Phenolic foam and method of manufacture thereof
AssigneeKingspan Holdings (IRL) Limited
InventorsVincent Coppock, Lynne Ripley, Ruud Zeggelaar
Life of this patent
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Abstract
A thermal insulating phenolic foam and method of manufacture thereof is provided. A phenolic foam is formed by foaming and curing a phenolic resin composition that comprises a phenolic resin, an acid catalyst, a blowing agent comprising a hydrocarbon having 6 carbon atoms or less, and an alkoxy alcohol. The resulting foam has low thermal conductivity and has excellent long term thermal stability.
Claims20
A phenolic foam formed by foaming and curing a phenolic resin foamable composition that comprises a phenolic resin, a surfactant, an acid catalyst, a blowing agent comprising a hydrocarbon having 6 carbon atoms or less, and an alkoxy alcohol either (a) having the formula:
- wherein n is 0 to 4, and wherein R is a C1 to C6 aliphatic chain, R1 is H or alkyl, or (b) being selected from the group consisting of:
- propylene glycol monomethyl ether, propylene glycol monoethyl ether,
- propylene glycol monopropyl ether, propylene glycol monobutyl ether,
- propylene glycol monopentyl ether, propylene glycol monohexyl ether,
- dipropylene glycol monomethyl ether, dipropylene glycol monoethyl ether,
- dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether,
- dipropylene glycol monopentyl ether, dipropylene glycol monohexyl ether
- tripropylene glycol monomethyl ether, tripropylene glycol monoethyl ether,
- tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether,
- tripropylene glycol monopentyl ether and tripropylene glycol monohexyl ether;
- wherein the foam has a closed cell content of 85% or more as determined according to ASTM D6226, and a density of from 10 kg/m3 or more and 100 kg/m3 or less as measured according to BS EN 1602:2013.
A method for manufacturing a phenolic foam comprising the steps of:
- foaming and curing a foamable composition comprising:
- a phenolic resin, a surfactant, an acid catalyst, a blowing agent comprising a hydrocarbon having 6 carbon atoms or less, and an alkoxy alcohol either (a) having the formula:
- wherein n is 0 to 4, and wherein R is a C1 to C6 aliphatic chain, R1 is H or alkyl, or (b) being selected from the group consisting of:
- propylene glycol monomethyl ether, propylene glycol monoethyl ether,
- propylene glycol monopropyl ether, propylene glycol monobutyl ether,
- propylene glycol monopentyl ether, propylene glycol monohexyl ether,
- dipropylene glycol monomethyl ether, dipropylene glycol monoethyl ether,
- dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether,
- dipropylene glycol monopentyl ether, dipropylene glycol monohexyl ether
- tripropylene glycol monomethyl ether, tripropylene glycol monoethyl ether,
- tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether,
- tripropylene glycol monopentyl ether and tripropylene glycol monohexyl ether;
- the foam has a closed cell content of 85% or more as determined according to ASTM D6226, and a density of from 10 kg/m3 or more and 100 kg/m3 or less as measured according to BS EN 1602:2013.
Dependencies are inferred from the claim text.