Low-density, furfuryl benzylic phenolic thermosetting foam product and method of preparing same
AssigneeThermoset AG
InventorStuart B. Smith
Life of this patent
Estimating the term…
Abstract
A low-density, low-friability, furfuryl-phenol thermosetting foam product is prepared by reacting, in the presence of a blowing agent and an acid catalyst, a furfuryl-alcohol monomer or polymer and a benzylic-ether phenol-formaldehyde resin, having a mole ratio of benzylic-ether phenol to formaldehyde of from about 1:3 to 1:11, which reaction provides a closed-cell, thermosetting foam product having a foam density of 0.5 pound per cubic foot or less.
Claims15
A method of preparing an ultralow-density thermosetting foam product composed substantially of closed cells and characterized by low friability, which method comprises:
- reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol mnomer, a furfuryl-alcohol polymer or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resole resin, the benzylic-ether resole resin having a mole ratio of formaldehyde to benzylic-ether phenol of from about 3:1 to 1:1, the reaction carried out in the presence of a sufficient amount of a blowing agent to form a low-density foam and a catalytic amount of a strong acid catalyst, to provide a thermosetting foam product having a foam density of less than about 0.5 pound per cubic foot.
A method of preparing a thermosetting foam product, which method comprises:
- reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol polymer, a furfuryl alcohol or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resin, having 4 to 10 phenolic rings and having a mole ratio of phenol to formaldehyde of from about 1:1 to 1:2, in the presence of from about 1 to 15 parts per 100 parts of polymer and resin of a blowing agent and of from about 0.05 to 10 parts per 100 parts of polymer and resin of a catalytic amount of a sulfonic-acid catalyst and a small cell-control amount of a silicone surfactant, to effect the generally simultaneous condensation of the phenol-formaldehyde resin and the condensation of the furfuryl compound, the amount of the polymer and the resin ranging from about 10% to 90% by weight of the reaction mixture, to provide an integral thermosetting foam product characterized by a low density of about 0.5 pcf or less and low friability.
Dependencies are inferred from the claim text.