Manufacture of phenolic foam
AssigneeSaint-Gobain Industries
InventorDaniel Hanton
Life of this patent
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Abstract
Phenolic foams, mixtures for producing phenolic foams, and processes of manufacturing phenolic foams are disclosed. The resin utilized is a base catalyzed polycondensation product of phenol and formaldehyde which is obtained in a solid, reactive, fusible, substantially anhydrous state. The resin is foamed and hardened by the application of heat without the use of a catalyst. Heat sensitive blowing agents, either in liquid form or in particulate form may be mixed with the resin prior to heating. Surfactants and lubricants may be utilized to enhance the uniformity of the voids in the foam. The resulting foams are non-acidic, are resistant to color changes, and are substantially anhydrous.
Claims36
A foamable phenolic resin mixture stable at room temperature from which cured and set foamed articles may be formed by heating alone in the absence of the addition of an agent for setting the resin, comprising a solid, reactive, heat-fusible water-insoluble phenolic resol resin of the resol type in particulate form, a blowing agent, and a surfactant, said mixture being devoid of any agent for setting the resin.
A process for producing an intermediate phenolic resin product expandable upon the application of heat alone in the absence of an agent for setting the resin, comprising
- forming a solid, heat-fusible, reactive, water-insoluble phenolic resol resin in a particulate and substantially anhydrous state by the condensation of from 1 to 3.1 moles of an aldehyde with one mole of a phenol in the presence of a basic catalyst, a fusibility agent, a dispersant and a protective colloid,
- drying said particulate phenolic resin,
- and thereafter uniformly mixing a blowing agent with the phenolic resin particles, said expandable product being produced in the absence of any agent for setting the resin.
A process for producing a foamable article comprising,
- mixing a fusible, reactive, particulate, phenolic resin of the resol type and a blowing agent, and shaping the mixture to a desired shape in the absence of any agent for setting the resin.
An intermediate foamable product, stable at room temperatures, of phenolic resin, from which foamed articles can be formed by heating alone in the absence of an agent for setting the resin, comprising a shaped mass of a solid, reactive, heat-fusible, water-insoluble phenolic resol resin, a blowing agent and a surfactant dispersed throughout the resin, said product being devoid of any agent for setting the resin.
Dependencies are inferred from the claim text.