Abstract: High density thermoset foams of acrylic polymers are prepared by dry mixing a hydroxy-functional acrylic polymer, e.g., a copolymer of styrene, ethyl acrylate, hydroxy alkyl acrylate and acrylic acid, with a crosslinking agent, e.g., a melamineformaldehyde condensate, and then subjecting the resulting mixture to conditions sufficient to cause the mixture to foam and to crosslink to a thermoset material.

Abstract: Particulate styrene polymers which contain a blowing agent and are surface-coated with a glycerol dialkyl ether, preferably mixed with a glycerol ester. The particles can be foamed, and the foamed particles can be fused to form moldings.

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: The disclosure relates to flexible heat expanding, fire retardant composite materials comprising an intumescent component in granular form, an organic binder component such as an elastomer, an organic char-forming component and fillers such as clay, silica, synthetic organic staple fibers or inorganic fiberglass or ceramic fibers. These composites, when subjected to heat at about 110.degree. C., can intumesce up to ten times their original volume.

Abstract: An improvement in intumescent compositions is provided comprising, in part, melamine formaldehyde resin, a cross-linking agent, and a hydrophilic setting agent. The composition chemically absorbs water to yield an intumescent material with reduced cracking properties which decomposes into gas and a solid foam residue upon heating.

Abstract: Opacifying agents of improved structural integrity and light scattering ability are disclosed. These agents are composed of hollow, substantially spherical agglomerates having discontinuous walls composed of solid, spherical microparticles. The microparticles are produced by admixing an aqueous, partially condensed aldehyde condensation product with an oily non-solvent material and an emulsifying agent to produce a water-in-oil emulsion. Polymerization acid catalyst is then admixed with the emulsion to produce the discrete, substantially spherical and opaque, solid microparticles. After inverting the emulsion to oil-in-water form and adding oil-soluble resin adhesive, elevated temperature is used to cure the adhesive while evaporatively removing residual oily non-solvent. This yields improved agglomerate opacifying agents of high physical stability.

Abstract: This invention relates to a process for the preparation of a finely divided, stable and relatively low viscosity dispersion of a polyisocyanate polyaddition product and an aminoplast and/or phenoplast and/or copolymer thereof in a hydroxyl containing compound and the use of such a dispersion as the starting component for the production of a polyurethane resin.

Abstract: The present invention relates to a process for the preparation of phenol-formaldehyde foams by mixing a resol phase having a viscosity of between 8 and 60 poises and a novolac phase comprising a true novolac, a blowing agent, phenolsulphonic acid and, optionally, phenol, the relative amounts of resol phase and of novolac phase being such that the resol phase represents 45 to 75% by weight of the mixture.

Abstract: A covering multilayer film or sheet structure for agricultural application, which consists essentially of:(1) a film or sheet of a resin composition comprising (A) 100 parts by weight of a thermoplastic resin selected from the group consisting of olefinic resins and vinyl chloride resins and (B) about 1 to about 40 parts by weight of an acetal resin, and(2) a layer of the thermoplastic resin (A) laminated to at least one surface of the film or sheet (1); and a method for maintaining an agricultural locus at temperatures suitable for the growth of plants, using aforesaid covering multilayer film or sheet.

Abstract: The flexible polyurethane foams having high flame resistance and smoke resistance can be produced by reacting a polyhydroxyl compound and a polyisocyanate with a urea derivative selected from the group consisting of(a) a compound represented by the general formula ##STR1## wherein at least one of R.sub.1, R.sub.2, R.sub.3 and R.sub.4 represents hydroxylalkyl, alkoxyalkyl, alkyl and aryl groups and the remainder represents hydrogen atom, and(b) a urea-formaldehyde condensation product in the presence of a catalyst, a surfactant and a blowing agent.These polyurethane foams can easily provide the favorable foam sheets by compression-molding these foams under heating.

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: 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: Composite foam panels are prepared from expanded thermoplastic particles of low density by generally encapsulating the particles in a phenolic foam matrix and providing a particulate expanded mineral substance such as perlite disposed generally adjacent the major surfaces of the panel.

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: A resin composition in the form of a covering film or sheet comprising (A) 100 parts by weight of a thermoplastic olefinic resin and (B) about 1 to about 20 parts by weight of an acetal resin; and a method for maintaining an agricultural locus at temperatures suitable for the growth of plants, using above covering film or sheet.

Abstract: A two component system, and method for its preparation, from which a phenol-formaldehyde resin foam may be prepared, which system comprises in a first component 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 a second component an acid catalyst system dispersed in a liquid polyhydroxy compound, in a weight ratio of acid catalyst to polyhydroxy compound of at least 1:1. These systems enable simpler handling and placement techniques being shelf storable, compared to the known shelf storable systems which involve three, or more, components.

Abstract: A covering multilayer film or sheet structure for agricultural application, which consists essentially of:(1) a film or sheet of a resin composition comprising (A) 100 parts by weight of a thermoplastic resin selected from the group consisting of olefinic resins and vinyl chloride resins and (B) about 1 to about 40 parts by weight of an acetal resin,and(2) a layer of the thermoplastic resin (A) laminated to at least one surface of the film or sheet (1); and a method for maintaining an agricultural locus at temperatures suitable for the growth of plants, using aforesaid covering multilayer film or sheet.

Abstract: The invention provides a composition for forming an intumescent material which upon heating decomposes into gas and a solid foam residue, comprising: a water-dispersible melamine formaldehyde resin which when cured is hydrophobic; a setting agent which hardens in the presence of water thereby to cause the composition to set; a cross-linking agent for curing the resin, the cross-linking agent being a polyamido compound; an ammonium phosphate; polyvinyl acetate; a solid polyhydroxy compound; and reinforcing fibrous material. To form the intumescent material, the composition is caused to set and the melamine resin is cured. The intumescent material has improved anti-cracking properties.

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: Flame retardant intumescent polyamides comprising repeating structural units of the formulas ##STR1## wherein X is independently chloro or bromo, and n and n' are each independently a positive integer are disclosed.

Abstract: The present invention provides particular phenol/formaldehyde resoles which are especially useful as foamable resins, and further provides cellular phenolic products having physical properties which are especially attractive for end-use application as construction foam. The resoles are characterized by a particular relationship between their viscosity and water content, expressed as the area bounded by certain points on a plot of resole viscosity on a logarithmic scale, as a function of water content of the resole, the particular area depending upon the mole ratio of formaldehyde-to-phenol at which the resole has been condensed. It has been found that phenol-formaldehyde resoles having the defined viscosity/water relationship are capable of providing phenolic foam having acceptable foam processability, a foam density from about 1.90 to about 3.

Abstract: Flame resistance of upholstered furniture is significantly improved by interposing between the cover fabric and the padding or applying to the top side of the cover fabric a layer of neoprene foam capable of forming when exposed to a burning cigarette or under the conditions of a standard flame spread test, a thermally insulating char which does not smolder, and which maintains its structural integrity. The neoprene foam must be so formulated that it also is capable of evolving at combustion temperature sufficient amount of water to efficiently cool the affected area. Normally, the latex from which the foam is prepared is formulated with a char promoter and a hydrated inorganic compound. Upholstered furniture of this invention passes a burning cigarette test and performs extremely well in the flame spread test.

Abstract: A process is provided for producing a radiation curable coating composition containing microcapsules comprising the steps of preparing a dispersion of substantially discrete microcapsules in a continuous phase, the continuous phase comprising a liquid volatile solvent, preparing a liquid radiation curable suspending medium, the liquid radiation curable suspending medium comprising one or more ethylenically unsaturated organic compounds having at least one terminal ethylenic group per molecule, mixing the dispersion of substantially discrete microcapsules in the continuous phase and the liquid radiation curable suspending medium with turbulent agitation to form an intimate mixture of the dispersion of microcapsules and the liquid radiation curable suspending medium, and applying heat and vacuum to the mixture, while maintaining the agitation, until the liquid volatile solvent is substantially removed from the mixture to form a dispersion of substantially discrete microcapsules in the liquid radiation curable s

Abstract: Foamed plastics with improved combustion characteristics and good mechanical strength are obtained by condensation of aminoplast precondensates with organic isocyanates in the presence of an acid curing catalyst and an accelerator for polyurethane formation, whereby the precondensate used as starting material is prepared by reacting formaldehyde with urea and/or melamine in a molar ratio of 1.80 to 4.5:1 at pH values of 4 to 9.5, adjusting then the pH to 7.0 to 8.0 and adding urea to obtain a molar ratio offormaldehyde to the total amount of aminoplast forming compound of 1.0-2.1:1.

Abstract: New and useful blends of thermosetting resins with copolymers of certain amounts of ethylene with another monomer copolymerizable therewith to provide solid but flexible polymers, and a third monomer containing epoxy side groups, and optionally carbon monoxide, are provided. These blends result in performance unattainable with the thermosetting resin alone in terms of flexibility, toughness, and adhesion. Such blends may be used, for example, to produce flexible, semirigid or rigid films, coatings, fibers, foams or molded articles.

Abstract: Flexible polyurethane foam having reduced tendency to form burning embers when it is ignited and burned is provided by incorporating into the reaction mixture before foaming a derivative of melamine wherein one or more hydrogens have been replaced by hydroxymethyl and/or lower alkoxymethyl groups.In one embodiment, flexible polyurethane foams of increased flame retardance are also provided, by also incorporating a halogenated phosphorus ester into the reaction mixture before foaming.

Abstract: Foamed plastics with improved combustion characteristics are produced by condensing an aqueous solution of formaldehyde-urea and/or melamine precondensates with polyisocyanates and optionally a polyol in the presence of an acid catalyst, being present in an amount of 1 part by weight per at least 20 parts by weight of precondensate, whereby this catalyst is added to the isocyanate before mixing with the precondensate or to the mixture of isocyanate and precondensate, but separately from the precondensate.

Abstract: Liquid prepolymers are prepared by interpolymerizing monomers including a hydroxy aromatic compound, an aldehyde and furfuryl alcohol. The resultant liquid prepolymers have a viscosity of about 100-500,000 centipoises at 25.degree. C. and contain about 1.1-6 moles of interpolymerized aldehyde and about 3.1-15 moles of interpolymerized furfuryl alcohol for each mole of interpolymerized hydroxy aromatic compound. The prepolymers are highly reactive and may be polymerized with or without other monomers to produce flame retardant solid or cellular interpolymers. In one variant, flame retardant solid or cellular polymers are produced by interpolymerizing organic polyisocyanates with the prepolymers. In another variant, solid or cellular interpolymers are produced by polymerizing the prepolymers without monomers such as polyisocyanate in the presence of unreacted furfuryl alcohol. Processes are provided for preparing the aforementioned novel liquid prepolymers and solid or cellular interpolymers.

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: This invention provides a low density (<2 pcf.) modified phenolic foam produced by combining a resole resin with a phosphorus-containing isocyanate-terminated prepolymer in the presence of a minor amount of a surfactant, a catalytic amount of an organotin catalyst, and a halocarbon blowing agent. Foam products producted by the method of the invention have a good combination of low combustibility, friability resistance and compressive strength.

Abstract: A process for the manufacture of a multicellular stretched sheet which comprises melt compounding a thermoplastic matrix polymer and an additive comprising a polymeric or non-polymeric organic compound or a metal salt of an organic acid, forming the blend into a shaped article and stretching the article at a temperature within the normal orientation temperature of the matrix polymer and below the glass-transition temperature of the polymeric additive or below the melting or softening point of the non-polymeric additive.

Abstract: Liquid prepolymers are prepared by interpolymerizing monomers including a hydroxy aromatic compound, an aldehyde and furfuryl alcohol. The resultant liquid prepolymers have a viscosity of about 100-500,000 centipoises at 25.degree. C. and contain about 1.1-6 moles of interpolymerized aldehyde and about 3.1-15 moles of interpolymerized furfuryl alcohol for each mole of interpolymerized hydroxy aromatic compound. The prepolymers are highly reactive and may be polymerized with or without other monomers to produce flame retardant solid or cellular interpolymers. In one variant, flame retardant solid or cellular polymers are produced by interpolymerizing organic polyisocyanates with the prepolymers. In another variant, solid or cellular interpolymers are produced by polymerizing the prepolymers without monomers such as polyisocyanate in the presence of unreacted furfuryl alcohol. Processes are provided for preparing the aforementioned novel liquid prepolymers and solid or cellular interpolymers.