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US 7,605,189 B1Granted
Process for producing a phenolic foam
OwnerGregory R. Brotzinventor
Life of this patent
Estimating the term…
Abstract
A process for producing a strong, lightweight, pH-neutral phenolic foam by providing a novelac resin and a resole resin with a solid-state blowing agent activated at a specific time in a melt for the formation of a foam.
Claims13
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- blending a novolac resin, resole resin and heat-activatable blowing agent together to form a mixture;
- roll-milling said mixture to form a gel;
- heating said gel;
- activating said blowing agent to provide gas in said gel;
- blowing said gel by said gas to form a foam;
- and
- heat-curing said foam.
4 more elements
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- blending a novolac resin and resole resin together to form a mixture;
- roll-milling said mixture to form a gel;
- blending a heat-activatable blowing agent directly into said gel;
- heating said gel;
- activating said blowing agent to provide gas in said melted gel;
- blowing said gel by said gas to form a foam;
- and
- heat-curing said foam.
5 more elements
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- blending a novolac resin and resole resin together to form a mixture;
- roll-milling said mixture to form a gel;
- cutting said gel off said rolls
- cooling said gel;
- grinding said cooled gel;
- blending a heat-activatable blowing agent with said ground material;
- rolling said material of gelled resin and heat-activatable blowing agent;
- heating said mixture;
- activating said blowing agent to provide gas in said heated mixture;
- blowing said mixture by said gas to form a foam;
- and
- heat-curing said foam.
9 more elements
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- blending a novolac resin and resole resin together to form a mixture;
- roll-milling said mixture to form a gel;
- cutting said gel off said rolls
- cooling said gel;
- grinding said cooled gel;
- blending a heat-activatable blowing agent directly with said ground material;
- rolling said material of novolac and resole resins and heat-activatable blowing agent;
- cutting said material off said rolls;
- cooling said material;
- grinding said material
- heating said ground material to a cure temperature that is above the activation temperature of said blowing agent;
- activating said blowing agent to provide gas in said material;
- blowing said material by said gas to form a foam;
- and
- heat-curing said foam.
12 more elements
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- providing a novolac resin in proportion with a resole resin in a ratio between 20:80 to 80:20 to form a novolac resin/resole resin mixture;
- compounding said novolac resin/resole resin mixture together to cause said two resins to cross link and form a gel;
- blowing said gel to form an expanded cellular foam structure;
- and
- curing said foam structure to rigidity.
2 more elements
A process for producing a strong, lightweight, pH-neutral, phenolic foam, comprising the steps of:
- providing a novolac resin in proportion with a resole resin in a ratio between 20:80 to 80:20 to form a novolac resin/resole resin mixture;
- adding a solid state blowing agent activatable by temperatures above 250 degrees F. to said novolac resin/resole resin mixture in a proportion of approximately 1% by weight of said novolac resin/resole resin mixture;
- mixing said novolac resin, resole resin and blowing agent together at a temperature below 250 degrees F. to cause said two resins to slightly react with a very loose cross linking;
- forming a gel from said resins;
- cooling said gel;
- hardening said gel;
- grinding said hardened gel into a fine powder;
- heating said powder at a temperature above the 250 degree F. activation temperature of said blowing agent;
- melting said powder;
- providing gas in said melted powder by the action of said activated blowing agent;
- forming an expanding mixture of said resins into a foam by the action of said gas;
- and
- curing said foamed resin after said expansion has ceased.
10 more elements
A method of producing a strong, lightweight phenolic foam, comprising the steps of:
- mixing a novolac resin and a resole resin together in a ratio between 20:80 to 80:20 by shear force melt processing at a temperature above their melting temperatures, causing said resins to react, producing a partial cross-linking and forming a gel;
- cooling said gel;
- hardening said gel;
- grinding said hardened gel into a fine powder;
- adding a solid state heat-activatable blowing agent in the range of 0.5% to 3% by weight based on the weight of said resin powder;
- blending said blowing agent into said phenolic resin powder by shear force melt processing to form a processed mixture;
- heating said mixture to activate said blowing agent to release gas in said mixture;
- forming a foam of such mixture by said released gas;
- and
- curing said foam.
7 more elements
Dependencies are inferred from the claim text.