Abstract: This invention provides a low density (<2 pcf.) modified phenolic foam produced by combining a resole resin with a phosphorus-containing isocyanate-terminated prepolymer in the presence of a minor amount of a surfactant, a catalytic amount of an organotin catalyst, and a halocarbon blowing agent. Foam products producted by the method of the invention have a good combination of low combustibility, friability resistance and compressive strength.

Abstract: This invention relates to the use of phenol-aldehyde-amine resin/diol curatives in the production of cellular polyurethane elastomers having outstanding energy absorbing properties. The elastomers are useful as energy managing components in automobiles and the like.

Abstract: Novel haloroalkyl polyphosphates are prepared by reacting at elevated temperatures a halosubstituted alkyl phosphate such as, for example, tris (2-chloroethyl) phosphate, and an unsubstituted trialkyl phosphate such as, for example, triethyl phosphate. The character of the mixture of the thermal condensates formed can be influenced by the ratio of reactants employed and the extent to which the reaction is allowed to proceed. The resulting reaction products possess superior flame retardant efficiency and impart durable flame resistance when incorporated into flexible urethane foams.

Abstract: Phenolic foam having improved punking resistance is obtained by effecting the formation of phenolic foam in the presence of an aralkyl-modified polyalkylsiloxane. Used with particular advantage as non punking additives to phenolic foam formulations are polymethylsiloxane oils in which silicon is additionally bonded to phenylethyl groups.

Abstract: Phenolic resoles are provided which are free of ionic species capable of being removed by the free acid form of a cation exchange resin and the free base form of an anion exchange resin. The deionized resoles of the invention have extended shelf-life due to their enhanced inherent stability towards self-condensation under otherwise adverse aging conditions. Notwithstanding their extended shelf-life, the resoles of the invention have excellent reactivity as foamable compositions, and are used with particular advantage for the formation of cellular phenolic resins. Also provided is a method for producing phenolic resoles having the aforementioned characteristics which comprises treatment of alkaline metal catalyzed condensates of a phenol and an aldehyde with cation and anion exchange resins in their respective free acid and free base forms.

Abstract: This invention relates to the use of methyl formate as an adjuvant in the formation of phenolic foam. The addition of methyl formate to phenol-aldehyde resoles causes a substantial reduction in resole viscosity and thus allows for the processing of resoles which are otherwise too viscous to be foamed. A further advantage of methyl formate as an adjuvant in the formation of phenolic foam is that it also functions as a blowing agent. In its use as a blowing agent, methyl formate is employed in combination with 1,1,2-trichloro-1,2,2-trifluoroethane. Depending upon the nature of the phenolic foaming resin, the use of methyl formate in combination with 1,1,2-trichloro-1,2,2-trifluoroethane as the source of blowing action further provides the advantageous result of allowing for the formation of phenolic foam of reduced friability.

Abstract: Novel copolymerization products are provided by the cationic polymerization of a di-(dihydropyranyl) compound with a substituted 1,3-dioxolane or a substituted 1,3-dioxane. The copolymerization products possess improved abrasion resistance and toughness as compared with the homopolymers of the di-(dihydropyranyl) monomers. Especially useful, particularly in providing foamed polymeric materials of improved friability resistance, are the polymerization reaction products of 3,4-dihydro-2H-pyran-2-methyl(3,4-dihydro-2H-pyran-2-carboxylate) and a bis-dioxolanyl or a bis-dioxanyl carbamate.

Abstract: Provided as novel compositions are: (1) unsaturated cycloaliphatic ester polyols prepared by the reaction of a monounsaturated cycloaliphatic carboxylic acid anhydride, a polyhydric alcohol and an alkylene oxide, and (2) brominated derivatives of said polyols. The brominated cycloaliphatic ester polyols of the invention are useful as flame-retarding agents and are especially suitable for use in the manufacture of flame-retarded cellular polyurethanes including flexible foams.

Abstract: Novel aromatic compounds are provided in which the aromatic nucleus has bonded thereto (1) at least one bromine or chlorine atom, (2) an amido group wherein nitrogen is bonded to at least one hydroxyalkyl group or an organic moiety bearing a hydroxyalkyl group, and (3) a hydroxyl-terminated oxyalkylated carboxylic acid ester group. The halogen-substituted aromatic amide-ester polyols of the invention are useful in imparting flame-retardancy to organic polymers normally susceptible to burning including polyurethanes such as, in particular, flexible polyurethane foams.