Abstract: The sol-gel polymerization of a phenolic-furfural mixture in dilute solution leads to a highly cross-linked network that can be supercritically dried to form a high surface area foam. These porous materials have cell/pore sizes .ltoreq.1000 .ANG., and although they are dark brown in color, they can be classified as a new type of aerogel. The phenolic-furfural aerogel can be pyrolyzed in an inert atmosphere at 1050.degree. C. to produce carbon aerogels. This new aerogel may be used for thermal insulation, chromatographic packing, water filtration, ion-exchange, and carbon electrodes for energy storage devices, such as batteries and double-layer capacitors.

Abstract: An aerogel composite material produced by compression molding of aerogel microspheres (powders) mixed together with a small percentage of polymer binder to form monolithic shapes in a cost-effective manner. The aerogel composites are formed by mixing aerogel microspheres with a polymer binder, placing the mixture in a mold and heating under pressure, which results in a composite with a density of 50-800 kg/m.sup.3 (0.05-0.80 g/cc). The thermal conductivity of the thus formed aerogel composite is below that of air, but higher than the thermal conductivity of monolithic aerogels. The resulting aerogel composites are attractive for applications such as thermal insulation since fabrication thereof does not require large and expensive processing equipment. In addition to thermal insulation, the aerogel composites may be utilized for filtration, ICF target, double layer capacitors, and capacitive deionization.

Abstract: Phenolic foam which can be used as insulation is a foamed phenol-formaldehyde resole resin which contains a peptide, a proteinaceous material, cysteine, glutamic acid, glycine, isoleucine, leucine, lysine, phenylalanine, serine, tryptophan, or mixtures thereof at an amount effective to reduce emission of free formaldehyde from the foamed resin.

Abstract: Process for the preparation of aerogels by subcritical drying of inorganic and organic hydrogels and lyogels to give aerogels, dielectric drying methods being used.

Abstract: A sprayable, foam-forming, phenolic resin composition having the combination of properties of:(i) a viscosity suitable for spraying,(ii) a cure rate suitable for spraying to prevent running or sagging of sprayed foam,(iii) which when suitably cured provides a foam having a high temperature resistance, and(iv) the cured foam produces substantially non-toxic fumes when burned. The sprayable, foam-forming, phenolic resin composition is made from a phenol-aldehyde resin; optionally a phenol compound; a catalyst for catalyzing a curing reaction of said phenol-aldehyde resin; and a gas-generating compound which generates a gas during said curing reaction of said phenol-aldehyde resin. The invention also provides a method for making a phenolic-resin foam layer and a sprayed phenolic-resin foam layer.

Abstract: The invention forms in situ carbon dioxide blown closed cell insulating foams in which blowing is achieved by the evolution of carbon dioxide resulting from partial hydrolysis of polyisocyanate (methyl diphenyl diisocyanate) by water in the resole. The invention uses no additional blowing agent. The reaction is fast and the resulting product has small, closed cells that exhibit long term thermal performance.

Abstract: A foaming resin composition consisting essentially of (A) an organic compound having a carbon-carbon double bond, (B) a compound having an SiH group, and (C) a compound having an OH group is foamed and cured at room temperature or under heat at relatively low temperatures, to obtain hard, semi-hard or soft plastic foam having good weather resistance and good compatibility with coating compositions and adhesives.

Abstract: Provided is a composition for making a foam including a reactive phenolic resin, urea, and an isocyanate. Also provided is a method for making the foam and a foam made from the composition.

Abstract: This invention relates to a process for producing phenolic foams frown phenolic resins using a blowing agent comprising 1,1,1,4,4,4-hexafluorobutane. These blowing agents are much more environmentally friendly than the conventional chlorofluorocarbons and do not adversely affect the properties of the foams produced.

Abstract: Disclosed is a compatibilized carbon black useful in melt processing of plastic material. The carbon black is coated with a compatibilizing agent which enhances the dispersibility of the carbon black in a melt of the plastic material. Further disclosed are processes for making plastic foam structures with the compatibilized carbon black.

Abstract: A process for the manufacture of a closed cell, rigid, polymer foam from polymer foam-forming ingredients containing a filler which comprises:(a) dispersing the filler in at least a portion of the foam-forming ingredients to form a filled dispersion, a fluorochemical surfactant being incorporated in the foam-forming ingredients either before, during or after the dispersing operation to form a dispersion containing a filler and a fluorochemical surfactant,(b) mixing the dispersion formed in step (a) with any remaining foam-forming ingredient or ingredients, and(c) foaming and curing the resultant foam-forming composition.The fluorochemical surfactant improves the stability, flowability and mixing of the dispersion during the foam production.

Abstract: The sol-gel polymerization of a phenolic-furfural mixture in dilute solution leads to a highly cross-linked network that can be supercritically dried to form a high surface area foam. These porous materials have cell/pore sizes .ltoreq.1000.ANG., and although they are dark brown in color, they can be classified as a new type of aerogel. The phenolic-furfural aerogel can be pyrolyzed in an inert atmosphere at 1050.degree. C. to produce carbon aerogels. This new aerogel may be used for thermal insulation, chromatographic packing, water filtration, ion-exchange, and carbon electrodes for energy storage devices, such as batteries and double-layer capacitors.

Abstract: Organic aerogel microspheres which can be used in capacitors, batteries, thermal insulation, adsorption/filtration media, and chromatographic packings, having diameters ranging from about 1 micron to about 3 mm. The microspheres can be pyrolyzed to form carbon aerogel microspheres. This method involves stirring the aqueous organic phase in mineral oil at elevated temperature until the dispersed organic phase polymerizes and forms nonsticky gel spheres. The size of the microspheres depends on the collision rate of the liquid droplets and the reaction rate of the monomers from which the aqueous solution is formed. The collision rate is governed by the volume ratio of the aqueous solution to the mineral oil and the shear rate, while the reaction rate is governed by the chemical formulation and the curing temperature.

Abstract: The sol-gel polymerization of a phenolic-furfural mixture in dilute solution leads to a highly cross-linked network that can be supercritically dried to form a high surface area foam. These porous materials have cell/pore sizes.ltoreq.1000.ANG., and although they are dark brown in color, they can be classified as a new type of aerogel. The phenolic-furfural aerogel can be pyrolyzed in an inert atmosphere at 1050.degree. C. to produce carbon aerogels. This new aerogel may be used for thermal insulation, chromatographic packing, water filtration, ion-exchange, and carbon electrodes for energy storage devices, such as batteries and double-layer capacitors.

Abstract: The invention relates to a process for producing a mainly closed cell phenolic foam by curing a foam system comprising at least a phenolic resin and a blowing agent. This curing is effected in the presence of an either or not alkylated morpholine which is fluorated whether completely or not and which corresponds to the following general structural formula:C.sub.n H.sub.x F.sub.y NOwherein:N.gtoreq.4x=2n+1-yy=2n+1-x.In this way, it is possible to obtain a phenolic foam having good insulation properties even if use is made of a blowing agent which is substantially free of CFC's or if the foam temperature is allowed to rise during the curing upto above 85.degree. C. to obtain a better curing.

Abstract: This invention relates to the production of low density resol foams from resol resins. The foams have a density of 2.0 pounds per cubic foot or less and are produced with a blowing agent of low boiling point HCFCs and perfluoroalkane.

Abstract: A process for the manufacture of a foamed product in which a reactive phenolic resin is mixed with urea and an isocyanate, and this mixture is then mixed with an acid catalyst. The phenolic resin polymerizes, thereby liberating water and formaldehyde. The water reacts with the isocyanate to liberate carbon dioxide and the formaldehyde reacts with the urea. As the phenolic resin polymerizes, it traps the carbon dioxide in bubbles, thereby forming a foamed product.

Abstract: A process whereby Resorcinol/Formaldehyde (RF) aerogel having a density of about 0.4-1.2 g/cc can be manufactured using a simple air drying procedure. This process is inherently simpler, quicker, and less expensive than the more conventional supercritical or subcritical CO.sub.2 extraction procedures. RF aerogels can be used as produced, such as in insulation applications, or pyrolyzed to form carbon aerogels with a density of about 0.9 g/cc for use in applications such as batteries, supercapacitors, etc.

Abstract: This invention relates to the production of low density resol foams from resol resins. The phenolic foams have a density of 2.0 pounds per cubic foot or less and are produced with a blended surfactant.

Abstract: Disclosed is a compatibilized carbon black useful in melt processing of plastic material. The carbon black is coated with a compatibilizing agent which enhances the dispersibility of the carbon black in a melt of the plastic material. Further disclosed are processes for making plastic foam structures with the compatibilized carbon black.

Abstract: Toughened thermosetting resins are disclosed comprising a thermosetting resin having a Tg of at least 150.degree. C., preferably 180.degree. C., and having dispersed substantially uniformly therethrough microspheres of a thermoplastic resin having a Tg of at least 150.degree. C., preferably 180.degree. C. It is preferred to use thermoplastic resins with functional groups on the surface thereof capable of bonding to an available group on the thermosetting resin. High performance structural composites made from such toughened resins are disclosed as well as the process of making such composites.

Abstract: A process for the production of plastic foams, preferably rigid foams containing urethane groups or urethane and isocyanurate groups, by reactinga) an organic and/or modified organic polyisocyanate withb) at least one relatively high-molecular-weight compound containing at least two reactive hydrogen atoms, and, if desired,c) a low-molecular-weight chain extender and/or cross-linking agent,in the presence ofd) a blowing agent,e) a catalyst and, if desired,f) assistants and/or additives,in which the blowing agent (d) used is at least one vinylfluoroalkane of the formula CH.sub.2 .dbd.CH--C.sub.n F.sub.

Abstract: Dimensionally stable, cured phenolic foams are described that have a thermal conductivity after 10-days below 0.0185 watts/m .degree.C., a density of 30 to 70 kg/cubic meter and a closed-cell content of at least 85%.

Abstract: A process for the production of plastic foams, preferably rigid foams containing urethane groups or urethane and isocyanurate groups, by reactinga) an organic and/or modified organic polyisocyanate withb) at least one relatively high-molecular-weight compound containing at least two reactive hydrogen atoms, and, if desired,c) a low-molecular-weight chain extender and/or crosslinking agent,in the presence ofd) a blowing agent,e) a catalyst and, if desired,f) assistants and/or additives,in which the blowing agent (d) used is at least one vinylfluoroalkane of the formula CH.sub.2 .dbd.CH--C.sub.n F.sub.

Abstract: A polyurethane resin, rigid polyurethane foam and composite thereof prepared by using a polyol comprising a phenol resin base polyol mixed with an aminophenol base polyol or a polyphenylpolyxylylenepolyamine base polyol or a polymethylenepolyphenylpolyamine base polyol.

Abstract: A method for drying foams, and in particular inorganic and organic aerogels, so that intricate internal pore/cell structure is maintained utilizing a select group of fluorocarbon solvents. Replacement of precursor diluents with a fluorocarbon solvent, followed by direct sublimation, is employed to dry the foam in place of critical point drying.

Abstract: An improved method of using polymer compositions to produce foamed plastics, wherein a major, auxiliary source of blowing agent for the foam is the decomposition of dialkyl dicarbonates. The dialkyl dicarbonates can be decomposed over temperatures ranging from about 10.degree. C. to about 45.degree. C. when used in combination with particular tertiary amine decomposition catalysts. Enhanced production of carbon dioxide is obtained by the addition of water.

Abstract: Disclosed is a foamable phenolic resin composition comprising, as indispensable components, 100 parts by weight as solids of a resol type phenolic resin, 3 to 100 parts by weight of an acidic curing agent, 1 to 50 parts by weight of a blowing agent, 0.1 to 50 parts by weight of a saccharide and 0.1 to 10 parts by weight of a foam stabilizer, in which a partial or complete acetylation product of a castor oil/ethylene oxide adduct having a hydroxyl value smaller than 15 mg-KOH/g, which is obtained by acetylating a castor oil/ethylene oxide adduct formed by adding 20 to 70 moles of ethylene oxide to 1 mole of castor oil is used as the foam stabilizer and/or a resol type liquid penolic resin obtained by subjecting a phenol and an aldehyde to addition condensation reaction in the presence of a catalyst having a metal ion-forming capacity, in which the residual amount of the catalyst is smaller than 0.

Abstract: A method of producing elastic foam having a base of polyurethane, in particular for use in the field of automobiles for sound damping. Allows production of foam parts directly in a desired shape in as few operations as possible. The foam is formed from a mixture of at least one polyurethane precondensate, at least on melamine precondensate and further additives for the foaming.

Abstract: A method of using blowing agent compositions to produce foamed plastics such as polyurethanes, polyesters and the like, wherein a major auxiliary source of blowing agent for the foam is the decomposition of dialkyl dicarbonates. The dialkyl dicarbonates can be decomposed over temperatures ranging from about 10.degree. C. to about 45.degree. C. when used in combination with particular tertiary amine decomposition catalysts.

Abstract: Organic aerogels that are transparent and essentially colorless are prepa from the aqueous, sol-gel polymerization of melamine with formaldehyde. The melamine-formaldehyde (MF) aerogels have low densities, high surface areas, continuous porsity, ultrafine cell/pore sizes, and optical clarity.

Abstract: A fire resistant resin for use as a binder in reinforced plastics and a resultant reinforced plastic includes the reaction product of (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.A method of making a fire resistant resin binder for reinforced plastics and the method of making such reinforced plastics including, (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.

Abstract: A fire resistant resin for use as a binder in reinforced plastics and a resultant reinforced plastic includes the reaction product of (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.A method of making a fire resistant resin binder for reinforced plastics and the method of making such reinforced plastics including, (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.

Abstract: The azeotrope of 1-chloro-1,2,2,2-tetrafluoroethane and dimethyl ether is useful as a refrigerant, aerosol propellant and polymer foam blowing agent.

Abstract: A semi-flexible or flexible phenolic foam composition having a substantially open cellular structure. It comprises the reaction product of a mixture of a phenol-aldehyde resin, a surfactant, a blowing agent; optionally a wetting agent and a catalyst. Also within the scope of the present invention is a method for producing a semi-flexible or flexible phenolic foam composition having a substantially opened cellular structure. This method comprises mixing a phenol-aldehyde resin with a surfactant, a blowing agent and optionally a cell opening and wetting agent; curing the mixture by reacting it with an acid catalyst; compressing the cured or semi-cured product below its original thickness and releasing the pressure, thereby obtaining the desired semi-flexible or flexible phenolic foam composition. The semi-flexible or flexible foam thus obtained possesses excellent insulation and flame retardant properties.

Abstract: A process for the production of porous phenolic resin fibers is disclosed, which process comprises graft-polymerizing to phenolic resin fibers a vinyl group-containing monomer capable of forming a thermally decomposable polymer, and thereafter subjecting the fibers to a heat treatment at a temperature high enough to cause thermal decomposition of the graft polymer. The product thus obtained is excellent in heat-resistance and adiabatic property in addition to useful properties inherent to phenolic resin fibers.

Abstract: In a method for producing resol type phenol resin foams by using starting material for the foams prepared by blending a resol type phenol resin, a blowing agent and a catalyst, a low molecular weight resol type phenol resin with the number average molecular weight of less than 200 and a high molecular weight resol type phenol resin with the number average molecular weight of greater than 200 are mixed at a weight ratio of from 5/95 to 80/20 and used as the resol type phenol resin. The resol type phenol resin foams are excellent in adhesion, fire-proofness capable of foaming cure in a short time and useful for sprayed-in-place foaming, etc. The phenol resin foams produced by the invention are capable of integral foaming with rigid urethane resin foam layer into foamed laminates of excellent thermal insulation, fire-proofness, etc.

Abstract: The polycondensation of resorcinol with formaldehyde under alkaline conditions results in the formation of surface functionalized polymer "Clusters". The covalent crosslinking of these "clusters" produces gels which when processed under supercritical conditions, produce low density, organic aerogels (density.ltoreq.100 mg/cc; cell size .ltoreq.0.1 microns). The aerogels are transparent, dark red in color and consist of interconnected colloidal-like particles with diameters of about 100.circle.. These aerogels may be further carbonized to form low density carbon foams with cell size of about 0.1 micron.TABLE I ______________________________________ Theo- [Form- retical Actual Formu- % alde- [Resor- density Density lation Solids hyde] cinol] Na.sub.2 CO.sub.3 (g/cc) (g/cc) ______________________________________ A 5.0% 0.29M 0.58M 0.0029M 0.050 0.079 B 5.0% 0.29M 0.58M 0.0019M 0.050 0.073 C 5.0% 0.29M 0.58M 0.0015M 0.050 0.070 D 4.0% 0.24M 0.47M 0.0012M 0.040 0.054 E 3.5% 0.21M 0.41M 0.0010M 0.035 0.044 F 2.

Abstract: The physical and mechanical properties of closed cell phenolic foam are improved by incorporating into certain foamable phenolic resole compositions small quantities of alkyl glucosides, particularly methyl glucosides. The alkyl glucosides also improve the process for preparing the closed cell phenolic foam.

Abstract: The invention relates to the preparation of closed cell phenolic resin foams produced from compositions of phenol-aldehyde resole resins, and the foam products thus prepared. More particularly the present invention relates to the preparation of phenolic resin foams by a method employing a novel modified phenolic foam catalyst. The invention also relates to these modified phenolic foam catalysts which include an aromatic sulphonic acid and resorcinol.

Abstract: An intumescent material comprises expandible graphite in a polymeric binder. The binder may be a flexible or elastomeric binder or a formaldehyde resin. A suitable flexible binder is a polymer selected from vinyl acetate polymers, styrene polymers, vinyl chloride polymers, acrylic polymers, vinyl butyral polymers, melamine/urea/phenol formaldehyde resins, polyesters and phenolic resins. A suitable elastomeric binder is a rubber. A suitable formaldehyde resin is melamine formaldehyde resin, urea formaldehyde resin, phenol formaldehyde resin or resorcinol formaldehyde resin.

Abstract: A phenol foam and a method for preparing substantially closed cell shaped resins on the basis of the condensation product between, on the one hand an either or not substituted phenol and/or phenol derivative and, on the other hand an aldehyde by using a blowing means for forming a hard phenol foam, whereby a physical blowing means comprising chlorine-propane is used.

Abstract: Phenolic foams having a cell structure that is resistant to rupture under pressure and a slow deterioration of thermal insulation value are claimed. These foams can be cured to achieve dimensional stability without substantial adverse affect on their structure.

Abstract: The present invention relates to hard foams having foamed and hardened phenolic resins as binding agents, and in which over 90% of the filler is aluminum hudroxide. The filler content is more than 100% with respect to the resin content of the foams. The foamble, filler-containing composition used for the production of the foams is very fluid and can be used directly for the production of moldings of any desired geometry. The aluminum hydroxide used has a grain size distribution such that between 30 to 60% of the filler is in the grain size range under 5 microns. The moldings containing the hard foam can also be in the form of composites. They are characterized not only by their good insulating properties but also by improved compressive strength, extremely little shirinkage tendency and extraordinarily high fire resistance. They are used mainly in the construction industry.

Abstract: The invention relates to the preparation of closed cell phenolic resin foams produced from compositions of phenol-aldehyde resole resins, and the foam products thus prepared. More particularly the present invention relates to the preparation of phenolic resin foams by a method employing a novel modified phenolic foam catalyst. The invention also relates to these modified phenolic foam catalysts which include an aromatic sulphonic acid and resorcinol.

Abstract: This invention relates to the manufacture of closed cell phenolic foams from low viscosity phenol-formaldehyde resole resin. This method of manufacture provides a foam which exhibits many of the advantageous characteristics of phenolic foams manufactured from high viscosity resole resin, including good thermal retention. There is provided a method of making a phenolic foam comprising the steps of mixing(a) a phenol-formaldehyde resole resin having a water content of approximately 7.5% and a viscosity of approximately 2,800 cps at 40.degree. C.;(b) a high molecular weight gel forming ethylene oxide-propylene oxide block copolymer surfactant, such as Pluronic F-127 (trade mark);(c) a catalyst;(d) a blowing agent;and curing the resulting foam.

Abstract: The polycondensation of resorcinol with formaldehyde under alkaline conditions results in the formation of surface functionalized polymer "clusters". The covalent crosslinking of these "clusters" produces gels which when processed under supercritical conditions, produce low density, organic aerogels (density .ltoreq.100 mg/cc; cell size .ltoreq.0.1 microns). The aerogels are transparent, dark red in color and consist of interconnected colloidal-like particles with diameters of about 100 .ANG.. These aerogels may be further carbonized to form low density carbon foams with cell size of about 0.1 micron.

Abstract: Foamed resinous products having excellent fire resistance, high thermal insulation and good resistance to heat are obtained at temperatures as low as room temperature and without the need for an added blowing agent by forming a mixture of a phenolic resole having a specified reactivity, an acid hardener for the resole and, uniformly dispersed through the mixture of resole and hardener, at least 20% by weight of a finely divided inert and insoluble particulate solid; products capable of being employed as wood-substitutes are obtained when a dihydric compound is included in the mixture and the solid is talc, fly ash and/or a hydraulic cement.

Abstract: A flame-retardant polymer is created by forming a first resin typically by reacting resorcinol with furfural in a ratio of one mole of the former to less than a mole of the latter in the presence of an alkaline catalyst. A resole is then formed by reacting typically phenol with formaldehyde in a ratio of one mole of phenol to more than a mole of the aldehyde in the presence of an alkaline catalyst. The first resin and resole are mixed together with a powered oxyborate compound such as zinc borate and allowed to polymerize to form the polymer.

Abstract: An insoluble and infusible substrate with a polyacene-type skelatal structure having a hydrogen/carbon atomic ratio of from 0.05 to 0.60 and containing open pores having an average diameter of not more than 10 micrometers, said substrate being a heat-treated product of an aromatic condensation polymer consisting of carbon, hydrogen and oxygen. The substrate, when doped with a dopant, gives an electrically conductive material. When having a specific surface area of at least 600 m.sup.2 /g, the substrate is especially useful as an electrode of an organic cell.