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To study oxazine ring formation in benzoxazine synthesis from phenol, primary amine and formaldehyde, reactions between 2-phenylaminomethylphenol (Mannich base) and formaldehyde in homogeneous dioxane/water solution are researched. Reaction orders, rate constants at different temperatures, and activation energy are calculated, the process of reaction is proposed, and the influence of acid and base is discussed. The reaction can occur at low temperature and generate the product 3,4-dihydro-2H-3-phenyl-1,3-benzoxazine. No intermediate 2-(N-hydroxymethyl-N-phenylamino)methylphenols are observed. The concentration of a Mannich base has little effect on the reaction rate, while the reaction is first-order to formaldehyde. Based on chemical properties of formaldehyde in aqueous solution, the reaction process includes the following three steps: degradation of poly(oxymethylene) glycols to methylene glycol, dehydration of methylene glycol to formaldehyde molecule, and the reaction between a Mannich base and formaldehyde molecule to benzoxazine. Dehydration of methylene glycols to formaldehyde molecules is the rate-controlling step.

N-Substituted aminomethylphenol (Mannich base) and 3,4-dihydro-2H-3-substituted 1,3-benzoxazine (benzoxazine) were synthesized from substituted phenol (p-cresol, phenol, p-chlorophenol), substituted aniline (p-toluidine, aniline, p-chloroaniline) and formaldehyde to study influence of substituent on equilibrium of benzoxazine synthesis from Mannich base and formaldehyde. (1)H-NMR and charges of nitrogen and oxygen atoms illustrate effect of substituent on reactivity of Mannich base, while oxazine ring stability is characterized by differential scanning calorimetry (DSC) and C-O bond order. Equilibrium constants were tested from 50 °C to 80 °C, and the results show that substituent attached to phenol or aniline has same impact on reactivity of Mannich base; however, it has opposite influence on oxazine ring stability and equilibrium constant. Compared with the phenol-aniline system, electron-donating methyl on phenol or aniline increases the charge of nitrogen and oxygen atoms in Mannich base. When the methyl group is located at para position of phenol, oxazine ring stability increases, and the equilibrium constant climbs, whereas when the methyl group is located at the para position of aniline, oxazine ring stability decreases, the benzoxazine hydrolysis tends to happen and equilibrium constant is significantly low.