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: The present invention relates to a process and an apparatus for producing phenolic foam laminates with improved surface appearance. The process involves applying pressure on the foam forming mixture through one of its facings by a flexible member. The member is sufficiently flexible to allow continual rise of the foam but also smoothes out any uneven rise under the applied pressure thereby producing a laminate which has a surface immediately below the facing substantially free of any voids, craters or wrinkles.

Abstract: A continuous process for the production of a phenolic foam composite comprises bringing a preformed layer of flexible insulating material whose thermal conductivity is less than 0.10 W/m.degree. C. for example polystyrene foam into contact with a phenolic foam forming mixture and allowing the phenolic foam forming mixture to foam and set so as to form a layer of phenolic foam bonded to the layer of flexible insulating material.A second preformed layer of flexible insulating material whose thermal conductivity is also less than 0.10 W/m.degree. C. can be brought into contact with the phenolic foam forming mixture so as to form a sandwich structure with the layers of flexible insulating material bonded to opposite faces of the layer of phenolic foam. The effect of the layers of flexible insulating material is to decrease the variation in properties of the foam through its cross section.