Urea formaldehyde foam

Abstract

A foaming system includes a foaming agent solution and a resin solution. In a preferred embodiment, the foaming agent solution includes from 1.6 to 4.8 mmols of dibutyl naphthalene sulfonic acid as surfactant, from 5 to 20 mmols of phosphoric acid as catalyst and foam intumescent agent, from 0 to 45.5 mmols of resorcinol as foam anti-collapsing agent, from 9.1 to 54.6 mmols of chloral hydrate as fire retardant agent and sufficient water to make a solution of about 5% solids concentration. The resin solution includes urea formaldehyde resin produced by reacting from 1.0 to 2.4 mols of formaldehyde per mol of urea, from 6.5 to 500 mmols polyethylene glycol as foam charring component, from 0.3 to 1.2 mmols of calcium chloride as foam uniform cell size component, from 3 - 310 mmols of dicyandiamide as foam hydrolysis resistance component, from 2 - 30 mmols of sodium bromide as foam aging component, from 0 - 150 mmols of furfuryl alcohol as formaldehyde odor masking component and sufficient water to prepare a solution of 40 to 45% solids concentration. One part by weight of the foaming agent solution is frothed and then from 0.9 to 1.5 parts by weight of the resin solution is sprayed on the froth to obtain foam.

Dependencies are inferred from the claim text.