Melamine Formaldehyde (MF) Resin

• Melamine resin or melamine formaldehyde (also shortened

to melamine) is a resin with melamine rings terminated with
multiple hydroxyl groups derived from formaldehyde.
This thermosetting plastic material is made
from melamine and formaldehyde.
• In its butylated form, it is dissolved in n-butanol and xylene. It is
then used to cross-link with alkyd, epoxy, acrylic,
and polyester resins, used in surface coatings.
• There are many types, varying from very slow to very fast curing.
• It was discovered by William F. Talbot, who applied to patent it on
December 12, 1936.
• A class of synthetic resins obtained by chemical combination
of melamine (a crystalline solid derived from urea) and formaldehyde (a
highly reactive gas obtained from methane).
• A complex, interlinked polymer that cures to a clear, hard, chemically
resistant resin, melamine formaldehyde is employed in plywood and
particleboard adhesives, laminated countertops and tabletops,
dishwasher-safe tableware, and automotive surface coatings.
• The chemical composition of melamine and formaldehyde and the
reaction by which these two compounds are polymerized into a
thermosetting network of interconnected molecules are described
briefly in the article aldehyde condensation polymer.
• Melamine was first synthesized by the German chemist Justus von Liebig in
1834.
• In early production, first calcium cyanamide was converted into dicyandiamide,
which was heated above its melting temperature to produce melamine. Today
most industrial manufacturers use urea in the following reaction to produce
melamine:
6 (NH2)2CO → C3H6N6 + 6 NH3 + 3 CO2
• In the first step, urea decomposes into cyanic acid and ammonia:
(NH2)2CO → HNCO + NH3
• Cyanic acid polymerizes to cyanuric acid, which condenses with the liberated
ammonia forming melamine. The released water reacts with cyanic acid, which
helps to drive the reaction:
6 HNCO + 3 NH3 → C3H6N6 + 3 CO2 + 3NH3
• Formaldehyde is produced industrially by the catalytic oxidation of methanol.
The most common catalysts are silver metal or a mixture of
an iron and molybdenum or vanadium oxides.
• In the commonly used formox process, methanol and oxygen react at
ca. 250–400 °C in presence of iron oxide in combination with molybdenum
and/or vanadium to produce formaldehyde according to the chemical
equation:
2 CH3OH + O2 → 2 CH2O + 2 H2O
• The silver-based catalyst usually operates at a higher temperature, about 650 °
C. Two chemical reactions on it simultaneously produce formaldehyde: that
shown above and the dehydrogenation reaction:
CH3OH → CH2O + H2
• In principle, formaldehyde could be generated by oxidation of methane, but
this route is not industrially viable because the methanol is more easily
oxidized than methane.
 SYNTHESIS
• Melamine formaldehyde (MF) resins are primarily made up of
melamine and formaldehyde with formaldehyde acting as the
crosslinker.
• The melamine reacts with formaldehyde under slightly alkaline
conditions to form mixturers of various methylolmelamines.
• The monomeric form hexamethylolmelamine and the MF resins
are very versatile crosslinking agents for a wide variety of
polymeric materials both water- and solventborne.
• To improve the solubility in solvents, melamine formaldehyde
(MF) resins, and the monomeric forms are often etherified with
alkohols such as methanol and n-butanol.
• After acidification, they readily react with thiol, hydroxyl, carboxyl
and amide groups to form three-dimensional thermoset polymer
networks.
Advantages
• Easily coloured (unlike Phenolics).
• Taste and odour free.
• Good resistance to solvents - stain resistant in general,
although dependent upon filler choice.
• Electrical properties relatively unaffected by high
humidity (unlike Phenolic).
• Self-extinguishing.
Disadvantages
• Inferior to Phenolic in dimensional stability in hot dry
conditions.
• More expensive than Urea or Phenolic.
• Limited resistance to concentrated acids and alkalies.
Applications
• Impact resistant crockery
(e.g. for hospitals and
picnics)
• toilet seats
• pan handles and knobs
• stain and cut resistant
decorative laminates.