Abstract: Polyether-based polyurethane foams including as the flame-retardant, an antimony compound, chlorine derived from at least one chlorinated paraffin and alumina trihydrate, and the polyol used to prepare the foams being a diol- or triol-based polyol wherein at least 50% of the hydroxyl end groups are primary hydroxyl end groups, having good flame-retardancy and without any significant fall-off in physical properties as the foams are able to tolerate relatively high levels of the flame retardant.

Abstract: The use of methylene chloride as a blowing agent for resinous foams, particularly urethane foams is improved by incorporating a low molecular weight polyhydroxy aliphatic compound having more than two hydroxyl groups. Simultaneously with the addition the amount of gelling catalyst (e.g., stannous octoate) required to obtain good foam, particularly the very soft foams, is reduced over that required using the methylene chloride without the addition of the polyhydroxy compound. Similarly, when the polyhydroxy compound of this invention is used, smaller amounts of the gelling catalyst are employed for equal foam properties when the fluorinated halocarbons are employed either alone or in combination with the methylene chloride.

Abstract: A process of forming polyurethane compositions which emit reduced amounts of toxic smoke on burning is described. The process comprises reacting a mixture of an organic compound having two or more active hydrogen atoms, an organic polyfunctional isocyanate, a catalyst and at least one metal salt of an aliphatic or alicyclic monocarboxylic acid wherein the metal is cobalt, copper, nickel or manganese. The metal salt is added to the mixture in an amount which is sufficient to reduce the formation of toxic substances when the polyurethane is ignited.

Abstract: A binder composition for binding foundry sand particles to form molds and cores in sand mold casting processes which may be aluminum alloy casting processes, comprising a thermosetting resin and powdery zinc carbonate which is dispersed in the resin and, while the molds and cores are heated by the poured molten metal, undergoes thermal decomposition with generation of carbon dioxide gas which aids the molds and cores to become readily disintegratable.

Abstract: The invention relates to a process for the manufacture of reinforced polyurethane foams based on the reaction of organic polyisocyanates and polyols in the presence of filler dispersions. These dispersions are prepared by in situ crushing of the filler in the polyisocyanate or polyol to a particle size of less than 7 microns.

Abstract: A fire-retarding polyurethane foam is applied to the interior surfaces of a mine such as mine shafts, entries and tunnels. The coating is applied by spraying a mixture of foam-forming ingredients including a hydrophilic polyoxyalkylene urethane prepolymer and a large amount of an aqueous slurry containing a phosphorous compound, alumina trihydrate and a char-forming material such as starch or wood cellulose. The foam coating acts as a protective sealant, and it can also be applied on other surfaces where insulation and fire retardancy are desired.

Abstract: A combustion resistant material which will not produce toxic gases when subjected to heat, and which can be formed by moulding or by coating it onto a receiving surface while its constituents are reacting is produced by reacting a mixture of:62 to 76: percent by weight aluminium oxide or hydroxide12 to 16: percent by weight phenol resin11.5 to 17.5: percent by weight furfuryl alcoholwith sulphonic acid which serves as hardener, the proportion by weight of the sulphonic acid being from one-tenth to one-twentieth of the amount of aluminium oxide. The viscosity of the reaction mixture can be adjusted by addition of thinners such as butanol or butylglycol, or of thickeners such as chalk, particulate silicic acid, talc or magnesium oxide.

Abstract: Epoxy compounds will react chemically with an amine to produce an epoxy prepolymer that will produce a self-standing cellular solid product upon heating.

Abstract: Furan-modified rigid isocyanurate foams are taught herein. The foams herein are prepared by either (1) the in situ polymerization of furfuryl alcohol and/or furfural during the foam formation reaction, or (2) the catalytic condensation of a furfuryl alcohol-blocked organic polyisocyanate.

Abstract: Improved hydrophilic crosslinked polyurethane foams are prepared by reacting (a) an isocyanate-capped polyoxyethylene prepolymer with (b) at least 20 moles of water per mole of NCO groups in the presence of (c) alumina hydrate, (d) a phosphorus fire-retardant additive and (e) an organic carbon compound which serves to react with phosphate anions at high temperatures (e.g., in the presence of a flame) and reinforces the char provided by combustion of the foam.

Abstract: Covers a water-modified diisocyanate mixture obtained from water-treating a diphenylmethane diisocyanate to provide a diisocyanate mixture comprising 3-25 percent by weight of diphenylmethane biuret isocyanate and 75-97 percent diphenylmethane diisocyanate. Also covers the use of said water-modified diphenylmethane diisocyanate in preparing an improved polyurethane or polyisocyanurate polymer. Also covers said polymers.

Abstract: A method for producing a phenol foam plastic, consisting in that polycondensation of phenols with formaldehyde is conducted with simultaneous foaming and curing in the presence of a foaming agent and an acid or alkaline catalyst. Used as the phenols are pyrocatechol, hydroquinone, resorcinol, 5-methyl resorcinol, shale alkyl resorcinols, shale total phenols, or various combinations of said phenols. The method is simple and permits obtaining a foam plastic with improved physico-mechanical properties.

Abstract: Bauxites are rendered compatible with polymer compositions employed in the carpet industry. Suitable bauxites, which can be employed as flame-retarding fillers, are characterized by a surface area of less than about 12 m.sup.2 /g, a pH in aqueous suspension of more than about 6.5 and a particle size distribution, wherein less than about 15% by weight of the particles have a size of less than 3 microns. Bauxites having a surface area in the range of about 12-20 m.sup.2 /g can also be rendered compatible by modifying their surfaces with a small but effective amount of modifier selected from inorganic phosphates, silicates, aliphatic and aromatic hydroxycarboxylic acids.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporating a particular resole resin catalyzed with alkaline earth metal hydroxides and neutralized with oxalic acid or its acid salts providing inert insoluble oxalate salts dispersed in said resole. Said salts are sized controlled and stabilized in an aqueous resole resin solution having about 60 to 99% resole resin by weight. Methods for preparing and foaming said compositions are disclosed.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporation dispersed metal powders in said composition providing a foamable resole composition curable to a non-corrosive foam. Methods for preparing, foaming and curing said non-corrosive foams are disclosed.

Abstract: This invention relates to an improved foamable resole resin composition comprising a resole resin, a blowing agent and a surfactant wherein said improvement comprises incorporation dispersed calcium oxide particles in said composition providing a foamable resole composition curable to a non-corrosive foam. Methods for preparing, foaming and curing said noncorrosive foams are disclosed.

Abstract: The instant invention is directed to a process for the production of inorganic-organic synthetic materials having high strength, elasticity, dimensional stability under heat, and flame resistance, consisting of a polymer-polysilicic acid gel composite material in the form of a solid/solid xerosol, said process comprising mixing(a) an organic polyisocyanate,(b) an aqueous basic solution and/or an aqueous basic suspension having an inorganic solid content of from 20 to 80% by weight, preferably from 30 to 70% by weight,(c) an organic compound containing at least one isocyanate reactive hydrogen atom and at least one non-ionic-hydrophilic group and(d) optionally catalysts and other additivesand leaving the resulting mixture to react, characterized in that components (a) and (b), optionally with the addition of part or all of component (d) are first mixed together to form a stable primary dispersion and thereafter component (c), optionally with the addition of all or part of component (d), is added to form the fi

Abstract: The flameproof styrene polymer foam in accordance with this invention is obtained by melting a granular mixture of styrene polymer and aluminum hydroxide having a grain size of 20-100 .mu.m and a specific surface of below 1 m.sup.2 /g in an extruder, incorporating a physical expanding agent, and homogenizing and extruding the mixture.

Abstract: The present invention relates to a process for expanding thermoplastic polymer compositions, notably those containing polymers having processing temperatures in excess of 200.degree. C. and/or containing an ingredient which is susceptible to ammonia, characterized in that as the blowing agent certain carbonates (notably zinc carbonate) are used. Preferably a nucleating agent and a weak acid are present to aid cell formation.The invention also includes expandable polymer compositions and blowing agent formulations containing the carbonates.

Abstract: A flexible, highly resilient, cold-cure, closed-mold polyurethane foam can be produced by reacting a foamable mixture comprising an organic polyisocyanate, water and a polyol. The foams of the invention are preferably prepared from a mixture of a hydroxyl-terminated graft copolymer and a hydroxyl-terminated polyoxyalkylene polyether in the presence of a co-catalyst mixture of at least one tertiary amine catalyst and at least one metal-containing basic catalyst. Said catalyst is selected from the group consisting of an alkali metal hydroxide, an alkaline earth metal hydroxide, an inorganic basic salt thereof derived from the reaction of said hydroxides with a weak inorganic acid, a metal organic basic salt catalyst derived from the reaction of at least one of said hydroxides with an organic acid and mixtures thereof. Useful metal organic catalysts are selected from the group consisting of the alkali and alkaline earth metal carboxylates, alkoxides and phenates.

Abstract: Silicon halides will react chemically with polyols to produce polyol silicate resinous products which will react chemically with polyisocyanates to produce polyisocyanate silicate solid or cellular solid products.

Abstract: In the foaming of a polymerizable medium (such as an unsaturated polyester resin) by using acid sensitive azo compounds, significant improvement in the foaming efficiency can be obtained by incorporating in the resin medium 0.001%-10% by weight based on the weight of the resin compounds which exert an inhibiting effect on free radical polymerization. Examples of such compounds include methacrylonitrile, alphamethylstyrene and laurylmercaptan.

Abstract: The method of production of chemically set compositions which show no shrinkage or which increase their volume during setting finding their application in building engineering, electrotechnical engineering and other fields of technology, consists in adding a special expanding system to a composition comprising synthetic resins or elastomers. Said system consists of an expanding agent, an expansion promoter, and if need be an expansion moderator, and sodium and/or potassium and/or magnesium fluosilicate. As the expanding agent substances are used having a porous structure and sorption properties, as for instance aluminosilicates, and as the expansion promoter substances are used having a polar structure and a critical diameter of the molecule smaller than that of the pores of the expanding agent, as for instance alcohols.

Abstract: A process for the manufacture of cross-linked foamable moldings from olefin polymers, wherein the olefin polymer is mixed with(a) a solid organic blowing agent which eliminates gases when heated,(b) an organic peroxide,(c) conventional additives and(d) an activating organic compound which lowers the decomposition temperature of the peroxide,And the mixture is molded thermoplastically and is crosslinked below the decomposition temperature of the blowing agent but above the decomposition temperature of the activated peroxide.The organic activator is preferably a transition metal salt of a long-chain fatty acid.The moldings may be used for the manufacture of foams, for example for insulating purposes.

Abstract: A molding composition is disclosed for forming in a single step a natural sandwich foam product having a cellular core and a thick, densified outer layer. A hard, particulate filler material such as fly ash is admixed with an unreacted, rigid polyurethane foam system, together with a density distribution control agent such as carbon tetrachloride which lowers the viscosity of the admixture. In molding, the mold cavity is charged with the admixture and the foam reaction is permitted to occur with the mold closed. The resultant, filled foam product has a thick outer layer formed adjacent the mold surface of substantially greater density than its core. In the densified layer, both the polyurethane and filler material components of the resultant product are concentrated to provide over three times the density of the core structure. Formulations are set forth which provide substantial layer thickness and an outer surface having a durometer hardness value of 50 or greater over the entire surface area.

Abstract: Urethane-modified carbodiimide-isocyanurate foams are prepared by catalytically condensing (a) an organic polyisocyanate with a polyol or (b) a quasi-prepolymer in the presence of a blowing agent and from 20 parts to 100 parts by weight of alumina trihydrate. The resulting foams are characterized by improved flame retardancy without loss in strength properties.

Abstract: Polyurethane/vinyl polymer composites are prepared without the requirement of the application of an external source of heat by the admixture of a composition comprising(A) a polyether polyol having an equivalent weight of 30-2500, such as an adduct of glycerine with propylene oxide;(B) an organic polyisocyanate, such as toluene diisocyanate;(C) an ethylenically unsaturated monomer, such as styrene;(D) a catalyst for polymerizing ethylenically unsaturated monomers such as tertiary butyl perbenzoate; and(E) a catalyst for urethane formation such as cobalt naphthenate.Foams may also be prepared by adding an appropriate foaming agent.

Abstract: This invention relates to a process for the manufacture of foams based on phenolic resins, wherein phenolic resins are reacted, in the presence of metal powders and/or metal oxide powders, with organic diisocyanates and/or polyisocyanates.

Abstract: The instant invention is directed to a process for the production of polyurethane foams wherein organic polyisocyanates are reacted with active hydrogen containing compounds, wherein either the polyisocyanate or the active hydrogen containing compound or both are used in the form of sedimenting, redispersible dispersions containing homogeneous i.e. non-foamed aminoplast /condensates as the dispersed phase.

Abstract: Polyester foam is formed by simultaneously cross-linking an unsaturated polyester resin and generating carbon dioxide as a blowing agent. The foam-forming components are divided into two equal volume parts which are metered together to effect the simultaneous reactions and form the foam. Apparatus is described for effecting the foam-forming method.

Abstract: Foamed articles are made by causing the cross-linking of a thermosetting in, preferably a polyester resin, concurrently with the production of carbon dioxide by the reaction of a carbonate with an inorganic acid. The carbonate is mixed with the resin and the acid then folded in in a progressively accelerated blending operation, whereupon carbon dioxide is generated to foam the resin, the carbonate, acid and setting time of the resin being selected to obtain an appropriate match between the progress of the foaming operation and the setting of the foam. The foam may be made in a mold coated with resin impregnated glass fibers, the impregnating resin becoming cross-linked with the foam. The impregnating resin may also be cross-linked with a resin gel coat, the glass fibers forming a tough layer between the gel coat and the foam.

Abstract: This invention relates to compositions and methods for forming polyether polyurethanes utilizing internal release additives for the purpose of facilitating mold release in the production of molded objects. The invention discloses four classes of internal release additives: (1) mixtures of aliphatic or aryl carboxylic acid and a polar metal compound; (2) carboxyalkylsiloxanes; (3) aliphatic glyoximes; and (4) aralkyl quaternary ammonium salts.

Abstract: Resilient polyester foam materials. Acyl halide, polyol, and polyhydroxy cross-linking agent are reacted in the presence of alkali metal carbonate to prepare the resilient polyester foams. A process similar to that used in the one-shot preparation of polyurethane foams is used. Preferred reactants are adipyl chloride, quadrafunctional polyol based on pentaerythritol, propoxylated pentaerythritol cross-linking agent, and sodium carbonate. The resilient polyester foams find use in products such as catamenial tampons.

Abstract: A chromatography solid support is prepared by reacting a nucleic acid base, a related compound thereof or a mixture thereof with an epoxy group-containing porous gel in a solvent in the presence of a carbonate.

Abstract: This invention relates to a method of imparting anisotropy to polymeric foams and to the resultant products. By this invention enhanced mechanical properties are produced in polymeric foams such properties being, for example, compressive yield strengths, modular tensile strengths, and the like. Importantly, other properties of enhanced value are achieved, as for example, improved thermal conductivity and enhanced burning rates.The process involved comprises mixing in liquid form various components of the foam which is to be produced in a foaming step which involves the action of the components in the presence of a foaming agent that effects the foam expansion, and mixed with these liquid mixtures is a low level concentration of relatively short fibers, one-half inch or less, the fibers being made from either an inorganic or organic material with fiber glass or aluminum fibers being preferred.

Abstract: Thermoplastic polystyrene laminates are disclosed, one of the layers of which comprises a filled polystyrene composition containing from about 5 to about 50 of filler, such as calcium carbonate, clay, asbestos, etc. The filled polystyrene composition is prepared from a filled polystyrene masterbatch of impact polystyrene, filler, rubber and mineral oil, cut back by mixing with other polystyrene, either crystal or impact polystyrene. Laminates may be prepared by coextrusion. The filled polystyrene layer may be foamed. The laminates may be used for making formed articles such as cups, containers, trays, plates, sheets, etc.

Abstract: Polyurethane and vinyl polymer composites are rapidly prepared without the requirement of the application of an external source of heat by the admixture of a composition comprising(A) a polyether polyol having an equivalent weight of 30-250, such as an adduct of glycerine with propylene oxide;(B) an organic polyisocyanate, such as toluene diisocyanate;(C) an ethylenically unsaturated monomer, such as styrene;(D) a catalyst for polymerizing ethylenically unsaturated monomers such as tertiary butyl perbenzoate; and(E) a catalyst for urethane formation such as lead octoate.Foams may also be prepared by adding an appropriate foaming agent.