Abstract: A thermal insulating phenolic foam and method of manufacture thereof is provided. A phenolic foam is formed by foaming and curing a phenolic resin composition that comprises a phenolic resin, an acid catalyst, a blowing agent comprising a hydrocarbon having 6 carbon atoms or less, and an alkoxy alcohol. The resulting foam has low thermal conductivity and has excellent long term thermal stability.

Abstract: A phenolic foam formed from a composition comprising a phenolic resin, a blowing agent, an acid catalyst, and a surfactant comprising: (i) an ethoxylated castor oil, and (ii) a polysiloxane comprising a side chain comprising polyethylene oxide wherein the total molecular weight of the polyethylene oxide of the side chain comprises less than 50% of the total molecular weight of the polysiloxane.

Abstract: A phenolic foam and method for manufacturing same are described herein. The foam is formed from a foamable phenolic resin composition, and a blowing agent, the phenolic foam comprising 1 to 5% by weight of red phosphorus based on the weight of the phenolic foam wherein said phenolic foam has a density of from 10 kg/m3 to 100 kg/m3, a closed cell content of at least 85% as determined in accordance with ASTM D6226 and wherein said foam has a FIGRA0.2 MJ of 120 W/s or less, when measured according to EN13823 and a thermal conductivity of 0.023 W/m.K or less, at 10° C., in accordance with EN 13166:2012. The foam has excellent thermal insulation performance and excellent fire performance.

Abstract: A phenolic foam and method for manufacturing same are described herein. The foam comprises at least on chlorinated hydrofluoroolefin, at least one hydrofluoroolefin and at least one hydrocarbon. The foam has excellent thermal insulation performance and excellent fire performance.

Abstract: A method for producing a shaped profile section in a continuous line process provides providing an outer facing web, an inner facing web and laying down an liquid foam reactants in the outer facing web. The method pre-forms the outer facing web into a desired outer profile shape prior to laying down the liquid foam reactants. The inner facing web is shaped with the liquid foam reactants within the pre-formed outer facing web to provide a desired inner profile shape for the shaped profile section. Also provided is an apparatus for producing a shaped profile section and a shaped profile section of the method.

Abstract: A thermal insulating phenolic foam and method of manufacture thereof is provided. A phenolic foam is formed by foaming and curing a phenolic resin composition that comprises a phenolic resin, an acid catalyst, a blowing agent comprising a hydrocarbon having 6 carbon atoms or less, and an alkoxy alcohol. The resulting foam has low thermal conductivity and has excellent long term thermal stability.

Abstract: A method for producing a shaped profile section in a continuous line process provides providing an outer facing web, an inner facing web and laying down an liquid foam reactants in the outer facing web. The method pre-forms the outer facing web into a desired outer profile shape prior to laying down the liquid foam reactants. The inner facing web is shaped with the liquid foam reactants within the pre-formed outer facing web to provide a desired inner profile shape for the shaped profile section. Also provided is an apparatus for producing a shaped profile section and a shaped profile section of the method.

Abstract: Phenolic closed-cell foam comprises a hydrocarbon blowing agent and includes an alkali metal silicate in an amount of at least 1% by weight. The foam has an aged thermal conductivity as determined by the procedures of EN13166:2008 of less than 0.025 W/m·K. The foam is formed from a phenolic resole resin mixture having a water content of greater than 15% by weight but less than 24% by weight.

Abstract: Phenolic closed-cell foam comprises a hydrocarbon blowing agent and includes an alkali metal silicate in an amount of at least 1% by weight. The foam has an aged thermal conductivity as determined by the procedures of EN13166:2008 of less than 0.025 W/m·K. The foam is formed from a phenolic resole resin mixture having a water content of greater than 15% by weight but less than 24% by weight.

Abstract: A rigid insulating phenolic foam body has at least one perforated facing. The facing is preferably perforated before the facing is adhered to the foam body. The facing may be a gas impermeable material such as a metallic foil. The perforations in the gas impermeable material reduce the drying and curing time, for phenolic foam bodies when compared with phenolic foam bodies with gas permeable facings.

Abstract: A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises a blend of chlorinated aliphatic hydrocarbon containing 2 to 5 carbon atoms and an aliphatic hydrocarbon containing from 3 to 6 carbon atoms mixed in a ratio of 60/40 to 5/5 parts by weight. The inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more and a water uptake less than 1 kg/m2. A phenolic foam with a higher pH value compared with conventional phenolic foam reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using the said blowing agent, does not harm the environment as an ozone or global warming depleting material.

Abstract: A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises an aliphatic hydrocarbon containing from 1 to 8 carbon atoms and the inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more. The phenolic foam has a higher pH value compared with conventional phenolic foam and reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using a hydrocarbon blowing agent, does not harm the environment as an ozone depleting or global warming material.

Abstract: A rigid insulating phenolic foam body (8) has at least one perforated facing (1). The facing (1) is preferably perforated before the facing (1) is adhered to the foam body. The facing (1) may be a gas impermeable material such as a metallic foil. The perforations (5) in the gas impermeable material reduce the drying and curing time, for phenolic foam bodies when compared with phenolic foam bodies with gas permeable facings.

Abstract: A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises an aliphatic hydrocarbon containing from 1 to 8 carbon atoms and the inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more. The phenolic foam has a higher pH value compared with conventional phenolic foam and reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using a hydrocarbon blowing agent, does not harm the environment as an ozone depleting or global warming material.

Abstract: A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises a blend of chlorinated aliphatic hydrocarbon containing 2 to 5 carbon atoms and an aliphatic hydrocarbon containing from 3 to 6 carbon atoms mixed in a ratio of 60/40 to 5/5 parts by weight. The inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more and a water uptake less than 1 kg/m2. A phenolic foam with a higher pH value compared with conventional phenolic foam reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using the said blowing agent, does not harm the environment as an ozone or global warming depleting material.

Abstract: A phenolic foam is made by foaming and curing a formable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises a blend of chlorinated aliphatic hydrocarbon containing 2 to 5 carbon atoms and an aliphatic hydrocarbon containing from 3 to 6 carbon atoms mixed in a ratio of 60/40 to 95/5 parts by weight. The inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and metal powder. The phenolic foam has a pH of 5 or more and a water uptake less than 1 kg/m2. A phenolic foam with a higher pH value compared with conventional phenolic foam reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using the said blowing agent, does not harm the environment as an ozone or global warming depleting material.

Abstract: A rigid insulating phenolic foam body (8) has at least one perforated facing (1). The facing (1) is preferably perforated before the facing (1) is adhered to the foam body. The facing (1) may be a gas impermeable material such as a metallic foil. The perforations (5) in the gas impermeable material reduce the drying and curing time, for phenolic foam bodies when compared with phenolic foam bodies with gas permeable facings.

Abstract: A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises an aliphatic hydrocarbon containing from 1 to 8 carbon atoms and the inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more. The phenolic foam has a higher pH value compared with conventional phenolic foam and reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using a hydrocarbon blowing agent, does not harm the environment as an ozone depleting or global warming material.

Abstract: This invention relates to a foamable resol type phenolic resin forming material comprising a liquid resol type phenolic resin, a foaming agent, a foam stabilizer, an additive and an acid curing agent, said additive containing a nitrogen-containing bridged cyclic compound and said foam stabilizer containing a chlorinated aliphatic hydrocarbon compound having 2 to 5 carbon atoms, and a phenolic resin foam product obtained by foaming and curing this forming material.

Abstract: A phenolic closed-cell foam includes polyvinyl pyrrolidone with a molecular weight of from 5,000 to 80,000 as a toughening agent. The polyvinyl pyrrolidone is present in the mixture (excluding blowing agent) in an amount of from 4% to 20% by weight. The foam cells are substantially free of holes or surface defects. The foam has superior fire performance.