In-place expanded cellular resinous bodies and processes for producing them from phenol-aldehyde resins with the aid of a peroxide

Claim 1

THE METHOD OF PREPARING A THERMOSET CELLULAR RESINOUS BODY COMPRISING ADMIXING AS ESSENTIAL REACTIVE INGREDIENTS (A) BETWEEN 50% AND 90% BY WEIGHT OF A THERMOSETTING PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOLE OF AT LEAST ONE PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND BETWEEN 1 AND 3 MOLES OF AT LEAST ONE ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, REACTIVE POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENETETRAMINE, AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% BASED ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AND AT A TEMPERATURE OF BETWEEN 50* C. AND 115* C. FOR A TIME OF BETWEEN 1/2 HOUR AND 20 HOURS, AND DEHYDRATING THE REACTION PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5% AND 0.1% BY WEIGHT OF AT LEAST ONE ACID STABLE, WATER SOLUBLE, SURFACE ACTIVE AGENT SELECTED FROM THE GROUP CONSISTING OF NON-IONIC ALKYL POLYETHERS WHEREIN THE ALKYL GROUPS CONTAIN FROM 8 TO 18 CARBON ATOMS, (C) A PERIOXIDE SOLUTION SELECTED FROM THE GROUP CONSISTING OF AN AQUEOUS SOLUTION OF HYDROGEN PEROXIDE OF A CONCENTRATION OF FROM 20% TO 90% H2O2 AND A SOLUTION CONTAINING FROM 40% TO 80% OF METHYL ETHYL KETONE PEROXIDE IN AN ORGANIC SOLVENT, THE PEROXIDE SOLUTION BEING IN AN AMOUNT PROVIDING FREE OXYGEN EQUAL TO THAT AVAILABLE IN FROM 1% TO 20% BY WEIGHT OF 100% H2O2, AND (D) APPROXIMATELY 49% TO 2% BY WEIGHT, OF AT LEAST ONE STRONG ACID SELECTED FROM THE GROUP CONSISTING OF HYDROCHLORIC ACID, SULFURIC ACID, NITRIC ACID, PHOSPHORIC ACID, PYROPHOSPHORIC ACID, POLYPHOSPHORIC ACID, WATER-SOLUBLE SULFONIC ACIDS, HYDROBROMIC ACID, HYDRIODIC ACID AND TRICHLORACETIC ACID, THE ACID COMPRISING NOT OVER 80% BY WEIGHT OF WATER, AND ALLOWING THE RESULTING MIXTURE TO EXPAND TO PRODUCE A THERMOSET CELLULAR BODY.

Claim 2

THE METHOD OF PREPARING A THERMOSET CELLULAR RESINOUS BODY COMPRISING ADMIXING AS ESSENTIAL REACTIVE INGREDIENTS (A) BETWEEN 50% AND 90% BY WEIGHT OF A THERMOSETTING PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOLE OF AT LEAST ONE PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND BETWEEN 1 AND 3 MOLES OF AT LEAST ONE ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, REACTIVE POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENETETRAMINE, AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% BASED ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AND AT A TEMPERATURE OF BETWEEN 50* C. AND 115* C. FOR A TIME OF BETWEEN 1/2 HOUR AND 20 HOURS, AND DEHYDRATING THE REACTION PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5% AND 0.1% BY WEIGHT OF AT LEAST ONE ACID STABLE, WATER SOLUBLE, SURFACE ACTIVE AGENT SELECTED FROM THE GROUP CONSISTING OF NON-IONIC ALKYL POLYETHERS WHEREIN THE ALKYL GROUPS CONTAIN FROM 8 TO 18 CARBON ATOMS, (C) A PERIOXIDE SOLUTION SELECTED FROM THE GROUP CONSISTING OF AN AQUEOUS SOLUTION OF HYDROGEN PEROXIDE OF A CONCENTRATION OF FROM 20% TO 90% H2O2 AND A SOLUTION CONTAINING FROM 40% TO 80% OF METHYL ETHYL KETONE PEROXIDE IN AN ORGANIC SOLVENT, THE PEROXIDE SOLUTION BEING IN AN AMOUNT PROVIDING FREE OXYGEN EQUAL TO THAT AVAILABLE IN FROM 1% TO 20% BY WEIGHT OF 100% H2O2, AND (D) APPROXIMATELY 49% TO 2% BY WEIGHT, OF AT LEAST ONE STRONG ACID SELECTED FROM THE GROUP CONSISTING OF HYDROCHLORIC ACID, SULFURIC ACID, NITRIC ACID, PHOSPHORIC ACID, PYROPHOSPHORIC ACID, POLYPHOSPHORIC ACID, WATER-SOLUBLE SULFONIC ACIDS, HYDROBROMIC ACID, HYDRIODIC ACID AND TRICHLORACETIC ACID, THE ACID COMPRISING NOT OVER 80% BY WEIGHT OF WATER, AND ALLOWING THE RESULTING MIXTURE TO EXPAND TO PRODUCE A THERMOSET CELLULAR BODY.