Jun.  16,2016  14  US 2016/0168306 Al  cally. Next, the reaction mixture was under a gradually  increasing vacuum over 3 hours to a full vacuum of at least 27  inches while maintaining a temperature of 163 °-165°  C., then  heating the reaction mixture to 175°  C. over 1 hour under full  vacuum, followed by maintaining the vacuum and tempera› ture at 17 5°  C. for 15 minutes, and then steaming the reaction  mixture (or water sparge) at 175°  C. for 60 minutes, and after  60 minutes, cooling the resin to 164°-167°  C. in about 15  minutes. Further, the process was concluded by removing the  vacuum distillate ( 426.6 g) and discharging the product  (212.9 g) from the reaction vessel.  [0152]  In this instance, no stabilizer was added as the melt  viscosity of the resin was 1333 cps at 175°  C. The condensate  dissolved completely in MEK, acetone, THF, methanol and  Dowanol PM at almost any concentration. The 33 wt. % to 60  wt.% solids remained dissolved in MEK with only trace at the  bottom for instance for more than 240 hours. The 70 wt. %  and 80 wt. % solids remained dissolved in MEK indefinitely.  [0153]  The process for Example 2 was initiated by charging  828.0 lbs phenol (8.8 moles), 1.66 lbs benzoic acid (0.2% of  phenol), and 120 lbs melamine (0.95 moles) into a reaction  vessel to form a reaction mixture. The reaction mixture was  heated to 80°  C., and 85.4 lbs of 49.79% aqueous formalde› hyde (60% of total charge) was added over 40 minutes. The  reaction mixture was atmospherically distilled while increas› ing the temperature of the reaction mixture to 123°  C., then  maintaining the 123 °  C. temperature for 2 hours before reduc› ing the reaction mixture temperature to 80°  C. 57 .2 lbs of  49.79% aqueous formaldehyde (40% of total charge) was  added in over 30 minutes to the reaction mixture, followed by  atmospherically distilled to 123°  C., maintained at the tem› perature of 123°  C. for 1.5 hours, and then increasing the  temperature over 45-50 minutes to 165°  C. and continuing to  distill atmospherically. Next, the reaction mixture was under  a gradually increasing vacuum over 3 hours to full vacuum of  at least 27 inches while maintaining a temperature of 163°- 1650 C., followed by heating the reaction mixture to 17 5°  C.  over 1 hour under full vacuum, then maintaining the vacuum  and temperature at 175°  C. for 15 minutes before steaming the  reaction mixture (or water sparge) at 175°  C. for 60 minutes,  and after 60 minutes cooling the resin to 164°-167°  C. in  about 15 minutes.  [0154]  In this instance, the melt viscosity of the resin was  1983 cps at 175°  C. About 3.2 lbs each of ortho and para  cresol was added to the resin. The resin was held in the reactor  for about 9 hours at 165°  C. Further, the process was con› cluded by collecting the vacuum distillate (634 lbs) and dis› charging the product (318 lbs) from the reactor assembly. The  condensate exhibited solubility similar to that of example 1.  For instance, the 33 wt. % solids dissolved readily in MEK  and remained dissolved for greater than 500 hours.  [0155]  The process for Example 3 is initiated by charging  221.5 g phenol (2.35 moles), 31.9 g melamine (0.25 moles),  36.6 g of 50% formaldehyde (0.61 moles) into a reaction  vessel to form a reaction mixture, heating the reaction mix› ture under distillation mode until distillation starts around  115-120°  C., gradually increasing the temperature up to about  170°  C. while water and phenol are removed atmospherically.  Then, applying a vacuum gradually until most of non-reacted  phenol is removed, and water sparging the reaction mixture at  about 180°  C. to reduce the phenol level to <l % in the final  product. The process is concluded by removing phenol (172  g) distillate and discharging the product (87 .3 g) from the  reaction vessel. The recovered product exhibited a solubility  of almost any concentration such as from 33 wt.% solids to 70  wt. % solids in common solvents such as MEK. Such solu› tions remained dissolved in a MEK for greater than 500 hours  or indefinitely without precipitation.  [0156]  The process for Example 4 was initiated by charging  593.5 g phenol (6.31 moles) and 75.2 g melamine (0.60  moles) into a reaction vessel to form a reaction mixture. The  reaction mixture was heated to 80°  C., and 53.14 g of 50.15%  aqueous formaldehyde ( 60% of total charge) was added over  15 minutes. The reaction mixture was atmospherically dis› tilled to 133°  C., then maintained at 133°  C. temperature for  2 hours, followed by reducing the reaction mixture tempera› ture to 80°  C. 35.45 g of50.15% aqueous formaldehyde (40%  of total charge) was added in about 20 minutes to the reaction  mixture, then atmospherically distilling the reaction mixture  to 133°  C., maintained at 133°  C. for 1.3 hours, and then  increasing the temperature over 60 minutes to 165°  C. while  continuing to distill atmospherically. Next, the reaction mix› ture was under a gradually increasing vacuum over 2 hours to  full vacuum of at least 27 inches while maintaining a tem› perature of 163°-165°  C., and then heating the reaction mix› ture to 175°  C. under full vacuum. Further, the process is  concluded by removing the vacuum distillate (439.7 g) and  discharging the product (236.7 g) from the reaction vessel.  The condensate exhibited a solubility of 33% and higher  solids dissolved in a solvent for 120 hours or greater.  [0157]  The process for Example 5 was initiated by charging  593.5 g phenol (6.31 moles), 4.3 g of acetic acid (0.72% of  phenol) and 75.2 g melamine (0.60 moles) into a reaction  vessel to form a reaction mixture. The reaction mixture was  heated to 80°  C., and 64.1 g of50.3% aqueous formaldehyde  (60% of total charge) was added in over 20 minutes. The  reaction mixture went under atmospherically distilling to  123°  C., then maintained at 123°  C. for 2 hours followed by  reducing the reaction mixture temperature to 80°  C. 42.5 g of  50.3% aqueous formaldehyde ( 40% of total charge) was  added over about 20 minutes to the reaction mixture, followed  by atmospherically distilling the reaction mixture to 123°  C.,  then maintaining the temperature at 123 °  C. for 1. 6 hours, and  finally increasing the temperature over 60 minutes to 165°  C.  and continuing to distill atmospherically. Next, the reaction  mixture was under a gradually increasing vacuum over 2  hours to full vacuum of at least 27 inches while maintaining a  temperature of 163°-165°  C., and then heating the reaction  Example 3  Preparation of Melamine-Phenol-Formaldehyde  Condensate  Example 5  Preparation of Melamine-Phenol-Formaldehyde  Condensate  Example 4  Preparation of Melamine-Phenol-Formaldehyde  Condensate  Example 2  Preparation of Melamine-Phenol-Formaldehyde  Condensate 