Abstract: This invention relates to a process for producing phenolformaldehyde foams, also known as phenolic foams, of improved properties. The inventive feature resides in using a controlled combination of the various components in the curing reaction mixture and in controlling the temperature within the mass of the curing mixture. The process is applicable to production of block or laminated foams. Phenolic foams find increasing use in building applications where their thermal insulation and fire resistant properties are of value.

Abstract: Fire retardant polystyrene insulating material is manufactured from expandable polystyrene scrap in admixture with a phenol-formaldehyde or melamine-formaldehyde resin in resole form, the resin containing a blowing agent and a surfactant. The insulating material is formed from the scrap-resin mix by applying dielectric heating to foam the resin, and cure the foamed resin to a closed cell structure.

Abstract: A mixture of CFC-113 and CFC-123 and/or CFC-123a where CFC-123 or CFC-123a is a significant portion of the total composition has been found to result in improved blowing agent performance in phenol-formaldehyde foams compared to CFC-113.The use of CFC-123 (or CFC-123a, or both), in combination with CFC-113 improves resole resin solubility and mixed ingredient solution stability, prior to foaming. In addition, because of the lower molecular weight of CFC-123 (or CFC-123a) compared to CFC-113 better blowing agent efficiency will be realized per unit weight. Also, the lower boiling points of CFC-123 and CFC-123a as compared to CFC-113 results in a more ready conversion of dissolved blowing agent to released gaseous blowing agent by the exothermic phenolic resin polymerization. And because of the lower molecular weight and lower boiling point factors, a lower density foam is realized.

Abstract: Spray dried thermosetting resin powders in an intermediate polymeric stage are produced in the form of hollow, thick-walled, macrospherical particles having a bulk density greater than about 35 lbs/ft.sup.3 and having particle diameters predominantly in the range of about 10 to 74 microns, preferably averaging about 30 microns in diameter with greater than 90% of the particles being in the 10 to 74 micron range. The powder is produced by centrifugal atomization of a concentrated resin solution through a porous sintered metal filter in a spray drying chamber, preferably without diluting or preheating the solution and without heating the resinous material above about 160.degree. F. during spray drying. The particles are advantageously used in the dry process molding of consolidated wood fiber structures, such as waferboard and chipboard, in which wood fiber elements mixed with the resin powder are consolidated under heat and pressure sufficient to cause the powder to melt, flow and cure.

Abstract: A phenolic resin composite foam is disclosed which is prepared by heating and foaming a novolak phenolic resin having a number average molecular weight of 250 to 600 and a bulk density of 0.15 to 0.5, a blowing agent, a blowing auxiliary compound and inorganic foamed particles. Additional materials for flame retardancy can be added. The foam produced has a high compressive strength, a high foaming and rapid curing rates, a low water absorption and a minimum of friability.

Abstract: This invention is concerned with a method for producing phenol resin foam possessing a compact cellular structure, a high closed cell ratio and improved heat resistance. The method consists of using a resole type phenolic resin having a number average molecular weight of 150-400, surface active agents, blowing agents and curing agents, wherein at least two surface active agents are chosen from general formulas A and B, but a selection of each type must be employed ##STR1## where R.sub.1 is a saturated aliphatic hydrocarbon group of 8-14 carbon atoms and/or a 2-phenylpropyl group, and m and n are integers and meet the requirement: ##EQU1## R.sub.2 is a saturated aliphatic hydrocarbon group of 4-12 carbon atoms, M is a hydrogen atom or SO.sub.2 Na, and x is an integer of 4-110.

Abstract: A mixture of CFC-113 and CFC-123 and/or CFC-123a where CFC-123 or CFC-123a is a significant portion of the total composition has been found to result in improved blowing agent performance in phenol-formaldehyde foams compared to CFC-113.The use of CFC-123 (or CFC-123a, or both), in combination with CFC-113 improves resole resin solubility and mixed ingredient solution stability, prior to foaming. In addition, because of the lower molecular weight of CFC-123 (or CFC-123a) compared to CFC-113 better blowing agent efficiency will be realized per unit weight. Also, the lower boiling points of CFC-123 and CFC-123a as compared to CFC-113 results in a more ready conversion of dissolved blowing agent to released gaseous blowing agent by the exothermic phenolic resin polymerization. And because of the lower molecular weight and lower boiling point factors, a lower density foam is realized.

Abstract: This invention relates to flame retardant phenol aldehyde foams which have a k value below 0.020 W/mk. The foams have as flame retardants a blend of a halosubstituted diphenyl oxide and an organic phosphorus compound. The feature of the invention is that unlike conventional flame retardants, the blend now used does not adversely affect the low k value i.e. the low thermal conductivity of the foam.

Abstract: Process for the preparation of cellular products and laminates based on anhydrous furan prepolymers which possess free OH groups, which is carried out at normal temperature using small amounts of silicon tetrachloride and/or phosphorus oxychloride as the crosslinking and expansion agent, characterised in that a combination of a furfuryl alcohol resin and/or a furfural/phenol (phenol and/or bisphenol A) resin with a bishydroxymethylfuran resin is used as the furan prepolymers, without the use of an acid, the silicon tetrachloride and/or phosphorus oxychloride being used in amounts of 0.1 to 5% by weight, based on the resin employed.

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: Intumescent coatings which form a thick, uniform, fine celled, low density foam upon exposure to a high intensity heat flux or flame are disclosed, the invention coatings comprise phenolic resin prepolymer containing a blowing agent and a nucleating agent; in the preferred embodiments the coatings also contains a silicone surfactant, the coatings are useful in thermal and fire protection systems.

Abstract: This invention relates to the manufacture of foam from phenolic resins and to the foam so produced. In order to overcome some of the limitations of the prior art closed cell phenolic foams, we have developed a method of preparing closed cell foams from modified, low cost phenol formaldehyde resoles, which exhibit high closed cell contents, low friability and low thermal conductivity. This specification provides a foam competitive with urethane foams, which have an aged thermal conductivity of about 0.16K. or less, but which will not generate fumes as toxic as those of urethane. There is, provided a method of making a phenolic foam material comprising the steps of(1) preparing a base catalyzed phenol-formaldehyde resole having a mole ratio of phenol to formaldehyde of between 1:3 and 1:4.

Abstract: An improved process is disclosed for the preparation of a cured substantially closed cell phenolic resin foam by preparing a mixture of a foamable phenol-aldehyde resin, a blowing agent, and an acid catalyst, allowing the mixture to foam, and curing the phenolic foam, wherein the improvement comprises:(a) maintaining the water content of the foamable mixture below about 14% by weight,(b) using a resin-soluble acid catalyst,(c) adding at least a minimum amount of two parts per hundred resin of surfactant to the mixture prior to foaming, and(d) adding a member of the lactone family to the mixture prior to foaming.

Abstract: Polyoxyalkylene foam stabilizing surfactants can be prepared by reacting a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid under free radical polymerization conditions in the presence of a free radical initiator, and by subjecting the reaction product obtained to a solvent extraction. The isolated components can be utilized as surfactants in producing cellular foams.

Abstract: A heat-resistant phenolic resin foam containing a hydrate of an inorganic compound which generates a water vapor at a temperature below the decomposition temperature of the phenolic resin foam, wherein(a) the hydrate of the inorganic compound has a pH of not more than 8 as its saturated aqueous solution, and(b) the hydrate of the inorganic compound is contained in an amount of 2 to 30% by weight in the phenolic resin foam.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: This invention relates to the manufacture of foam from phenolic resins and to the foam so produced. In order to overcome some the the limitations of the prior art closed cell phenolic foams, we have developed a method of preparing closed cell foams from modified, low cost phenol formaldehyde resoles, which exhibit high closed cell contents, low friability and low thermal conductivity. This specification provides a foam competitive with urethane foams, which have an aged thermal conductivity of about 0.16K. or less, but which will not generate fumes as toxic as those of urethane. There is, provided a method of making a phenolic foam material comprising the steps of(1) preparing a base catalyzed phenol-formaldehyde resole having a mole ratio of phenol to formaldehyde of between 1:3 and 1:4.

Abstract: The invention relates to new sound- and heat-insulating compositions, which comprise a finely dispersed leather powder of animal origin, a phenoplast resin or an aminoplast resin and optionally, together with the latter one, urea and/or a modified furane resin and optionally a wetting and/or foaming agent and an acid catalyst and optionally water.The compositions according to the invention have remarkable noise- and heat-insulating properties.

Abstract: The present invention is directed to aqueous phenol formaldehyde resoles that have particular application in manufacturing phenolic foam insulation. The resoles are essentially phenol formaldehyde condensation polymers having molar ratios of formaldehyde to phenol of from about 1.7:1 to 2.3:1, preferably from 1.75:1 to 2.25:1 and most preferably about 2:1. The resoles have a weight average molecular weight greater than 800 and preferably from 950-1500. The resoles also have a number average molecular weight greater than 350 and preferably from about 400 to about 600 and a dispersivity greater than about 1.7, preferably from 1.8 to 2.6. Phenol formaldehyde resoles having these characteristics are processable into phenolic foams having a low k value and having other physical characteristics which make the phenolic foam especially useful as an insulation material.

Abstract: There is disclosed a non-flammable rigid foam on the basis of phenolic resin and furane resin, containing aluminum hydroxide and further components as a filler system. The weight ratio of resin substance:filler substance is at least 1:2.5 and up to 1:3.2 and the bulk density is from 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin compound is the reaction product obtained by the reaction with one another of50-62 weight parts resolic resin0-15 weight parts furanic resin25-40 weight parts furfuryl alcohol0.5-1.

Abstract: Generally closed cell phenolic foams are prepared which have a K-factor of less than 0.2, preferably from about 0.116 to about 0.170 Btu/hr - .degree.F. - ft - .sup.2 per inch of foam thickness when measured at 24.degree. Centigrade. The foams are prepared from a resole resin which has been stripped to a water level of less than 7 percent by weight, preferably from about 3 to about 6 percent by weight based on resin weight. A viscosity adjusting amount of a solvent, such as phenol, and from about 10 to about 20 weight percent, based on resin weight, of a polyglycol are also part of a foam forming formulation. Conventional surfactants, blowing agents and acidic catalysts are used to prepare the foams. The foams so prepared generally have no tendency to autoxidize when placed in an oven heated to a temperature of 250.degree. Centigrade. The foams so prepared also have enhanced resistance to flame penetration.

Abstract: Phenolic foams and a method of producing phenolic foam material from phenol-formaldehyde resins having a phenol to formaldehyde mole ratio of between about 1:3 and 1:4.5 are described. These materials are useful for insulation and other uses, particularly in the building trades. They are dimensionally and thermally stable, fire resistant and low in cost.

Abstract: Polyoxyalkylene foam stabilizing surfactants can be prepared by reacting a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid under free radical polymerization conditions in the presence of a free radical initiator, and by subjecting the reaction product obtained to a solvent extraction. The isolated components can be utilized as surfactants in producing cellular foams.

Abstract: The non-flammable rigid foam e.g. used as a building material complies with the requirements of DIN 4102 and which provides a non-toxicity of the combustion fumes according to DIN 53436. It has a mass ratio of resin component: filler of at least 1:2.5 and a bulk density amounting to 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin component is formed by reaction of50-62 mass parts resolic resin0-15 mass parts furane resin25-40 mass parts furfuryl alcohol0.5-11.5 mass parts foam stabilizerincluding 14-17 mass parts per 100 mass parts of resin component plus filler of a curing agent mixture of phosphoric acid, boronhydrofluoric acid, p-toluene sulphonic acid and water. The filler used is a mixture of40-55 mass % aluminium hydroxide10-35 mass parts boric acid2-7 mass parts sodium tetraborate5-10 mass parts manganese dioxide1-5 mass parts copper-II-oxide1-4 mass parts magnesium hydroxysilicate1-2 mass parts aluminium silicate.

Abstract: A method for manufacturing a phenolic resin foam is provided which comprises the steps of mixing a composition consisting of 100 parts by weight of a resol-type phenol-formaldehyde resin, 5 to 40 parts by weight of a curing agent consisting of an acid, and a foaming agent consisting of an isocyanate or a mixture thereof with water, and heating the composition for foaming, an amount of the isocyanate being 5 to 30 parts by weight if the foaming agent is the isocyanate alone, and the amount of the isocyanate being not less than its equivalent weight and an amount of water being 5 to 30 parts by weight if the foaming agent is the mixture of the isocyanate with water. If 100 parts by weight of a urethane-modified phenol-formaldehyde resin are used in place of 100 parts by weight of the resol-type phenol-formaldehyde resin, 0.1 to 1.5 parts by weight of a curing agent consisting of a tin compound are used in place of the acid curing agent.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: Polyoxyalkylene foam stabilizing surfactants can be prepared by reacting a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid under free radical polymerization conditions in the presence of a free radical initiator, and by subjecting the reaction product obtained to a solvent extraction. The isolated components can be utilized as surfactants in producing cellular foams.

Abstract: Amino-resin products, which include aminoplast foams, can be modified by reacting an aminoplast precondensate, which contains an excess of formaldehyde or to which supplemental formaldehyde or another lower monoaldehyde or dialdehyde has been added before processing, with a hardening agent or with a solution of hardening agent, surfactant, and foamer in the presence of an additive that consists of one or more mononuclear or binuclear phenols, phenolic ethers, or acenaphthene derivatives with the overall formulas ##STR1## in which X is H, OH, SO.sub.3 H, Cl, CH.sub.3, or C.sub.2 H.sub.5 andR is H or an alkyl radical, with 1 to 9 carbon atoms, at a pH between about 1 and 2, mixed if necessary with aromatic sulphonic acids, at a pH between about 1 and 2. The modified products can be employed wherever free formaldehyde is undesirable.

Abstract: The present invention is directed to a method of preparing a phenolic foam that has cell walls which are substantially free of perforations. The method comprises using certain anhydrous aryl sulfonic acids as the foaming and curing catalysts. The useful anhydrous aryl sulfonic acids are those which have a pKa of less than about 2.0 and which change the compatibility of the phenolic resole with water. The preferred anhydrous aryl sulfonic acid is a combination of toluene sulfonic acid and xylene sulfonic acid. The invention is also directed to a phenolic foam having cell walls which are substantially free of perforations and to foamable phenolic resole compositions for preparing the phenolic foam.

Abstract: A novel polymer is provided as the condensation reaction product of a non-aqueous mixture of a phenol and an aldehyde in a molar ratio of about 0.5 to 1 phenol to aldehyde, containing refractory fibers, such as carbon, graphite, silica, having an aspect and metal oxides and silicates, which fibers have an aspect ratio of about 10. The phenol is selected from metacresol, orthocresol, 3,5-dimethylphenol, resorcinol and substituted resorcinols, the preferred material being mostly resorcinol. The aldehyde is selected from furfural and mixtures of furfural and paraformaldehyde. The condensation polymerization reaction can be effected by adding an acid catalyst to the mixture or by employing a curing agent which provided a polyfunctional amine reactive with either or both the aldehyde and the phenol.

Abstract: The non-flammable rigid foam e.g. used as a building material complies with the requirements of DIN 4102 and which provides a non-toxicity of the combustion fumes according to DIN 53436. It has a mass ratio of resin component:filler of at least 1:2,5 and a bulk density amounting to 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin component is formed by reaction of50-62 mass parts resolic resin,0-15 mass parts furane resin,25-40 mass parts furfuryl alcohol,0,5-11,5 mass parts foam stabilizer including 14-17 mass parts per 100 mass parts of resin component plus filler of a curing agent mixture of phosphoric acid, boronhydrofluoric acid, p-toluene sulphonic acid and water. The filler used is a mixture of40-55 mass % aluminium hydroxide10-35 mass parts boric acid2-7 mass parts sodium tetraborate5-10 mass parts manganese dioxide1-5 mass parts kopper-II-oxide1-4 mass parts magnesium hydroxysilicate1-2 mass parts aluminium silicate.

Abstract: A phenolic resin foam having excellent mechanical strength and flame resistance is obtained by letting a resinous mixture comprising a benzylic ether type phenolic resin, a blowing agent, an aromatic sulfonic acid, a polyisocyanate compound, and water to stand at room temperature or more so as to allow the mixture to foam and solidify.

Abstract: A method and a composition are provided for molding low density desiccant syntactic foam articles. A low density molded desiccant article may be made as a syntactic foam by blending a thermosetting resin, microspheres and molecular sieve desiccant powder, molding and curing. Such articles have densities of 0.2-0.9 g/cc, moisture capacities of 1-12% by weight, and can serve as light weight structural supports.

Abstract: Closed-cell phenolic foam having a uniform cell structure in which the cell walls are substantially free of both ruptures and perforations is disclosed. The phenolic foam has initial k values of less than 0.15 with substantially no increase of k value over time and good density and compressive strengths. The phenolic foam is prepared by foaming and curing a foamable phenolic resole composition containing an aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent, and optionally other additives with an acid foaming and curing catalyst in a substantially closed mold which exerts a restraining pressure on the foaming composition in excess of ambient atmosphericpressure of greater than about 3 pounds per square inch. The aqueous phenol formaldehyde resole is essentially a phenol formaldehyde condensation polymer having a molar ratio of formaldehyde to phenol of from about 1.7:1 to 2.3:1, preferably from 1.75:1 to 2.25:1 and most preferably about 2:1.

Abstract: Improvement in the preparation of open-pored phenolic resin foams by the foaming of intimate mixtures of water-containing phenolic resol resins in the viscosity range of from 1000 to 20,000 cP, low-boiling organic liquids in which the phenolic resol resins are not soluble as blowing agents and acid-containing hardeners, the improvement comprising adding to the foamable phenolic resol resin before or during the preparation of the foamable mixture, 1.0 to 6.0 weight-percent of ethoxylated castor oil and 0.5 to 5 weight-percent of an alkyl sulfate salt of the general formulaC.sub.x H.sub.2x+1 --O--SO.sub.3 --Me.sup.+wherein x an integer from 8 to 18 and Me is an alkali metal or a triethanolamine cation.

Abstract: A continuous process for manufacturing quick-setting phenolic foams is improved by using as the hardening agent a concentrated, substantially anhydrous solution of boron trioxide, and using as the blowing agent an organic liquid having a boiling point of 20.degree.-80.degree. C. Curing times are shortened and the resultant foam, having uniformly molecularly dispersed therein about 0.25-10.5% by weight of boron, calculated as boric anhydride, has substantially uniform cells, improved fire resistance characteristics and superior mechanical properties.

Abstract: The present invention is directed to a method of producing phenolic foams comprising introducing into a substantially closed volume a phenolic resole resin foamable composition and allowing the composition to foam in this volume wherein a pressure in excess of ambient atmospheric pressure is achieved within this volume. This pressure in excess of ambient atmospheric pressure generally is in excess of about 2 pounds per square inch, typically in excess of about 5 pounds per square inch, and preferably in excess of about 6 pounds per square inch, gauge pressure.The present invention is also directed to foams produced by the method of the invention.

Abstract: The closed cell content of a phenolic is significantly increased by the incorporation therein of a finely divided hydrated alumina.

Abstract: Polyoxyalkylene surfactants for cellular forms can be prepared by reacting a polyoxyalkylene adduct and an esterified unsaturated dibasic acid in the presence of a free-radical initiator.

Abstract: A two-part pack, and method for its preparation, from which a phenol-formaldehyde resin foam may be prepared, which system comprises in the first part of the pack a phenol-formaldehyde resin, a blowing agent which is an inert, low boiling liquid, an effective amount of a nitrogenous modifier capable of permitting dispersion of the blowing agent in the resin, and a surfactant; and in the second part of the pack an acid catalyst system dispersed in a liquid polyhydroxy compound, in a weight ratio of polyhydroxy compound to acid catalyst of at least 1:1. These two-part packs enable simpler handling and placement techniques being shelf storable, compared to the known shelf storable systems which involve three, or more, components.

Abstract: Polyoxyalkylene foam stabilizing surfactants can be prepared by reacting a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid under free radical polymerization conditions in the presence of a free radical initiator, and by subjecting the reaction product obtained to a solvent extraction. The isolated components can be utilized as surfactants in producing cellular foams.

Abstract: A novel polymer is provided as the condensation reaction product of a non-aqueous mixture of a phenol and an aldehyde in a molar ratio of about 0.5 to 1 phenol to aldehyde, containing refractory fibers, such as carbon, graphite, silica, having an aspect and metal oxides and silicates, which fibers have an aspect ratio of about 10. The phenol is selected from metacresol, orthocresol, 3,5-dimethylphenol, resorcinol and substituted resorcinols, the preferred material being mostly resorcinol. The aldehyde is selected from furfural and mixtures of furfural and paraformaldehyde. The condensation polymerization reaction can be effected by adding an acid catalyst to the mixture or by employing a curing agent which provided a polyfunctional amine reactive with either or both the aldehyde and the phenol.

Abstract: The present invention comprises a new phenolic-aldehyde based resinous, thermosetting polyol and a method for its production. According to the invention, phenol is condensed using acid catalysis, under freely evaporative atmospheric conditions with a molar excess of aldehyde, in the presence of polyhydroxyl component.

Abstract: Plastics are produced by reacting at least one compound containing sulfonic acid groups with at least one aldehyde in the presence of a hydroxy compound in an acidic concentrated aqueous solution having a water content of about 20 to 30% by weight. If a tenside is present the reactants will form a foam. The preferred sulfonic acid-containing compound is the sodium salt of diisobutylnaphthalene sulfonic acid, the preferred hydroxy compound is a phenol, vix. resorcinol, and the preferred aldehyde is formaldehyde which may be formed in situ from hexamethylenetetramine, paraformaldehyde, trioxane, or the like.

Abstract: The present invention relates to foams made of resol-type phenolic resins which do not discolor as quickly as prior-art phenolic foams. With the additive in accordance with the invention, even colored foams will not darken as readily. The foams in accordance with the invention contain as stabilizers salts of phosphinic acid or phosphonic acid, such as the primary alkali phosphites or the alkali phosphinates. The stabilizers, which protect the foams against the action of light and/or air and/or heat, are used in amounts ranging from 0.1 to 5 weight percent. The present invention further relates to methods of preparing such foams. In a preferred method, the stabilizers are admixed with an expandable resol-type phenolic resin, the mixture so obtained is mixed with the other substances necessary to formation of a foam, and the whole mixture is then foamed conventionally.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting a polyoxyalkylene adduct and an esterified unsaturated dibasic acid in the presence of a free-radical initiator.

Abstract: The tetramethylol derivative of 4,4'iso-propylidenediphenol is dissolved in a solution of water and ethylene or propylene carbonate to yield concentrated solutions of the derivative in a form which may readily be used in the manufacture of foams or used as a liquid binder for molded ceiling products. Based on 100 parts by weight of the tetramethylol derivative, these solutions contain from about 15 to about 35 parts by weight of water and from about 5 to about 30 parts by weight of ethylene carbonate or propylene carbonate, with the total parts by weight of the water and carbonate varying from about 40 to about 45.

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.

Abstract: A low-friability, flame-retardant, thermosetting foam product is prepared by reacting, in the presence of a blowing agent and a strong acid catalyst, a furfuryl-alcohol polymer and a phenol-formaldehyde resin, having a mole ratio of phenol to formaldehyde of from about 1:1.2 to 1:2.0, which reaction provides a low-friability, flame-retardant, thermosetting foam product.

Abstract: This invention relates to cellular plastic compositions of condensation products of phenol-urea and formaldehyde useful for thermal and acoustical insulation and methods for their preparation in which the phenol is present in amounts of about 1 to about 20 percent by weight wherein the condensation product prior to foaming and setting as a rigid cellular plastic has a viscosity at room temperature of approximately 30 to 36 seconds, No. 1 Zahn cup, and a pH maintained in the range of about 6 to 8.