Abstract: This invention relates to the manufacture of foam from phenolic resins and to the foam so produced. In order to overcome some of the limitations of the prior art closed cell phenolic foams, we have developed a method of preparing closed cell foams from modified, low cost phenol formaldehyde resoles, which exhibit high closed cell contents, low friability and low thermal conductivity. This specification provides a foam competitive with urethane foams, which have an aged thermal conductivity of about 0.16K. or less, but which will not generate fumes as toxic as those of urethane. There is, provided a method of making a phenolic foam material comprising the steps of(1) preparing a base catalyzed phenol-formaldehyde resole having a mole ratio of phenol to formaldehyde of between 1:3 and 1:4.

Abstract: An improved process is disclosed for the preparation of a cured substantially closed cell phenolic resin foam by preparing a mixture of a foamable phenol-aldehyde resin, a blowing agent, and an acid catalyst, allowing the mixture to foam, and curing the phenolic foam, wherein the improvement comprises:(a) maintaining the water content of the foamable mixture below about 14% by weight,(b) using a resin-soluble acid catalyst,(c) adding at least a minimum amount of two parts per hundred resin of surfactant to the mixture prior to foaming, and(d) adding a member of the lactone family to the mixture prior to foaming.

Abstract: A process for the preparation of improved closed cell foams having improved toughness and improved stability to light by the reaction of a urethane polyol or an amide polyol with a liquid phenol-formaldehyde polyol and a polyisocyanate is described.

Abstract: Modified benzyl ether-containing resole polyols derived from a phenolic component, a non-aqueous aldehyde, and a halogen-containing aliphatic hydroxyl component are prepared using a metal derivative as a catalyst. These polyols react with organic polyisocyanates to yield closed cell, low friability, low combustibility, rigid polyurethane foams without the need for post curing at elevated temperature. They are also useful in the preparation of modified rigid polyisocyanurate foams.

Abstract: This invention relates to the manufacture of foam from phenolic resins and to the foam so produced. In order to overcome some the the limitations of the prior art closed cell phenolic foams, we have developed a method of preparing closed cell foams from modified, low cost phenol formaldehyde resoles, which exhibit high closed cell contents, low friability and low thermal conductivity. This specification provides a foam competitive with urethane foams, which have an aged thermal conductivity of about 0.16K. or less, but which will not generate fumes as toxic as those of urethane. There is, provided a method of making a phenolic foam material comprising the steps of(1) preparing a base catalyzed phenol-formaldehyde resole having a mole ratio of phenol to formaldehyde of between 1:3 and 1:4.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: There is disclosed a non-flammable rigid foam on the basis of phenolic resin and furane resin, containing aluminum hydroxide and further components as a filler system. The weight ratio of resin substance:filler substance is at least 1:2.5 and up to 1:3.2 and the bulk density is from 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin compound is the reaction product obtained by the reaction with one another of50-62 weight parts resolic resin0-15 weight parts furanic resin25-40 weight parts furfuryl alcohol0.5-1.

Abstract: Phenolic foams and a method of producing phenolic foam material from phenol-formaldehyde resins having a phenol to formaldehyde mole ratio of between about 1:3 and 1:4.5 are described. These materials are useful for insulation and other uses, particularly in the building trades. They are dimensionally and thermally stable, fire resistant and low in cost.

Abstract: The non-flammable rigid foam e.g. used as a building material complies with the requirements of DIN 4102 and which provides a non-toxicity of the combustion fumes according to DIN 53436. It has a mass ratio of resin component: filler of at least 1:2.5 and a bulk density amounting to 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin component is formed by reaction of50-62 mass parts resolic resin0-15 mass parts furane resin25-40 mass parts furfuryl alcohol0.5-11.5 mass parts foam stabilizerincluding 14-17 mass parts per 100 mass parts of resin component plus filler of a curing agent mixture of phosphoric acid, boronhydrofluoric acid, p-toluene sulphonic acid and water. The filler used is a mixture of40-55 mass % aluminium hydroxide10-35 mass parts boric acid2-7 mass parts sodium tetraborate5-10 mass parts manganese dioxide1-5 mass parts copper-II-oxide1-4 mass parts magnesium hydroxysilicate1-2 mass parts aluminium silicate.

Abstract: A method for manufacturing a phenolic resin foam is provided which comprises the steps of mixing a composition consisting of 100 parts by weight of a resol-type phenol-formaldehyde resin, 5 to 40 parts by weight of a curing agent consisting of an acid, and a foaming agent consisting of an isocyanate or a mixture thereof with water, and heating the composition for foaming, an amount of the isocyanate being 5 to 30 parts by weight if the foaming agent is the isocyanate alone, and the amount of the isocyanate being not less than its equivalent weight and an amount of water being 5 to 30 parts by weight if the foaming agent is the mixture of the isocyanate with water. If 100 parts by weight of a urethane-modified phenol-formaldehyde resin are used in place of 100 parts by weight of the resol-type phenol-formaldehyde resin, 0.1 to 1.5 parts by weight of a curing agent consisting of a tin compound are used in place of the acid curing agent.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: Flexible, resilient, polyurethane foam having improved flame retardancy and intumescent properties is prepared from the reaction of polyether polyol with organic isocyanate and an additive combination comprising: (i) a polyester polyol, (ii) an halogenated flame retardant, and (iii) water or alcohol soluble urea-formaldehyde resin.

Abstract: A process for producing a resin foam by using an aqueous medium, which comprises(a) treating a resin compound with said aqueous medium to cause the aqueous medium to adhere to and be held by the resin compound, said resin compound being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces,(b) melt-kneading the resin compound treated with the aqueous medium under such an elevated pressure that evaporation of the aqueous medium is substantially inhibited, and(c) thereafter releasing the kneaded resin composition from the pressurized state to foam it; and a thermoplastic resin compound used for the aforesaid process.

Abstract: A novel tire sealant and inflator composition comprising a resin, a latex sealant, alkylene glycol, fibers, an alkanolamine, a foaming agent, and water. The composition is packaged in aerosol cans with a chlorofluorocarbon propellant/inflator and used to seal and inflate punctured tires. The composition is applied to the punctured tire through the valve stem, and acts to seal the puncture and inflate the tire sufficiently to support the weight of the car.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: The invention relates to a particulate agent based on free-flowing pulverulent ammonium polyphosphates of the general formulaH.sub.(n-m)+2 (NH.sub.4).sub.m P.sub.n O.sub.3n+1in which n is an integer having an average value of from approximately 20 to 800 and the ratio of m to n is approximately 1, for impeding the combustibility of combustible materials. The agent is comprised of(a) approximately 75 to 99% by weight of ammonium polyphosphate, and(b) approximately 1 to 25% by weight of a hardened water-insoluble polycondensation product of melamine and formaldehyde encasing the individual ammonium polyphosphate particles.

Abstract: The non-flammable rigid foam e.g. used as a building material complies with the requirements of DIN 4102 and which provides a non-toxicity of the combustion fumes according to DIN 53436. It has a mass ratio of resin component:filler of at least 1:2,5 and a bulk density amounting to 50 kg/m.sup.3 to 450 kg/m.sup.3. The resin component is formed by reaction of50-62 mass parts resolic resin,0-15 mass parts furane resin,25-40 mass parts furfuryl alcohol,0,5-11,5 mass parts foam stabilizer including 14-17 mass parts per 100 mass parts of resin component plus filler of a curing agent mixture of phosphoric acid, boronhydrofluoric acid, p-toluene sulphonic acid and water. The filler used is a mixture of40-55 mass % aluminium hydroxide10-35 mass parts boric acid2-7 mass parts sodium tetraborate5-10 mass parts manganese dioxide1-5 mass parts kopper-II-oxide1-4 mass parts magnesium hydroxysilicate1-2 mass parts aluminium silicate.

Abstract: A phenolic resin foam having excellent mechanical strength and flame resistance is obtained by letting a resinous mixture comprising a benzylic ether type phenolic resin, a blowing agent, an aromatic sulfonic acid, a polyisocyanate compound, and water to stand at room temperature or more so as to allow the mixture to foam and solidify.

Abstract: Aminoplast resin is prepared by reacting urea or melamine with formaldehyde in the presence of a stabilizer compound. Dispersions of the resin in a polyol reacted with a polyisocyanate produce polyurethane products having low flammability properties.

Abstract: The invention relates to a method for producing a fibre composite material, which comprises glass- and/or mineral fibres, expanded microspheres and a curable resin. In the method a melt of glass or mineral is prepared and the melt is converted to discrete fibres by means of nozzles. A water-based solution or dispersion of a thermosetting resin is applied to the fibres, which solution or dispersion contains microspheres. The obtained material is collected and the microspheres are brought to expand before or after the collecting. The invention also relates to a final treatment of the obtained material in which the material is pressed or formed and brought to set to the C-stage. The invention also relates to the products obtained by the method.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting under free radical polymerization conditions a polyoxyalkylene adduct, a cyclic nitrogenous vinyl monomer and an esterified unsaturated dibasic acid in the presence of an organic or inorganic per-compound and a metal catalyst.

Abstract: Novel polymers of excellent heat- and flame-resistance are obtained by reacting together an aqueous solution of an aminoplast precondensate such as a urea-formaldehyde syrup, an organic polyisocyanate comprising di(isocyanatophenyl)methane or a mixture of di(isocyanatophenyl)methane with poly(isocyanatophenyl)polymethylenes, and an isocyanate-reactive organic polyol in the presence of a tertiary amine as catalyst and a poly(haloalkyl)phosphate, especially tris-(2-chloroethyl)phosphate.Under normal circumstances, foamed materials are obtained, but non-foamed materials can be obtained by carrying out the reaction in the presence of a CO.sub.2 absorbent.

Abstract: Polyurethane foams prepared from the reaction of polyester polyol with organic isocyanate have improved flame retardance and dripping ember retardance by incorporation of an additive comprising (1) halogenated flame retardant, and (2) water or alcohol soluble urea-formaldehyde resin.

Abstract: A method of making light weight flame resistant structures from bonded polyimide macroballoons and products thereof. An aromatic tetracarboxylic acid dianhydride is reacted with an oxoimine to produce an N-substituted imide, which is then esterfied with a suitable alcohol. The resulting liquid is dried and the dry residue is reduced to a uniform powder having particles with diameters generally in the 0.5 to 10 mm. range. The powder is preferably further dried, either before or after final size reduction, in a moderate vacuum at moderate temperature to remove any excess residual alcohol. The powder spontaneously expands to form a closed cell foam when heated to a temperature in the range of about 90.degree. to 150.degree. C. for a suitable period. When the powder is expanded in a closed mold, a well consolidated, uniform, closed cell foam product results. The closed cell foam produced has excellent flexibility and resistance to heat and flame, and does not shrink appreciably when exposed to flame.

Abstract: A two-part pack, and method for its preparation, from which a phenol-formaldehyde resin foam may be prepared, which system comprises in the first part of the pack a phenol-formaldehyde resin, a blowing agent which is an inert, low boiling liquid, an effective amount of a nitrogenous modifier capable of permitting dispersion of the blowing agent in the resin, and a surfactant; and in the second part of the pack an acid catalyst system dispersed in a liquid polyhydroxy compound, in a weight ratio of polyhydroxy compound to acid catalyst of at least 1:1. These two-part packs enable simpler handling and placement techniques being shelf storable, compared to the known shelf storable systems which involve three, or more, components.

Abstract: A flame-retardant, rigid, thermosetting foam product is prepared by reacting, in the presence of a blowing agent and a catalyst, particularly an organic metal catalyst, a furfural alcohol polymer, a phenol-formaldehyde resin, a melamine and methylene diphenyl isocyanate, which reaction provides for a rigid foam characterized by low friability and good heat- and flame-resistant properties.

Abstract: A method of preparing a flame-retardant benzylic-ether phenolic modified foam product and the resulting foam product produced thereby, which method comprises reacting and mixing benzylic-ether phenol-formaldehyde resin, having a hydroxyl number of from about 400 to 600, with from about 50 to 150 parts by weight of a boric-acid catalyst to each 100 parts of the resin, optionally in the presence of melamine, to form a resin prepolymer, and, thereafter, reacting the prepolymer so formed, in the presence of a blowing agent and an organometal catalyst, with a methylene diisocyanate in an exothermic reaction, to provide a nonfriable, substantially closed-cell, flame-retardant benzylic-ether phenolic modified foam product characterized by substantially acid methylene linkages in the resulting thermosetting foam product.

Abstract: Unsaturated polyester foams having fine and uniform cells are prepared at an atmospheric temperature from an admixture which comprises in combination a liquid unsaturated polyester resin, a hydrazide compound, a cobalt compound and a powdered inorganic compound selected from the group consisting of percarbonates, perborates and perphosphates.

Abstract: Polyester silicate resinous products are produced by mixing an organic epoxide compound, hydrated silica, Lewis acid and a polycarboxylic acid and/or polycarboxylic acid anhydride, then heating the mixture to from 150.degree. C. to 250.degree. C. for 30 minutes to 4 hours. The polyester is silicate resinous products may be used as a coating agent, as a molding powder and as an adhesive.

Abstract: A porous open-cell reactive filled material containing a polymeric matrix and a reactive filler. According to the invention, use is made as the polymeric matrix of foamed polyvinylformal and foamed polyurethane. As the reactive filler use is made of finely divided ion-exchange fibres, complex-forming fibres or mixtures thereof in an amount of from 10 to 80% by mass of the final material. Use is made of ion-exchange fibres on the basis of polyvinylalcohol, polyacrylic, cellulose-regenerated, phenolaldehyde, polyolefine, polyvinylhalide fibres. As the complex-forming fibres use is made of fibres based on polyacrylic, polyvinylalcohol, cellulose-regenerated fibres.

Abstract: Plastics are produced by reacting at least one compound containing sulfonic acid groups with at least one aldehyde in the presence of a hydroxy compound in an acidic concentrated aqueous solution having a water content of about 20 to 30% by weight. If a tenside is present the reactants will form a foam. The preferred sulfonic acid-containing compound is the sodium salt of diisobutylnaphthalene sulfonic acid, the preferred hydroxy compound is a phenol, vix. resorcinol, and the preferred aldehyde is formaldehyde which may be formed in situ from hexamethylenetetramine, paraformaldehyde, trioxane, or the like.

Abstract: A porous open-cell filled reactive material containing a polymeric matrix of foamed polyvinylformal or foamed polyurethane and a finely-divided oxidation-reduction reactive fiber as a filler in an amount of from 10 to 80% by mass of the final material. The oxidation-reduction properties of the fibers are ensured through the use of oxidation-reduction agents which are covalently bonded with the fiber. As the oxidation-reduction agents use is made of the following compounds: polyhydric phenols, anthraquinones, naphthoquinones, phenothiazine dyestuffs. The oxidation-reduction fibers also comprise metal-containing fibers based on polyvinyl alcohol, cellulose-regenerated fibers, acetate cellulose or polyacrylic polymers.

Abstract: A process for the preparation of polyurethane foams modified with melamine-formaldehyde precondensates, in which the precondensates employed are storage-stable, aqueous 40-85% strength by weight resin solutions which are obtained by condensing melamine with formaldehyde in a molar ratio of 1:1.1-1.75 in aqueous solution at a pH which, at least periodically, is above 8, and at from 60 to 130.degree. C., until one part by volume of resin solution can be diluted with from 0.5 to 4 parts by volume of water at 20.degree. C. without causing a persisting cloudiness.

Abstract: Polyoxyalkylene surfactants for cellular foams can be prepared by reacting a polyoxyalkylene adduct and an esterified unsaturated dibasic acid in the presence of a free-radical initiator.

Abstract: Aminoplast foams of hardened reaction products of aldehydes and at least bifunctional modified .alpha.,.omega.-ureas which contain at least one ether, thioether, acetal, ester, ester amide and/or carbonate group and have a molecular weight of from 200 to 10,000.

Abstract: A low-density, low-friability, furfuryl-phenol thermosetting foam product is prepared by reacting, in the presence of a blowing agent and an acid catalyst, a furfuryl-alcohol monomer or polymer and a benzylic-ether phenol-formaldehyde resin, having a mole ratio of benzylic-ether phenol to formaldehyde of from about 1:3 to 1:11, which reaction provides a closed-cell, thermosetting foam product having a foam density of 0.5 pound per cubic foot or less.

Abstract: A low-friability, flame-retardant, thermosetting foam product is prepared by reacting, in the presence of a blowing agent and a strong acid catalyst, a furfuryl-alcohol polymer and a phenol-formaldehyde resin, having a mole ratio of phenol to formaldehyde of from about 1:1.2 to 1:2.0, which reaction provides a low-friability, flame-retardant, thermosetting foam product.

Abstract: A method of reducing the formaldehyde emissions from formaldehyde condensation polymers is disclosed. A substance having two or more amide linkages, such as a polyacrylamide polymer is incorporated in the polymer solution immediately or shortly before use, the acrylamide polymer reacting with free formaldehyde in the solution or that generated as a result of hydrolytic breakdown of the formaldehyde condensation polymer. The incorporation of polyacrylamide polymers in a urea-formaldehyde resin solution used in the production of urea-formaldehyde insulating foams is of particular benefit.

Abstract: This invention relates to cellular plastic compositions of condensation products of phenol-urea and formaldehyde useful for thermal and acoustical insulation and methods for their preparation in which the phenol is present in amounts of about 1 to about 20 percent by weight wherein the condensation product prior to foaming and setting as a rigid cellular plastic has a viscosity at room temperature of approximately 30 to 36 seconds, No. 1 Zahn cup, and a pH maintained in the range of about 6 to 8.

Abstract: A process for the manufacture of a resilient foam based on a melamine-formaldehyde condensate, wherein an aqueous or alcoholic solution or dispersion containing a melamine-formaldehyde precondensate, an emulsifier, a blowing agent and a hardener is foamed by ultra-high-frequency irradiation and the foam is hardened by crosslinking the precondensate. The foam may be employed for heat and sound insulation, and as a packaging material.

Abstract: Additive of the cellular plastic type, method for manufacturing the additive and use of the additive. The additive is intended to be mixed with a hardening or air-drying component, preferably, liquid paint. The additive of this invention is characterized in that a mixture of closed cellular plastic particles, disintegrated foamed urea formaldehyde resin and chopped fiberglass filaments or strands from part of the additive.

Abstract: A continuous process for the production of flame-resistant foamed plastics material by condensation of aqueous aminoplast precondensates with diisocyanates or polyisocyanates, wherein, in a first mixing stage, the isocyanate is mixed with 4 to 14% by weight of catalyst, the catalyst being an organic amine and/or an organic metal compound, at temperatures of 40.degree. to 130.degree. C., with a residence time of 1 to 8 seconds, and directly thereafter, in a second mixing stage, the aminoplast precondensate and, simultaneously but separately from the aminoplast, an acid curing catalyst are introduced, after which the foamable mixture thereby produced is discharged continuously.

Abstract: Flame retardant polymer resins formed by an acid condensation reaction from a mixture of resorcinol and furfural with a molar excess of the aldehyde. In one particular embodiment the resin is formed of a mixture of two prepolymer solutions with at least a boric acid catalyst, one or both of the prepolymer solutions being an acid-condensation reaction product of resorcinol and furfural with excess aldehyde functionality, or one of the prepolymers being a mix of substantially unreacted resorcinol and furfural with a slight molar excess of aldehyde.

Abstract: Organic polyisocyanates are reacted chemically with aldehyde-broken down alkali metal cellulose silicate polymers to produce polyurethane products.

Abstract: Hollow plastic microspheres made from thermoplastic or thermosetting plastic compositions are described.The hollow plastic microspheres can be used as filler materials in plastics, in plastic foam compositions and in concrete and asphalt compositions. The hollow plastic mircospheres can be made from low heat conductivity plastic compositions and blown with a low heat conductivity gas and used to make improved insulation materials and composites and insulating systems.The hollow plastic microspheres can be made to contain a thin transparent or reflective metal coating deposited on the inner wall surface of the microspheres by adding to the blowing gas small dispersed metal particles and/or gases of organo metal compounds and decomposing the organo metal compounds.The hollow plastic microspheres can also be made in the form of filamented plastic microspheres with a thin plastic filament connecting adjacent plastic microspheres.

Abstract: Hollow glass microspheres made from a low heat conductivity glass composition containing a high vacuum and a thin metal coating deposited on the inner wall surface of the microspheres are described. The hollow glass microspheres are used to make superior insulation materials in the construction of highly efficient solar energy collectors.The hollow glass microspheres can also be made to contain a thin transparent or reflective metal coating deposited on the inner wall surface of the microspheres by adding to the blowing gas small dispersed metal particles and/or gases of organo metal compounds and decomposing the organo metal compounds.The hollow glass microspheres can be made from low heat conductivity glass compositions. The microspheres can be used to make improved insulation materials and composites and insulating systems.The hollow glass microspheres can be used as filler materials in plastics, in plastic foam compositions and in concrete and asphalt compositions.

Abstract: Hollow glass microspheres made from a low heat conductivity glass composition containing a high vacuum and a thin metal coating deposited on the inner wall surface of the microspheres are described. The hollow glass microspheres are used to make superior insulation materials in the construction of highly efficient solar energy collectors.The hollow glass microspheres can also be made to contain a thin transparent or reflective metal coating deposited on the inner wall surface of the microspheres by adding to the blowing gas small dispersed metal particles and/or gases of organo metal compounds and decomposing the organo metal compounds.The hollow glass microspheres can be made from low heat conductivity glass compositions. The microspheres can be used to make improved insulation materials and composites and insulating systems.The hollow glass microspheres can be used as filler materials in plastics, in plastic foam compositions and in concrete and asphalt compositions.

Abstract: Hollow plastic microspheres made from thermoplastic or thermosetting plastic compositions are described.The hollow plastic microspheres can be used as filler materials in plastics, in plastic foam compositions and in concrete and asphalt compositions. The hollow plastic microspheres can be made from low heat conductivity plastic compositions and blown with a low heat conductivity gas and used to make improved insulation materials and composites and insulating systems.The hollow plastic microspheres can be made to contain a thin transparent or reflective metal coating deposited on the inner wall surface of the microspheres by adding to the blowing gas small dispersed metal particles and/or gases of organo metal compounds and decomposing the organo metal compounds.The hollow plastic microspheres can also be made in the form of filamented plastic microspheres with a thin plastic filament connecting adjacent plastic microspheres.

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: A process and apparatus are provided for making desired shapes of urea-formaldehyde suitable for use as insulation from urea-formaldehyde foam. Fluid urea-formaldehyde foam (A) is formed into discrete particles (A') in particle generator (10) which also partially cures particles (A'). After particles (A') are fully cured, they are blended with fluid urea-formaldehyde foam in mixing apparatus (11) which includes blending head (66) to produce mixture (C) which is a coherent mass. Mixture (C) is molded to the desired cross-sectional shape by molding conveyor (12). Cutter (132) cuts formed mixture (C) into the desired length. Thereafter oven (146) is utilized for fully curing the product which is then enclosed in a suitable packaging material.