Abstract: This invention relates to a process for the production of a decorative thermosetting laminate with an abrasion-resistant surface layer, which laminate comprises paper sheets impregnated with a thermosetting resin. In the process a continuous paper is impregnated with a noble thermosetting resin such as melamine-formaldehyde resin. At least one side of the paper is coated with 2-20 g/m.sup.2, preferably 3-12 g/m.sup.2 of small, dry and hard particles evenly distributed over the whole wet surface of the resin on the continuous paper. The resin is dried, whereupon the particle coated impregnated paper, so-called prepreg is possibly cut to sheets. At least one such sheet or continuous paper is placed as a surface layer on a base layer and bonded thereto.

Abstract: A method for preparing wood laminates from a plurality of wood veneers using as the adhesive a combination of a phenolaldehyde resin with a low molecular weight acetone-formaldehyde resin as a cure rate accelerator.

Abstract: A process for producing hollow structures of carbon material having desired shape and properties of carbon by obtaining a carbon paste composition, molding portions of the hollow structure by a method selected from the group consisting of an injection molding method, an extrusion molding method, a casting method or a fluidizing method, bonding the molded portions together using a paste composition, solidifying the bonded portion by precarbonizing, the hollow structures thus provided, and then calcining in an inert gas atmosphere as required. Hollow structures of carbon materials having a rigid bond, excellent impermeability, and complicated shape can be readily accurately and inexpensively produced without working after calcining.

Abstract: An improved phenol formaldehyde resin not requiring fillers or extenders and capable of bonding wafers or veneers having a moisture content of 10% or above is disclosed. The adhesive composition is prepared by mixing together a caustic solution of a high molecular weight PF resin, a dispersion of PF resin which is characterized in that it can swell in aqueous caustic medium but not go into solution, and alkylene carbonates or phenol resorcinol formaldehyde resins. Optionally, borax is utilized. The disperse phase is made by converting a solution of PF resin into a fine particle size particulate form by precipitation, spray drying or freeze drying, and partially cross-linking the resin during or subsequent to the formation of the fine particle size dispersion. The PF resin is partially cross-linked by (a) heat, by (b) acid catalysis, or by (c) a reaction with cross-linking chemicals.

Abstract: A multi-layer laminate web for furniture formed of a polyolefin web containing a mixture or blend of specific proportions by weight of a propylene homopolymer or copolymer and specific proportions by weight of a low pressure polyethylene, polyvinylalcohol, ethylene-vinylalcohol copolymer, ethylene-acrylic acid copolymer, ethylene-acrylate ester-acrylic acid copolymer or -terpolymer and/or polycaprolactone or a mixture of blend of low pressure polyethylene with one or more of the foregoing polymers, copolymers or terpolymers and specific proportions by weight of a finely divided mineral filler or mineral filler mixture having on the surface thereof a substance having polar and non-polar groups, and a surface layer having an average thickness from 3 to 30 microns applied over the polyolefin web. A method for producing a furniture laminate is also disclosed.

Abstract: Rubber compounding novalak type resins are prepared by reacting (A) an alkyl substituted resorcinol or phenol prepared by reacting at least one of the compound of the formula ##STR1## wherein R.sub.1 and R.sub.2 may be the same or different radicals selected from the group consisting of --H, --OH, --NH.sub.2 and an alkyl of 1 to about 20 carbon atoms with a mono or polyunsaturated hydrocarbon selected from the group consisting of butene, diisobutylene, piperylene, dipentene, dicyclopentadiene, cyclopentadiene, isoprene, butadiene, pinene, styrene and divinylbenzene in the presence of an acid catalyst, wit (B) an aldehyde selected from the group consisting of formaldehyde, paraformaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, crotonaldehyde, benzaldehyde and furfural.

Abstract: The invention relates to a resin for the production of cellulose based products, such as particle boards. The resin is a condensation product of formaldehyde, urea and phenol and optionally melamine with a molar ratio of 1.4-0.8 moles of urea, 0.006-0.04 moles of phenol and 0-0.04 moles of melamine per mole formaldehyde. The invention also relates to a method of producing such a resin. According to the method a separately prepared cross-linking agent containing a co-condensate of phenol, formaldehyde and urea or containing a co-condensate of phenol and formaldehyde together with urea, is added to a pre-condensate of formaldehyde, urea and optionally melamine, whereafter the mixture is condensed. As an alternative the cross-linking agent can be added to a finished condensate of formaldehyde, urea and optionally melamine.The invention also relates to a method of manufacturing glued cellulose based products.

Abstract: The invention relates to a method for the production of a resin which is used for manufacturing of an adhesive for cellulose based products. According to the method 30-70% by weight of a urea phenol resin with a molar ratio of 1.4-0.6 moles or urea, 0.006-0.3 moles of phenol and 0-0.04 moles of melamine per mole formaldehyde, are mixed with 70-30% by weight of a melamine resin with a molar ratio formaldehyde: melamine of 1.7-2.4. The urea-phenol resin has been prepared by adding a cross-linking agent containing a co-condensate of phenol, formaldehyde and urea to a pre-condensate of formaldehyde, urea and optionally melamine and condensing under acid conditions.According to a further embodiment the cross-linking agent is added to a evaporated condensate of formaldehyde, urea and optionally melamine.

Abstract: A method of manufacturing a liquified fiber-phenol-formaldehyde resin includes heating a mixture of phenol, formaldehyde, liquified cellulosic fiber and alkali at a temperature of 60.degree. C. to 100.degree. C. and a pH of 8-13. The liquified cellulosic fiber comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and liquified fiber. Also disclosed are fibrous articles manufactured using this resin as a binder, such as fiberboards, particle board, plywood, oriented strand board, and waferboard.

Abstract: A process for producing a tubular rubber product such as a rubber hose and a rubber coupling in which a polyamide resin and/or polyester resin layer is formed to the main body of a tubular rubber product. The resin layer is formed either by coating an organic solvent-soluble nylon to the surface of the main body of the tubular rubber product applied with the surface treatment of a halogenoid compound, or by polyamide resin or polyester resin film having a softening point in the vulcanization temperature region and treated with an adhesive mainly comprising a resorcine-formaldehyde resin and a rubber latex or treated with an adhesive rubber mainly comprising a resorcine, a formaldehyde-forming substance and a vinylpyridine-butadiene-styrene copolymer rubber and then bonding under vulcanization onto the main body of the non-vulcanized tubular rubber product.

Abstract: It has now been found that when there is a partial or complete replacement of the sodium hydroxide that is used to make a sodium phenolate resole resin by a molar equivalent of potassium hydroxide, a far faster curing resin is obtained. Such potassium-modified phenoli resins exhibit significant improvement in cure speed without loss of flowability. To the contrary, these resins act as though they were lower molecular weight condensation products. Reduced application rates are possible. The combination of faster cure and lower application rates has allowed such resins to be used as effective adhesives for plywood, for example, with veneer and interior plies having a higher moisture content than was previously possible. Generally, resins according to the invention may contain from about 1% to about 15%, and preferably from about 1% to about 7% by weight, of potassium hydroxide, or more.

Abstract: Dry-film, negative-acting photoresist layers are used in the formation of many articles such as circuit boards, printing plates and the like. Laminable monolayers of photoresist can suffer from slow speeds, brittleness, variable adhesive characteristics, and narrow processing latitude during development and exposure. The use of a crosslinked or crosslinkable integral thermoplastic adhesive laer on the dry-film, negative-acting photoresist layer improves the properties and performance of the photoresist.

Abstract: A heat shapable resin laminate sheet, composed of several heat-bonded support webs impregnated with duroplastic binders, the deformation temperature to be utilized in shaping the laminate sheet being higher than the temperature utilized in molding it, which comprises a number of individual laminations, each of which is formed separately of one or more support webs impregnated with duroplastic binders and layers of thermoplastic binders arranged between the individual laminations, the melting point temperatures of the thermoplastic binders being equal to or lower than the deformation temperature, and a process of shaping the laminate sheet.

Abstract: Disclosed herein are an oxygen-cathode for use in electrolysis or an alkali chloride, comprising a current collector made of a compact carbonaceous material, electrode substrate(s) made of a porous carbonaceous material and the catalyst carried on the electrode substrate(s), wherein the electrode substrate(s) and the current collector have been joined together and integrated into one body as carbon, and a process for preparing the oxygen-cathode.

Abstract: A non-woven textiles comprising a web of organic fibers bonded together by a binder applied to the fibers as a powdered mixture of a non-heat reactive phenolic resin and at least one thermoreactive condensation resin selected from the group consisting of phenolic resins, epoxy resins and amino resins and then fused and a method of producing said textiles.

Abstract: A process is disclosed for the production of a tungsten carbide-activated electrode, particularly an electrode which is utilizable as a cathode, and which consists of an electrically-conductive substrate with an active surface layer of tungsten carbide. The tungsten carbide is adhesively bonded through chemical reaction to the surface of a substrate which is constituted of graphite or a graphite-like material. The graphite-like material is a graphite binder mixture, whose binder material components, other than the graphitic filler granules, are only carbonized, and may not be completely graphited.

Abstract: A method of manufacturing a lignosulfonate-phenol-formaldehyde resin includes heating a mixture of phenol, formaldehyde, lignosulfonate and alkali at a temperature of 60.degree. C. to 100.degree. C. and a pH of 8-13. The lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate and the lignosulfonate is mixed with said phenol and formaldehyde before substantial reaction between said phenol and said formaldehyde. Also disclosed are fibrous articles manufactured using this resin as a binder, such as fiberboards, particle board, plywood, oriented strand board, and waferboard.

Abstract: Adhesive compositions affording strong bonds of high environmental resistance between elastomers and substrates such as metals are provided. The adhesive compositions comprise an admixture of (i) olefinic organosilane, (ii) water, and (iii) an alumino zirconium metallo-organic complex of chelated aluminum moiety, an organofunctional ligand and zirconium oxyhalide. The adhesive composition preferably includes a polymer resin selected from phenolic-formaldehyde resins, urea-formaldehyde resins, resorcinol-formaldehyde resins or melamine-formaldehyde resins.

Abstract: A room temperature setting adhesive composition capable of giving high initial bond strength as well as cured bonds having good resistance to water and boiling contains, as main components thereof, (A) an emulsion containing an acetoacetylated polyvinyl alcohol and a vinyl acetate copolymer produced by copolymerizing an acetoacetylated, ethylenically unsaturated monomer and another ethylenically unsaturated monomer and (B) a resorcinol resin precondensate and, as a curing agent, (C) hexamethylenetetramine.

Abstract: Disclosed herein are an oxygen-cathode for use in electrolysis of an alkali chloride, comprising a current collector made of a compact carbonaceous material, an electrode substrate made of a porous carbonaceous material and the catalyst carried on the electrode substrate, wherein the electrode substrate and the current collector have been joined together via the mutually facing carbonized surfaces thereof, and a process for preparing the oxygen-cathode.

Abstract: A process for producing a tubular rubber product such as a rubber hose and a rubber coupling in which a polyamide resin and/or polyester resin layer is formed to the main body of a tubular rubber product. The resin layer is formed either by coating an organic solvent-soluble nylon to the surface of the main body of the tubular rubber product applied with the surface treatment of a halogenoid compound, or by polyamide resin or by polyester resin film having a softening point in the vulcanization temperature region and treated with an adhesive mainly comprising a resorcine-formaldehyde resin and a rubber latex or treated with an adhesive rubber mainly comprising a resorcine, a formaldehyde-forming substance and a vinylpyridine-butadiene-styrene copolymer rubber and then bonding under vulcanization onto the main body of the non-vulcanized tubular rubber product.

Abstract: A novel process for the production of glass fiber products is provided. By the inventive process glass fibers are combined with a heat curable binder and then consolidated onto a conveyor where a glass fiber mass is placed onto the surface of the consolidated mass of glass fibers and heat curable binder. The resulting product is then subsequently cured and then coated on-line with a suitable coating. Glass fiber products made by the novel inventive process are also disclosed.

Abstract: An adhesive for adhering fibrous materials, particularly polyester fibrous material to rubber is disclosed, which comprises polyhydric phenol-polysulfides, resorcin excess resorcin-formaldehyde condensates, and RFL solution composed of resorcin-formaldehyde condensate and rubber latex.

Abstract: An improved process for the preparation of a glass fiber product useful as range insulation for pyrolytic self-cleaning oven units is disclosed. An integral part of the inventive process involves a two stage curing of the insulation product. When range insulation produced by the inventive process is used in pyrolytic self-cleaning oven units, the insulation emits reduced levels of smoke and odor during the self-cleaning cycle.

Abstract: A backing sheet for the weathering-resistant coating of thin, plane backings in continuous presses without recooling comprising(A) a paper impregnated with curable melamine resin in an amount of 40 to 60 weight percent of aminoplast resin, based on the weight of the paper, in the dried state, and(B) a coating of curable acrylic resin on the impregnated paper in an amount of 60 to 150 g/m.sup.

Abstract: A method of manufacturing a lignosulfonate-phenol-formaldehyde resin includes heating a mixture of phenol, formaldehyde, lignosulfonate and alkali at a temperature of 60.degree. C. to 100.degree. C. and a pH of 8-13. The lignosulfonate comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and lignosulfonate and the lignosulfonate is mixed with said phenol and formaldehyde before substantial reaction between said phenol and said formaldehyde. Also disclosed are fibrous articles manufactured using this resin as a binder, such as fiberboards, particle board, plywood, oriented strand board, and waferboard.

Abstract: Polymethylol ketones are disclosed as ingredients in various resins which find use as the resin component of heat and pressure consolidated laminates, especially decorative laminates having a core of a color complementing that of the decor sheet.

Abstract: A process for the manufacture of triple- and multi-layer particle board employing phenol formaldehyde resin compositions for gluing particles in the outer layers of the board characterized by the use of a phenol formaldehyde resin composition having a viscosity of about 30-90 seconds (4-mm DIN cup), a solids content of between about 30 and 39 percent by weight and an alkali content of less than 8 percent by weight is provided.

Abstract: The outside surfaces of a ski are made by treating a fibrous material with a compound based on phenolic resin and containing 60 to 80 mass percent of dry matter, said phenolic resin being curable at 100.degree. to 120.degree. C., whereupon the thus-treated fibrous material is allowed to stand at 70.degree. to 90.degree. C. for a period of time long enough for said phenolic resin to partially polycondense, whereupon said material is applied to the ski blank and the resultant intermediate product is exposed to the effect of a temperature ranging within 100.degree. and 120.degree. C. and a pressure ranging within 0.5 and 2.0 MPa for complete polycondensation of said phenolic resin to occur and for said fibrous material to firmly adhere to the ski blank at the same time.

Abstract: A modified phenol-formaldehyde binding resin is particularly useful in the formation of man-made boards including bonded fibers, fibrous particles, and a plurality of uniformly, or randomly shaped pieces, masses or sheets bonded together with the modified phenol-formaldehyde binding resin. The resin binder is especially adapted to bonding wood fibers and particles, comprising the condensation product of a phenol, formaldehyde and a water-soluble carbohydrate-phenol complex from steam digestion of wood chips, and the production thereof. Various objects can be manufactured using these resins, such as particle objects and objects or sheet materials made by bonding together a plurality of uniformly or randomly shaped masses, for example, fiberboards such as hardboard and insulation board; particle board; plywood; oriented strand board; and waferboard.

Abstract: An impregnating composition for warp free laminates, is made from the diluted reaction mixture of: a phenolic component selected from at least one of phenol, resol, xylenol, resorcinol, naphthol; alkyl substituted phenol, where alkyl contains from 4 to 13 carbon atoms; and aldehyde.

Abstract: An improved method of making a carbon composite product wherein a fabric comprised of oxidized or otherwise stabilized polyacrylonitrile fibers is heat treated and then coated with a closely controlled amount of a carbonaceous binder such as a polyimide resin. The fabric is then further heat treated to thermally fuse the resin to the fabric to form a rigid, easily handleable material. The carbonaceous binder is applied to the fabric in a manner whereby substantial encapsulation of the individual fibers is avoided. Next the material is cut into swatches of a predetermined size and shape and the segments are arranged into a basic or starting substrate having a volume greater than the desired volume of the end product. The basic substrate thus formed is then subjected to controlled temperatures and pressures to form a shaped substrate having a known fiber volume, a high degree of open porosity and a shape substantially corresponding to the shape desired of the end product.

Abstract: A resin containing laminate is made, where the resin comprises the cured admixture of phenolic resin, sulfur containing lignin, and a catalytic reactant containing 50 wt. % to 100 wt. % of an alkaline-earth compound and 0 wt. % to 50 wt. % of an alkali-metal compound.

Abstract: Polyester reinforcement fibers are treated to improve adhesion to rubber by applying a dissolved aromatic urethane coating to the fibers followed by coating the fibers with a resorcinol-formaldehyde latex and then heating the fibers sufficiently to convert the aromatic urethane to an aromatic isocyanate and applying to and curing a layer of rubber on said treated polyester fibers.

Abstract: A method of making an elastomeric coated fabric container utilizing cured elastomeric coated fabric and adhering the edges of each layer of fabric to the other with an adhesive film and curing the adhesive film under heat and pressure to form said container.

Abstract: Disclosed are a new adhesive and a process for making wood laminates with the adhesive. In a preferred embodiment, the adhesive will comprise a phenol-formaldehyde condensation product having a molar ratio of phenol to formaldehyde in the range of 1:1.5 to 1:2.5, a sodium hydroxide catalyst, and from 5 to 50% bentonite clay based upon the phenol-formaldehyde condensation product solids. The preferred process employs the new adhesive to prepare laminates using high moisture content veneers, such as southern pine. The laminates exhibit average percent wood failures of from 85 to 98%.

Abstract: Humid aged adhesion of rubber containing a phenol formaldehyde resin bonded directly to bright steel cord is improved by coating the bright steel cord with an amino functional organo silane.

Abstract: An aqueous coating composition is provided for filamentary materials that yields coated filamentary material with improved weavability and that yields reinforced elastomeric materials having improved properties of flexibility and fatigue resistance. The aqueous adhesive coating composition has a vinyl-pyridine-containing copolymer or terpolymer latex, a non-selfcrosslinkable elastomeric latex, a carboxylated butadiene polymer, and a phenolic aldehyde condensate polymer. The vinyl pyridine-containing elastomeric latex is produced from a vinyl pyridine-containing monomer, 1,3-diene hydrocarbon monomer or the terpolymer is produced in the same way with the addition of a vinyl containing monomer. The non-selfcrosslinkable elastomeric latex has a low gel content of less than around 40 weight percent and a low average particle size of less than around 2000 angstroms.

Abstract: An aqueous coating composition for filamentary materials that are to be used in reinforcing elastomeric matrix materials is provided that renders reinforced elastomeric materials having improved properties of flexibility and fatigue resistance. The aqueous adhesive coating composition has a vinyl-pyridine-containing copolymer or terpolymer latex, a phenolic aldehyde condensate polymer, and a non-self-crosslinkable elastomeric latex with a low gel content of less than around 40 weight percent and a low average particle size of less than around 2000 angstroms. The vinyl pyridine-containing elastomeric latex is produced from a vinyl pyridine-containing monomer, 1,3-diene hydrocarbon monomer or the terpolymer is produced in the same way with the addition of a vinyl containing monomer. In addition the aqueous adhesive coating composition may contain a wax emulsion, antioxidant, and carboxylated styrene butadiene copolymer latex.

Abstract: A pre-cure resistant liquid phenol-formaldehyde resin binder composition having low viscosity and low surface tension for efficient spray application as fine droplets in waferboard manufacture comprising a highly condensed and cross-linkable phenol-formaldehyde resin of relatively high average molecular weight and a non-resinous methylolated phenol condensate having an average molecular weight of 200-300.

Abstract: The present invention is directed to a brazing material for joining graphite structures that can be used at temperatures up to about 2800.degree. C. The brazing material formed of a paste-like composition of hafnium carbide and uranium oxide with a thermosetting resin. The uranium oxide is converted to uranium dicarbide during the brazing operation and then the hafnium carbide and uranium dicarbide form a liquid phase at a temperature about 2600.degree. C. with the uranium diffusing and vaporizing from the joint area as the temperature is increased to about 2800.degree. C. so as to provide a brazed joint consisting essentially of hafnium carbide. This brazing temperature for hafnium carbide is considerably less than the eutectic temperature of hafnium carbide of about 3150.degree. C.

Abstract: The invention is an improved hardener for use with phenolresorcinol-formaldehyde wood bonding adhesives. The hardener is conveniently made and shipped as a stable dry powdered material. It is then slurried in water at the point of use for convenience with continuously mixed and dispensed liquid-liquid, two part adhesive systems. The hardener comprises paraformaldehyde or alphapolyoxymethylene, fillers, viscosity and/or rheology control agents, and a solid acidic material. The latter ingredient is a critical component used to adjust the pH of an aqueous slurry to the range of 4.0 to 5.5. Oxalic acid is preferred. In this pH range, the formaldehyde polymers are stable and the slurried hardener does not give off significant formaldehyde odor for periods up to several days. Bonding performance is improved because the characteristics of the hardener and resulting adhesive have very little variation over time.

Abstract: An aramid reinforcing element or cord is dipped in an aqueous adhesive composition of a phenolic-aldehyde resin and a vinyl pyridine latex and dried. The treatment is repeated again and preferably for three times. The repeatedly treated cord is then cured with a rubber compound to give improved H-adhesion values. If desired, a primer treatment with an epoxide may proceed the aqueous adhesive composition treatments.

Abstract: Aqueous dispersions of a phenolic resole and a thermoplastics polymeric material or a rubber, suitable for use as adhesives, are prepared by(a) dissolving a solid thermoplastics polymeric material, such as a polyvinyl acetal or a nylon polyamide, or rubber in a phenol,(b) adding a nonionic or anionic surface active agent and/or protective colloid,(c) adjusting the mixture to a pH above 7 by addition of a base,(d) adding aqueous formaldehyde solution, or a formaldehyde donor, to a molar ratio of phenol to formaldehyde within the range 1:1 to 1:3,(e) if necessary, adding water, and(f) heating the mixture to form a phenolic resole.

Abstract: A process for the preparation of hard paper involves impregnating lengths of cellulose-containing material with plasticizer-containing mixture of a phenol-resol resin solution and cresol-resol resin solution according to a one-step method, subsequent drying, and then hardening of the resin-impregnated paper. The impregnating solution employed is a mixture of a 50-80% by weight phenol-resol resin solution with a 40-70% by weight cresol-resol resin solution, to which has been admixed, before impregnation, a plasticizer and additional water. The water is added in amounts of 4-12% by weight, based on the sum total weight of solid resins and plasticizer in the total solution mixture.

Abstract: The invention relates to bowling lanes in which at least part of the lane approach surface and at least part of the lane surface proper is of a suitable decorative laminate panel, the foul line configuration being molded or incorporated in said laminate.

Abstract: A base material for the production of printed circuits according to the additive method includes a laminate base made up of laminated-together core sheets impregnated with hardenable resin, and a cover layer made up of a substrate sheet preimpregnated with phenolic resol resin and provided with an adhesive layer of an elastomeric polymer. The preimpregnated substrate sheet is also provided with a further resin impregnation containing a self-crosslinking copolymer of acrylic monomers and up to 30% by weight of a hardenable phenolic resol resin.

Abstract: An aqueous alkaline dispersion of a rubbery graft or over polymerized copolymer of a diene and a vinyl pyridine on a polyacrylate seed (core or substrate), said acrylate polymer having a Tg of not above about -20.degree. C., desirably also containing a polybutadiene, and a water soluble, heat reactable phenolic resin, in certain amounts is useful in forming an adhesive for bonding glass fiber reinforcing elements or cords to rubber compounds or stocks. After dipping the glass fiber cord in the one-step adhesive dip, the coated cord is heated to dry it and heat cure or heat set the adhesive on the cord. Thereafter, the adhesive containing glass fiber cord is combined or laminated (calendered) with a curable rubber compound and the resulting assembly is cured to form a composite in which the glass fiber cord is bonded to the rubber by means of said adhesive.

Abstract: An improvement in a bowling lane having a decorative laminate surface which improvement comprises incorporating into the core of the laminate a plurality of alternating layers of glass cloth impregnated with a thermosetting resin and crepe paper also impregnated with a thermosetting resin, the glass cloth and crepe paper being interlaminarily bonded to one another.

Abstract: A vacuum bag autoclave type procedure for curing layers of phenolic resin pregnated fibrous material to form a composite structural part. A straight up heat rise cure cycle is employed in conjunction with a layup and bagging procedure that ensures a relatively free bleed of excess resin during cure and a high-capacity vacuum system for removal of volatiles generated during cure. This method of fabrication releases the majority of volatiles prior to gelation and produces a part having a pore structure that provides an escape path for gases generated during cure and postcure to prevent delamination.