Abstract: A process for the manufacture of a resilient foam based on a melamine-formaldehyde condensate, wherein an aqueous or alcoholic solution or dispersion containing a melamine-formaldehyde precondensate, an emulsifier, a blowing agent and a hardener is foamed by ultra-high-frequency irradiation and the foam is hardened by crosslinking the precondensate. The foam may be employed for heat and sound insulation, and as a packaging material.

Abstract: Flame retardant polymer resins formed by an acid condensation reaction from a mixture of resorcinol and furfural with a molar excess of the aldehyde. In one particular embodiment the resin is formed of a mixture of two prepolymer solutions with at least a boric acid catalyst, one or both of the prepolymer solutions being an acid-condensation reaction product of resorcinol and furfural with excess aldehyde functionality, or one of the prepolymers being a mix of substantially unreacted resorcinol and furfural with a slight molar excess of aldehyde.

Abstract: Closed cell phenol-aldehyde foam is prepared by a method which includes a novel frothing and curing technique. An admixture containing a liquid phenolaldehyde resole resin, a volatile blowing agent, and a surfactant is frothed to produce a stable froth containing closed cells. The cell walls are formed of the liquid resole resin and the closed cells are expanded by the blowing agent in gaseous phase. The froth is formed into an uncured shape and the liquid resole resin is cured to the solid state in the presence of an acid catalyst to produce cured closed cell foam. The internal temperature throughout the shape during curing is above the boiling point of the blowing agent but less than 212.degree. F., and is sufficiently low to prevent further expansion of the shape in an amount to rupture the closed cell walls and thereby form an open cell structure.

Abstract: A phenolic foam produced without the use of a conventional chlorofluorocarbon or hydrocarbon blowing agent is disclosed. The phenolic foam is produced as the reaction product of a mixture comprising a phenolic resole, a surfactant and stannous chloride. The phenolic foams can be formulated to contain a substantial proportion of closed cells.

Abstract: Flame retardant polymer resins formed by an acid condensation reaction from a mixture of resorcinol and furfural with a molar excess of the aldehyde. In one particular embodiment the resin is formed of a mixture of two prepolymer solutions with at least a boric acid catalyst, one or both of the prepolymer solutions being an acid-condensation reaction product of resorcinol and furfural with excess aldehyde functionality, or one of the prepolymers being a mix of substantially unreacted resorcinol and furfural with a slight molar excess of aldehyde.

Abstract: Curable organic resin compositions, such as epoxy resins, are provided, based on the use of dialkyl hydroxy arylsulfonium salts in combination with certain orgainc oxidants such as iodosoaromatic esters, or the use of certain amines or transition metals in combination with organic peroxides. The curable compositions can provide flexible or rigid organic resin foam when used with a volatile organic solvent as a result of exothermic heat of cure.

Abstract: Phosphoric acid is reacted with mono- or polyfunctional epoxides containing methyol or alkoxymethyl groups, to provide resins which are curable simply by heating and contain as much as about 30 weight percent of phosphoric acid. Improved flame retardancy and water resistance are imparted to structural foams by impregnating them with these resins and curing in-situ.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, or phenolic resin, a hardening agent, a surface active agent and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

Abstract: The present invention relates to a process for the preparation of phenol-formaldehyde foams by mixing a resol phase having a viscosity of between 8 and 60 poises and a novolac phase comprising a true novolac, a blowing agent, phenolsulphonic acid and, optionally, phenol, the relative amounts of resol phase and of novolac phase being such that the resol phase represents 45 to 75% by weight of the mixture.

Abstract: A closed cell phenolic-resin foam material comprising phenolic-resin foam forming reactants, a blowing agent, and a surfactant which is the capped reaction product of an alkoxylated amine and a copolymerizable mixture of dialkyl maleate with N-vinyl-2-pyrrolidone or N-vinyl caprolactam.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, of phenolic resin, a hardening agent, a surface active agent, a finely divided hydrophilic material and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

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.

Abstract: Low temperature curable organic resin compositions, for example, epoxy resins are provided, which can be either exothermically cured or cured in several minutes or less at relatively low temperatures. Certain diaryliodonium salts have been found to spontaneously release strong protonic acids when used in combination with a copper salt and a reducing agent.

Abstract: Diaryliodonium salts have been found to be effective thermal initiators for the polymerization of a variety of cationically polymerizable materials including epoxides, cyclic ethers, phenol formaldehyde resins, etc., when used in combination with various cocatalysts. Among the cocatalysts which have been found to be effective are, for example, copper chelates and mixtures of such copper chelates with various reducing agents such as ascorbic acid, tin.sup.+2 salts, etc.

Abstract: Composite foam panels are prepared from expanded thermoplastic particles of low density by generally encapsulating the particles in a phenolic foam matrix and providing a particulate expanded mineral substance such as perlite disposed generally adjacent the major surfaces of the panel.

Abstract: A foam product and method of producing the same for use in preserving cut flowers is provided which method provides in the manufacture of the product of foaming under mild conditions to preserve the wettability, and the preservative qualities of the foaming material and its additives so as to improve the life of the cut flowers which are mounted in the product.

Abstract: Low temperature curable organic resin compositions, for example, epoxy resins are provided, which can be either exothermically cured or cured in several minutes or less at relatively low temperatures. Certain diaryliodonium salts have been found to spontaneously release strong protonic acids when used in combination with a copper salt and a reducing agent.

Abstract: A method for producing a phenol foam plastic, consisting in that polycondensation of phenols with formaldehyde is conducted with simultaneous foaming and curing in the presence of a foaming agent and an acid or alkaline catalyst. Used as the phenols are pyrocatechol, hydroquinone, resorcinol, 5-methyl resorcinol, shale alkyl resorcinols, shale total phenols, or various combinations of said phenols. The method is simple and permits obtaining a foam plastic with improved physico-mechanical properties.

Abstract: A two component system, and method for its preparation, from which a phenol-formaldehyde resin foam may be prepared, which system comprises in a first component 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 a second component an acid catalyst system dispersed in a liquid polyhydroxy compound, in a weight ratio of acid catalyst to polyhydroxy compound of at least 1:1. These systems enable simpler handling and placement techniques being shelf storable, compared to the known shelf storable systems which involve three, or more, components.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporating a particular resole resin catalyzed with alkaline earth metal hydroxides and neutralized with oxalic acid or its acid salts providing inert insoluble oxalate salts dispersed in said resole. Said salts are sized controlled and stabilized in an aqueous resole resin solution having about 60 to 99% resole resin by weight. Methods for preparing and foaming said compositions are disclosed.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporation dispersed metal powders in said composition providing a foamable resole composition curable to a non-corrosive foam. Methods for preparing, foaming and curing said non-corrosive foams are disclosed.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporation dispersed calcium oxide particles in said composition providing a foamable resole composition curable to a non-corrosive foam. Methods for preparing, foaming and curing said noncorrosive foams are disclosed.

Abstract: A process for producing a closed cell phenolic-resin foam material comprising a phenolic-resin polymer and a surfactant which is branched, non-ionic, with a hydroxyl value less than 50 achieved by capping excess hydroxyl groups; the material, and a structural laminate employing the material. The material has a thermal conductivity which is low initially and remains low for a long period of time.

Abstract: A closed cell phenolic-resin foam material comprising phenolic-resin foam forming reactants, a blowing agent, and a surfactant which is the capped reaction product of an alkoxylated amine and a copolymerizable mixture of dialkyl maleate with N-vinyl-2- pyrrolidone or N-vinyl caprolactam.

Abstract: A phenolic material having improved cell structure and surface skin characteristics is prepared by mixing, foaming and curing a foamable composition comprising a phenol-formaldehyde resin; an acid catalyst; a foaming agent-mixture containing a low boiling fluorocarbon, a surface active agent and a polyhydric alcohol; and a filler/extender mixture functioning as a cell structure control agent comprised of a water soluble inorganic salt and ammonium lignin sulfonate.

Abstract: Curable organic resin compositions, such as epoxy resins, are provided, based on the use of a diaryliodonium salt-redox catalyst curing system. The curable compositions can provide flexible or rigid organic resin foam when used with a volatile organic solvent as a result of exothermic heat of cure.

Abstract: The present invention provides particular phenol/formaldehyde resoles which are especially useful as foamable resins, and further provides cellular phenolic products having physical properties which are especially attractive for end-use application as construction foam. The resoles are characterized by a particular relationship between their viscosity and water content, expressed as the area bounded by certain points on a plot of resole viscosity on a logarithmic scale, as a function of water content of the resole, the particular area depending upon the mole ratio of formaldehyde-to-phenol at which the resole has been condensed. It has been found that phenol-formaldehyde resoles having the defined viscosity/water relationship are capable of providing phenolic foam having acceptable foam processability, a foam density from about 1.90 to about 3.

Abstract: The present invention provides particular phenol/formaldehyde resoles which are especially useful as foamable resins, and further provides cellular phenolic products having physical properties which are especially attractive for end-use application as construction foam. The resoles are characterized by a particular relationship between their viscosity and water content, expressed as the area bounded by certain points on a plot of resole viscosity on a logarithmic scale, as a function of water content of the resole, the particular area depending upon the mole ratio of formaldehyde-to-phenol at which the resole has been condensed. It has been found that phenol-formaldehyde resoles having the defined viscosity/water relationship are capable of providing phenolic foam having acceptable foam processability, a foam density from about 1.90 to about 3.

Abstract: The method of production of chemically set compositions which show no shrinkage or which increase their volume during setting finding their application in building engineering, electrotechnical engineering and other fields of technology, consists in adding a special expanding system to a composition comprising synthetic resins or elastomers. Said system consists of an expanding agent, an expansion promoter, and if need be an expansion moderator, and sodium and/or potassium and/or magnesium fluosilicate. As the expanding agent substances are used having a porous structure and sorption properties, as for instance aluminosilicates, and as the expansion promoter substances are used having a polar structure and a critical diameter of the molecule smaller than that of the pores of the expanding agent, as for instance alcohols.

Abstract: Foamed phenolic resins containing CaSO.sub.4. nH.sub.2 O, where n is 0-2, having reduced tendency to shrink and reduced weight loss on aging.

Abstract: Improved phenolic foams are produced having a more uniform cell structure, improved mechanical and thermal properties, and improved foam structure by foaming a phenol-aldehyde oligomer condensate such as a resole, an extended resole, or a mixture of a resole and a novolac resin in the presence of N-methyl-2-pyrrolidone.

Abstract: A closed cell phenolic-resin foam material comprising phenolic-resin foam forming reactants, a blowing agent, and a surfactant which is the capped reaction product of an alkoxylated amine and a copolymerizable mixture of dialkyl maleate with N-vinyl-2-pyrrolidone or N-vinyl caprolactam.

Abstract: A process for producing a closed cell phenolic-resin foam material comprising a phenolic-resin polymer and surfactant which is branched, non-ionic, with a hydroxyl value less than 50 achieved by capping excess hydroxyl groups; the material, and a structural laminate employing the material. The material has a thermal conductivity which is low initially and remains low for a long period of time.

Abstract: A non-swellable three-dimensional polymer having a component which is a residue of an optically active compound, which residue is chemically removable from said polymer to leave behind in the physical structure of said polymer a void corresponding to the size and shape of said residue of optically active compound, and a particular steric arrangement of functional groups within the void of said polymer corresponding to the chemical structure of said residue of optically active compound, the original polymer having recurring units of the formulas ##STR1## wherein A, C and D are residues bonded to B of compounds which residues are polymerizable or polycondensable and B is a residue of an optically active compound; a process for preparing such polymer and the form of such polymer containing such void and free of the residue of optically active compounds.

Abstract: A phenolic foam that is non-corrosive to metallic substrates over which it is applied is disclosed herein. The foam is prepared by hardening an intimate mixture of a conventional foamable phenolic resole resin containing a blowing agent, a hardener and a surface active agent, and sodium tetraborate.

Abstract: Process for hardening liquid resols comprising using for the hardening, strong acids which if they are solid at room temperature are used in the form of their mixtures with inert finely divided solid diluents or if they are liquid or gaseous at room temperature adsorbed onto an adsorbing agent.

Abstract: Liquid oxyalkylated polyol prepolymers are prepared by oxyalkylating a prepolymer prepared from a hydroxy aromatic compound, an aldehyde and furfuryl alcohol with an alkylene oxide containing about 2-4 carbon atoms. The oxyalkylated polyol prepolymers have a viscosity of 1000-500,000 centipoises at 25.degree. C. and contain about 1.1-6 moles of interpolymerized aldehyde, about 3.1-15 moles of interpolymerized furfuryl alcohol, and about 1-10 moles of interpolymerized alkylene oxide for each mole of interpolymerized hydroxy aromatic compound. The resultant prepolymers are highly reactive and may be further polymerized with or without monomers such as polyisocyanate to produce flame retardant solid or cellular interpolymers. Flame retardant solid or cellular polyurethanes are prepared in one variant by interpolymerizing organic polyisocyanates with the oxyalkylated polyol prepolymers. In another variant, flame retardant closed cell cellular interpolymers are provided.

Abstract: Liquid prepolymers are prepared by interpolymerizing monomers including a hydroxy aromatic compound, an aldehyde and furfuryl alcohol. The resultant liquid prepolymers have a viscosity of about 100-500,000 centipoises at 25.degree. C. and contain about 1.1-6 moles of interpolymerized aldehyde and about 3.1-15 moles of interpolymerized furfuryl alcohol for each mole of interpolymerized hydroxy aromatic compound. The prepolymers are highly reactive and may be polymerized with or without other monomers to produce flame retardant solid or cellular interpolymers. In one variant, flame retardant solid or cellular polymers are produced by interpolymerizing organic polyisocyanates with the prepolymers. In another variant, solid or cellular interpolymers are produced by polymerizing the prepolymers without monomers such as polyisocyanate in the presence of unreacted furfuryl alcohol. Processes are provided for preparing the aforementioned novel liquid prepolymers and solid or cellular interpolymers.

Abstract: A high compressive strength phenolic resin foam is made by: adding between about 0.5 to 5.0 parts of a dual surfactant system and about 8 to 25 parts of a blowing agent, to 200 parts of a phenolic resole resin to form a pre-mix; agitating this pre-mix with about 20 to 70 parts of an aqueous dual sulfuric-phosphoric acid solution to provide a foaming phenolic material; immediately thereafter pouring or injecting the material into a mold or onto a suitable substrate, to provide a phenolic foam having a substantially uniform compressive strength of at least 40 psi. at between about 20% to 50% compression, at a deflection rate of between about 2 in./min. to about 5 in./min.

Abstract: Process for hardening liquid resols comprising using for the hardening, strong acids which if they are solid at room temperature are used in the form of their mixtures with inert finely divided solid diluents or if they are liquid or gaseous at room temperature adsorbed onto an adsorbing agent.

Abstract: A cellular high-temperature insulation composite molded product comprising the molded and cured product obtained by preparing a mixture of(1) a dry blend of(a) expanded perlite,(b) a calcium aluminate cement,(c) a refractory clay, and(d) wollastonite, with(2) an aqueous liquid composition comprising(a) an auxiliary binder, and(b) waterAnd molding and curing the mixture, and a method for the production of the above-described cellular high-temperature insulation composite molded product. Additional embodiments comprise use of reinforcing fibers and a surface active agent additionally in the aqueous liquid composition, generally as a foamed aqueous liquid composition and use of a chemical cement curing accelerator additionally in the aqueous liquid composition.