# US 11,299,598 B2 · Flame-retardant phenolic resin foam

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- Number: US 11,299,598 B2
- Document ID: US11299598B2
- Status: Granted
- Kind: B2
- Application number: 17/050,838
- Filed: 2019-04-26
- Published: 2021-07-29
- Granted: 2022-04-12
- Earliest claimed: 2018-04-27
- Assignees: Asahi Kasei Construction Materials Corporation
- Applicants: Asahi Kasei Construction Materials Corporation
- Inventors: Hisashi Mihori; Noriaki Kikuchi; Masami Komiyama
- Web page: https://patentgrep.com/patent/US11299598B2

## CPC

- C08J 9/04: using blowing gases generated by a previously added blowing agent
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2361/06: of aldehydes with phenols
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

A phenolic resin foam has a density of 30 kg/m3 to 80 kg/m3, a closed cell ratio of 85% or more, and reaches a total amount of heat release of 8 MJ/m2 in a time of 20 minutes or more in a heat release test performed using a cone calorimeter.

## Claims

### Claim 1

A phenolic resin foam having a density of 30 kg/m3 to 80 kg/m3, a closed cell ratio of 85% or more, and reaching a total amount of heat release of 8 MJ/m2 in a time of 20 minutes or more in a heat release test performed using a cone calorimeter.

### Claim 2 (depends on 1)

The phenolic resin foam according to claim 1, having a peak at either or both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction.

### Claim 3 (depends on 1)

The phenolic resin foam according to claim 1, having a highest intensity peak at either or both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction.

### Claim 4 (depends on 1)

The phenolic resin foam according to claim 1, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction.

### Claim 5 (depends on 1)

The phenolic resin foam according to claim 1, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 0.5≤A/B≤4.5.

### Claim 6 (depends on 1)

The phenolic resin foam according to claim 1, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 1.0≤A/B≤4.5.

### Claim 7 (depends on 2)

The phenolic resin foam according to claim 2, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 0.5≤A/B≤4.5.

### Claim 8 (depends on 3)

The phenolic resin foam according to claim 3, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 0.5≤A/B≤4.5.

### Claim 9 (depends on 4)

The phenolic resin foam according to claim 4, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 0.5≤A/B≤4.5.

### Claim 10 (depends on 2)

The phenolic resin foam according to claim 2, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 1.0≤A/B≤4.5.

### Claim 11 (depends on 3)

The phenolic resin foam according to claim 3, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 1.0≤A/B≤4.5.

### Claim 12 (depends on 4)

The phenolic resin foam according to claim 4, having a peak at both a diffraction angle 2θ of 14.9° to 15.9° and a diffraction angle 2θ of 16.2° to 17.2° in an X-ray diffraction pattern obtained through analysis by X-ray diffraction, and that when maximum intensity of a peak at 14.9° to 15.9° is taken to be A and maximum intensity of a peak at 16.2° to 17.2° is taken to be B, 1.0≤A/B≤4.5.