Polymeric Composite Foam

A polymeric composite foam comprising a continuous phase of a furan polymer or phenolic and furan polymer and a disperse phase of foamed polystyrene polymer wherein the composite foam is prepared by reacting a liquid foamable composition comprising 10-50% w/w of foamable unexpanded polystyrene beads and 50-95% w/w of a resin or resin mixture selected from the group consisting of a furan resin, a phenolic and furan resin, and a phenolic resin and furfuryl alcohol and an effective amount of an acid catalyst wherein the reacted foamable composition achieves temperatures sufficient to polymerise the resin or resin mixture and expand the polystyrene polymer without requiring the application of external heat or energy sources;

• the weight percent of polystyrene polymer in the composite foam is in the range 10-50 and the composite foam has a density in the range 25-200 kg/m3.

A method of forming a mass of polymeric composite foam comprising adding a liquid foamable composition comprising 10-50% w/w of foamable unexpanded polystyrene beads and 50-95% w/w of a resin or resin mixture selected from the group consisting of a furan resin, a phenolic and furan resin, and a phenolic resin and furfuryl alcohol and an effective amount of an acid catalyst to a temporary mould in the shape of the mass and removing the temporary mould after the liquid composition commences to expand, and wherein the said catalysed foamable composition achieves temperatures sufficient to polymerise the resin or resin mixture and expand the polystyrene polymer beads without requiring the application of external heat or energy sources.