. 

The tabs below cover a few phenolic plywood uses.

Phenolic faced plywood is a popular material used for building house furniture such as cabinets. Its smooth, neat-looking, and repellent surface makes it a great material, particularly for cabinets that are placed in moisture-prone areas like the kitchen and the bathroom. And because of its high moisture resistance, it became a popular material for countertops as well.

The material is used to build store and laboratory furniture too. In laboratories, the plywood’s smooth and water repellent surface makes it easier to clean spilt chemicals or liquid. And because it repels liquid, it does not stain easily too. The same goes for stores, specifically restaurants and food shops.

The material is also used as a flooring material. Some manufacturers offer specialized phenolic boards with anti-slip material as covering, making it a viable material to use as flooring, particularly in areas that are prone to water and moisture. Specialized phenolic plywood is often seen in environments that are slip prone such as warehouses and scaffolding. 

Although rare, phenolic boards can be used in construction works as well. Some contractors use it to create cement forms. It may not be the best material, but its smooth surfaces prevent the cement from sticking to it and works just right. 

Advantages and Disadvantages

Phenolic plywood also has pros and cons. Here are a few to take note of.

Durability. Phenolic boards are highly resistant to cracks, scratches, and splitting thanks to their synthetic coating. It is fire-resistant too and is not prone to rotting, which makes it better than plywood. 

Repels water. The material is also highly resistant to moisture and any type of liquid thanks, again, to its coating which is a phenolic resin. And because it is non-porous unlike plywood, it is not prone to rotting and molds. 

Safe to use. Phenolic resin plywood is a great material too if you prioritize safety in your home or workplace. The boards are built as a non-microbial and non-absorbent material, which can naturally repel bacteria, fungi, and even mildew buildup.

Natural coloration. Phenolic boards are also available in a wide range of colors. And since its tint is natural, it can last for years as long as you properly take care of it. 

May still absorb water. While the material is proven to be highly resistant to water and moisture, it does not mean it is waterproof. As explained above, the veneers of the boards are the only parts that are coated in phenolic resin, leaving the edges open and unprotected.

Cannot be painted. Using phenolic boards may want you to ditch the chance to paint it with colors you like. Regular paints do not bond well with their smooth surface. And although special paints may work, they will not last long as the paint usually peels off on its own eventually.

Cost and Shelf Life of Phenolic Plywood

There are several factors that could affect its life. But on average, phenolic plywood can last for at least 20 years—or more if properly maintained. When it comes to pricing, its value depends largely on the type of board. Although a standard phenolic panel costs the same as high quality hardwood and marine-grade wood.

Different Types of Phenolic Plywood 

There are several kinds of phenolic plywood on the market today. Aside from it having a distinct natural coloration, manufacturers also began to develop boards that cater to specific functions or purposes.  

To give you an overview, phenolic boards come in seven different colors. You will find boards in yellow, red, dark brown, light brown, natural wood brown, green, and black. Although take note that some stores offer two kinds of colors only—mostly brown and black. 

When it comes to specialized phenolic plywood, the boards are developed differently. Some are made of fine and high-quality wood while others were integrated with modern technologies to fit specific functions. A few examples are phenolic film faced plywood and phenolic faced birch. 

Here’s how they differ.

Phenolic film-faced plywood is specialized plywood developed to be used for concrete shuttering. Its surface is covered with impregnated paper made from natural wood pulp and cotton linter—a high-quality veneer with superior water absorption and liquid-retaining properties—rather than phenolic resin. The material also makes the panel highly resistant to water, chemicals, and moisture.

The veneers are hot-pressed onto each surface of the board to make the material smooth as well as non-absorbent. The edges are also sealed, which standard phenolic plywood typically doesn’t have.

Unlike film-faced plywood, which is designed for a particular purpose, phenolic-faced birch is standard phenolic plywood but with a core that is made from high-grade birch wood. Its edges are sealed as well with acrylic paint to prevent water and moisture from penetrating the insides of the material.

Phenolic Plywood Alternatives 

Phenolic plywood is quite expensive and difficult to find in the U.S. If you want the same quality but at a different price and is accessible, consider the following alternatives.

Medium-density Fiberboard (MDF)

Another engineered wood plank, medium-density fiberboard or MDF is a material created by combining wood fibers using high-grade adhesive. It is way cheaper than a phenolic-coated ply and is environmentally friendly. It is not prone to termite infestation as well since the material is manufactured with chemicals that can repel insects. 

The only disadvantage is that MDF is not as durable as phenolic resin plywood. How tough and reliable the product is also dependent on the adhesive that was used. Thus, expect MDF products with different physical properties and durability. 

Polyurethane Board

Polyurethane plank is another great alternative for phenolic boards as both products provide almost the same quality and characteristics. Marine-grade and high-quality hardwood are recognized as the closest product that is similar to phenolic boards. However, they are not as cheap as polyurethane boards.

Polyurethane board is a material made of polyurethane—a synthetic material also known as plastic. It is a lightweight and fairly durable type of plank. It is the closest product similar to phenolic plywood because it repels water and moisture effectively thanks to polyurethane.

And because it is a non-porous material, the chance for it to rot or split is low.

The only difference is that polyurethane plywood is budget-friendly. It may not be as durable as phenolic boards but adding fiberglass as its veneers may add toughness to it. 

Particle Board

Particle board is the cheapest alternative you can substitute for phenolic plywood. The board is made of wood particles and is essentially a recycled material. The particle board may be cheap. But it is not that reliable durability-wise. It is, in fact, commonly used for design and aesthetics rather than structural work.

Phenolic Plywood Suppliers

Phenolic boards are mostly manufactured by Scandinavian companies as the birchwood used for the material is out of Scandinavian birch. It is popular in European countries but has since gaining popularity in the U.S. for the past few years.

There are now several manufacturers of phenolic plywood across the U.S. Some provide metric sizes while others follow the country’s standard sizing. Custom cut boards are available as well. 

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