Abstract: A continuous process is provided for preparing a solid gel resin selected from resorcinol-formaldehyde gel resins, phenol-formaldehyde gel resins, and phenol-resorcinol-formaldehyde gel resins, using an extruder having at least one feed zone with a first temperature and at least one reaction zone with a second temperature that is higher than the first temperature. The process comprises steps of adding ingredients to the extruder at the feed zone, mixing the ingredients under heat to effectuate reaction between the ingredients to produce a liquid product exiting the extruder, and converting the liquid product exiting the extruder to the solid gel resin. A solid gel resin produced by the continuous process is also provided.

Abstract: A fire retardant intumescent coating composition is disclosed, which includes expandable graphite, an aromatic polyamine resin, and a phosphorous-containing compound. An overlay for applying to a wood substrate is also disclosed, which includes a core layer comprising a substrate and a resin composition, a top layer on one side of the core layer comprising the fire retardant intumescent coating composition, and an optional bottom layer on the opposite side of the core layer from the top layer. A process of forming the overlay is also disclosed, which includes applying the resin composition to the core layer substrate to form a resinated core layer, and applying a coating composition on the resinated core layer, directly or indirectly, to form the top layer; wherein the coating composition comprises expandable graphite, an aromatic polyamine resin, and a phosphorous-containing compound.