On the structure and cure acceleration of phenol-urea-formaldehyde resins with different catalysts

Phenol-urea-formaldehyde (PUF) resins with different catalysts calcium oxide (CaO), sodium carbonate (Na₂CO₃), zinc oxide (ZnO), and magnesium oxide (MgO)] were prepared to accelerate the cure of the resin at low temperature. The cure-acceleration effects of catalysts on chemical structure and cure characteristics of PUF resins were investigated by using both liquid ¹³C nuclear magnetic resonance (NMR) and differential scanning calorimetry (DSC). The liquid ¹³C NMR analysis indicated that the catalyst such as CaO seemed to present a retarded effect on the polycondensation reaction of phenolic components with urea units, while the Na₂CO₃ appeared to promote the self-condensation reaction of phenolic methylol groups at para position toward the formation of para-para methylene linkage. Both ZnO and MgO in PUF resins promoted self-condensation reaction of para methylol groups and condensation reaction of ortho methylol groups with para methylol groups. The catalysts such as Na₂CO₃, ZnO, and MgO can make PUF resins cure at a low temperature. Among these catalysts, the MgO had the most significant accelerating effect on polycondensation and cure reaction of PUF resin.