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    • 9. 发明授权
    • Closed cell phenolic foam
    • 闭孔酚醛泡沫
    • US4576972A
    • 1986-03-18
    • US760050
    • 1985-07-29
    • James LuntEdwin J. MacPhersonPaul J. Meunier
    • James LuntEdwin J. MacPhersonPaul J. Meunier
    • C08G8/24C08G14/08C08J9/14
    • C08J9/147C08G14/08C08G8/24C08J2361/34
    • 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 1:4.5 and containing substantially no free phenol but including residual formaldehyde;(2) neutralizing, concentrating and acidifying said resole;(3) reacting with co-reactants consisting essentially of urea and resorcinol in an amount such that the molar ratio of combined urea and resorcinol to free formaldehyde in said resole is about 1:1, the ratio of urea to formaldehyde being selected so that in a test starting at ambient temperature a reaction temperature of 70.degree. to 75.degree. C. is reached during foaming within a period of 4 to 8 minutes, the urea being reacted first where urea and resorcinol are separately reacted with the resole;(4) (a) combining the product of step 3 with a surfactant in an amount sufficient to be effective as a cell stabilizer and(b) a blowing agent in an amount sufficient to form a foam;(5) initiating foam formation by adding to the mixture of step 4 a catalyst comprising an acidic material to reduce the pH of the mixture to below 4;(6) curing the mixture of step 5.
    • 本发明涉及从酚醛树脂和如此生产的泡沫制造泡沫。 为了克服现有技术的闭孔酚醛泡沫的一些限制,我们开发了一种由改性的低成本酚甲醛树脂制备闭孔泡沫的方法,其具有高闭孔含量,低脆性和低热导率。 本说明书提供与聚氨酯泡沫体竞争的泡沫体,其具有约0.16K的老化热导率。 或更少,但不会产生像聚氨酯那样有毒的烟雾。 提供了一种制备酚醛泡沫材料的方法,其包括以下步骤:(1)制备苯酚与甲醛的摩尔比在1:3至1:4.5之间的基本催化的苯酚 - 甲醛甲阶酚醛树脂,并且基本上不含游离酚 但包括残留甲醛; (2)中和,浓缩和酸化所述甲阶酚醛树脂; (3)与基本上由尿素和间苯二酚组成的共反应物反应,其量使得所述甲阶酚醛和间苯二酚与游离甲醛的摩尔比为约1:1,选择尿素与甲醛的比例使得在 在环境温度下开始的试验是在4-8分钟的发泡期间达到70〜75℃的反应温度,尿素首先反应,尿素和间苯二酚分别与甲阶酚醛反应; (4)(a)将步骤3的产物与足够有效作为细胞稳定剂的量的表面活性剂组合,和(b)足以形成泡沫的量的发泡剂; (5)通过向步骤4的混合物中加入包含酸性物质的催化剂以将混合物的pH降低至4以下来开始泡沫形成; (6)固化步骤5的混合物。