Abstract: Aminoplast foams of hardened reaction products of aldehydes and at least bifunctional modified .alpha.,.omega.-ureas which contain at least one ether, thioether, acetal, ester, ester amide and/or carbonate group and have a molecular weight of from 200 to 10,000.

Abstract: A method of reducing the formaldehyde emissions from formaldehyde condensation polymers is disclosed. A substance having two or more amide linkages, such as a polyacrylamide polymer is incorporated in the polymer solution immediately or shortly before use, the acrylamide polymer reacting with free formaldehyde in the solution or that generated as a result of hydrolytic breakdown of the formaldehyde condensation polymer. The incorporation of polyacrylamide polymers in a urea-formaldehyde resin solution used in the production of urea-formaldehyde insulating foams is of particular benefit.

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: 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: A method for preparing macroporous aminotriazine-aldehyde resins by reaction in the presence of an acid catalyst and a miscible porogen. The resin product has high surface area and porosity and displays excellent sorption capacity.

Abstract: Here is described the manufacture of a cured urea/formaldehyde resin foam having a shrinkage on drying of less than 20% by volume, by a method which includes the step of producing a homogeneous wet foam from an aqueous resin solution and an aqueous solution of a hardener for the resin, the freshly made wet foam having a total reactive resin solids content of at least 35% by weight. Apparatus for producing the cured resin foam includes a foaming column having upstream and downstream regions constituted by different inert materials.

Abstract: A process and apparatus are provided for making desired shapes of urea-formaldehyde suitable for use as insulation from urea-formaldehyde foam. Fluid urea-formaldehyde foam (A) is formed into discrete particles (A') in particle generator (10) which also partially cures particles (A'). After particles (A') are fully cured, they are blended with fluid urea-formaldehyde foam in mixing apparatus (11) which includes blending head (66) to produce mixture (C) which is a coherent mass. Mixture (C) is molded to the desired cross-sectional shape by molding conveyor (12). Cutter (132) cuts formed mixture (C) into the desired length. Thereafter oven (146) is utilized for fully curing the product which is then enclosed in a suitable packaging material.

Abstract: Urea-formaldehyde polymers having reduced formaldehyde emissions are produced by incorporating in the prepolymer an aromatic substance incapable of reacting with urea formaldehyde in alkaline media but capable of reacting with urea formaldehyde in acid media in an amount sufficient to reduce or eliminate the free formaldehyde emissions therefrom. Also disclosed is a cellular urea-formaldehyde foam which is resistant to acid-induced hydrolysis, the foam prepared by incorporating a polyalkyl polynuclear metal sulfonate foaming agent in the acid catalyst solution for the urea-formaldehyde prepolymer.

Abstract: An improved process for the production of thermoset foams having a predetermined shape by subjecting a reactive amine to a condensation reaction in an enclosed mould cavity, wherein the reaction is carried out under conditions whereby by-product water found during the reaction is substantially free to move out into a space adjacent to and in communication with said foam, and controlling the temperature and care of said foam by regulation of the web bulb temperature of the gaseous mass inside said space. Foam products made in accordance with the process of the invention, e.g. urea-formaldehyde furfuryl alcohol-based insulating foams, are also claimed.

Abstract: A method for producing stable urea-formaldehyde polymers which have reduced aldehyde vapor emissions during their production and use is disclosed, such urea-formaldehyde polymers particularly useful in the production of urea-formaldehyde insulating foam and as adhesives in the production of plywood and particleboard. An alkali or alkaline earth metal borohydride is added to the urea-formaldehyde resin solution prior to or during cure thereof. The boroydride reacts with free formaldehyde in the resin solution or any free formaldehyde subsequently generated in the resin due to hydrolytic break down. The amount of borohydride added the resin solution should be sufficient to reduce the emission of free formaldehyde therefrom.

Abstract: Opacifying agents of improved structural integrity and light scattering ability are disclosed. These agents are composed of hollow, substantially spherical agglomerates having discontinuous walls composed of solid, spherical microparticles. The microparticles are produced by admixing an aqueous, partially condensed aldehyde condensation product with an oily non-solvent material and an emulsifying agent to produce a water-in-oil emulsion. Polymerization acid catalyst is then admixed with the emulsion to produce the discrete, substantially spherical and opaque, solid microparticles. After inverting the emulsion to oil-in-water form and adding oil-soluble resin adhesive, elevated temperature is used to cure the adhesive while evaporatively removing residual oily non-solvent. This yields improved agglomerate opacifying agents of high physical stability.

Abstract: A porous thermoplastic sheet is formed by adding a material to a polymer latex to passivate the aqueous phase of the latex. An additional material of a preselected particle size, corresponding to the desired pore size of the final product is then added. The latex composition is gelled and is then formed into a sheet. The sheet is dried and cured or sintered and the solubles are extracted therefrom with a solvent. A preferred polymer latex is PTFE.

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: Microspheric opacifying agents are provided by admixing an aqueous, partially condensed, aldehyde condensation product with an oily material containing an emulsifying agent thereby forming a water-in-oil emulsion, admixing an amphiphilic acid catalyst with the emulsion and polymerizing the condensation product to form discrete, substantially spherical, opaque, solid particles. Additionally, the solid particles may be separated from the oily continuous phase and admixed with water for the further removal of oily material, and thereby causing the formation of spherical agglomerates or "super particles" having a substantially greater opacity than the aforesaid discrete particles. The super particles are hollow, substantially spherical particles having substantially spherical, discontinuous walls composed of agglomerated substantially spherical particles.

Abstract: A method of making a cured foamed amino formaldehyde product utilizes an amino formaldehyde precondensate of water content below 20% by weight in order to obtain a less brittle product. A liquid foamable composition is made by dispersing a curing catalyst and a blowing agent in the precondensate and the composition is heated to cause the blowing agent to form a foam and the precondensate to cure.

Abstract: This foaming system includes a foaming agent solution and a resin solution. The foaming agent includes the relative amounts of 15 to 30 parts by weight of a salt of an alkyl diphenyl oxide sulfonate, 10 to 25 parts of 85% phosphoric acid and 15 to 25 parts urea, all in an aqueous solution. The resin solution includes a resin prepared by reacting 1 to 2.4 mols of formaldehyde per 1 mol of urea, 6.5 to 500 mmols polyethylene glycol as foam charring agent, 0.3 to 1.2 mmols of calcium carbonate as uniform foam cell size agent, 3 to 310 mmols of dicyandiamide as foam hydrolysis resistance agent, 2 to 30 mmols of sodium bromide as foam aging agent, and sufficient water to make a 35 to 45% solution. In preparing the foam, one part by weight of the foaming agent solution of about 5% solids concentration is aerated and then 1.0 to 1.5 parts by weight of the resin solution is sprayed thereon to obtain foam with an average linear shrinkage of about 0.25%.

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: A combination of conventional frothing agent and a particular amino-aldehyde resin provides better recovery of mineral values than can be obtained with either agent alone.

Abstract: An expansion agent comprising a foamable mixture of (a) 15-53 weight % of a foaming agent having 6 to 78 carbon atoms selected from the group of an ammonium salt, aliphatic amine salt and/or an alkali metal salt of an alkyl sulfate, hydroxyalkyl sulfate, alkyl ether sulfate and/or aryl alkyl ether sulfate; (b) 5-42 weight % of a dispersant having 22 to 260 carbon atoms selected from the group of an alkyl alkyleneoxy amine and/or its quaternary alkylsulfate, alkylhalide or alkylphosphate derivative; and (c) 5-40 weight % of a stabilizer having 8 to 68 carbon atoms selected from the group of a sodium and/or potassium salt of an alkyl sulfosuccinate; and the combination of said mixture with a synthetic resin, latex or natural rubber to provide a coating or finishing composition; the process of applying said composition to a substrate and the treated substrate product having incorporated the composition of the invention.

Abstract: The present invention relates to a method for producing foam plastics and a device for effecting same. The method resides in foaming with continuous and proportioned injection of all components successively in two stages, mixing water, resin and a foaming agent under pressure with compressed air to obtain homogenized foam with a foam coefficient of 15 to 20, with subsequent injection thereinto of a curing catalyst together with compressed air. The device for carrying out the proposed method comprises proportioners the inlets whereof are connected to tanks each being intended for a respective component, as well as curing and foaming chambers communicating through two closely adjacent coaxially arranged pipes forming an annulus, the outer pipe being provided with diametrically oposite connections for letting into the annulus the catalyst and compressed air.

Abstract: Amino resin foams of the urea-formaldehyde or urea-melamine-formaldehyde type formed from a one-phase solution of methylene chloride solvent, propylene glycol co-solvent, catalyst and polymer precursors which may be urea and formaldehyde or urea, melamine and formaldehyde. As reaction occurs between the polymer precursors in the solution, the methylene chloride in the solution vaporizes foaming the resin. In the product foam, the propylene glycol acts as a plasticizer and the methylene chloride as the blowing agent in a closed-cell foam having superior stability and insulative properties. The product foam is useful in building insulation and for other insulative purposes.

Abstract: Production of foamed plastics with improved combustion characteristics by condensing aqueous solutions of aminoplast precondensates with at least bifunctional organic isocyanate whereby an acid curing catalyst and an accelerator for polyurethane formation is used. For performing the condensation, the aqueous solution of the precondensate is added to the mixture of isocyanate and the accelerator at the same time as but separately from the acid curing catalyst.

Abstract: Flame retarded polyurethane foams are prepared from a reaction mixture comprising as the flame retardant additive a compound containing 2,2,2-trichloroethyl group.

Abstract: This invention relates to methods and apparatus for successively dispensing predetermined quantities of urea formaldehyde foamed resin mixture having as constituents a resin component and a hardener component in which a prefoamed one of said components and the other component are independently fed under pressure to a mixing chamber where they are mixed and from which, they are dispensed, any residue of the urea formaldehyde foamed resin mixture left in the mixing chamber after said predetermined quantity has been dispensed therefrom being swept and removed prior to the mixing chamber being supplied with the next batch of said components.The present invention is particularly useful for filling pre-cast cavity building blocks with insulating foamed material.

Abstract: A process for producing stable urea-aldehyde polymers with high structural strength from two storable liquid ingredients. In this process, partially cured liquid urea-formaldehyde resin is reacted with an aqueous cross-linking solution comprising one or more alkyl or aryl dialdehydes containing two to eight molecular carbons and the hydrogen ion concentration needed to catalyze the completion of the reaction of the dialdehydes and the urea-formaldehyde. The process for producing urea-aldehyde polymers, having improved structural strength and reduced aldehyde vapor emission during their production and prolonged use, is especially effective for manufacturing products for the building industry, such as urea-aldehyde insulating foam, wood-filled particle board, and plywood. The increased polymer strength and the elimination of the hazardous and objectionable aldehyde odor is achieved by maintaining the molecular ratio of total aldehyde moieties to urea to about 1.

Abstract: Hydrophilic floral display foam blocks are prepared from frothed urea-formaldehyde, and wherein the urea-formaldehyde contains an alkyl-aryl sulfonate, and wherein the alkyl-aryl sulfonate has been exposed to an aqueous solution of a quaternary ammonium salt in an amount sufficient to provide at least equal molar concentrations of the quaternary ammonium salt to the alkyl-aryl sulfonate present in the foam. The urea-formaldehyde foam may also contain quantities of sodium molybdate to enhance the stability and lifetime of cut flowers retained in the foam material. Also, the urea-formaldehyde foam may contain starch to help suppress the free formaldehyde odor and help increase the biodegradability of the cured foam. The resulting foam is hydrophilic in nature, and hence is readily wetted, with the hydrophilic characteristic not adversely affecting the life of cut flowers retained therein.

Abstract: An aqueous solution of urea-formaldehyde prepolymer has improved storage life, and cellular urea-formaldehyde foam prepared by discharging the solution, a curing catalyst, and compressed air into the atmosphere develops fewer shrinkage cracks and is stronger when the solution contains at least 5% glucose, fructose, and/or sucrose.