Porous resin composition and method of using and preparing same

Claim 1

A PROCESS FOR THE MANUFACTURING OF OVERALL LIGHT DENSITY, HIGH STRENGTH FILLING MATERIAL COMPRISING BLENDING TOGRTHER AN EXPANDABLE MATERIAL COMPRISING 5 TO 25% BY WEIGHT OF PELLETS OF A RESINOUS MATERIAL SELECTED FROM THE GROUP CONSISTING OF PHENOL-ALDEHYDE RESINS, NATURAL RUBBER, BUTADIENE-ACRYLONITRILE COPOLYMERS AND CHLOROPRENE POLYMERS CONTAINING A NORMALLY SOLID AGENT DECOMPOSABLE AT ELEVATED TEMPERATURES TO RELEASE NITROGEN GAS, 95 TO 75% OF A MATRIX COMPRISING 20 TO 95% OF SHORT FIBERS OF AN ORGANIC POLYMER SELECTED FROM THE GROUP CONSISTING OF POLYHEXAMETHYLENE ADIPAMIDE, CELLULOSE ACETATE, POLYACRYLONTRILE, A POLYESTER WHICH IS THE REACTION PRODUCE OF TEREPHTHALIC ACID AND ETHYLENE GLYCOL, AND MIXTURES OF THE FOREGOING AND FROM 80 TO 5% OF A DRY PARTICULATE RESINOUS CEMENTING AGENT SELECTED FROM THE GROUP CONSISTING OF AN EPOXY RESIN WHICH IS THE REACTION PRODUCT OF BIS-PHENOL AND EPIHALOHYDRIN, PHENOLALDEHYDE RESINS, POLYHEXAMETHYLENE ADIPAMIDE AND MIXTURES OF THE FOREGOING SAID CEMENTING AGENT HAVING A LOWER MELTING POINT THAN THE SHORT ORGANIC POLYMER FIBERS AND NOT HIGHER THAN THE TEMPERATURE AT WHICH THE EXPANDING AGENT IS ACTIVATED, HEATING SAID BLENDED MIXTURE OF PELLETS AND MATRIX TO A TEMPERATURE WHEREBY THE CEMENTING AGENT MELTS AND THE DECOMPOSABLE AGENT IN THE EXPANDABLE MATERIAL GASIFIED CAUSING EXPANSION OF SAID EXPANDABLE MATERIAL WHICH IN TURN CAUSES THE MATRIX TO BE COMPACTED TO FORM A DISPERSE PHASE OF LOW DENSITY, LOW MODULUS EXPANDED RESINOUS MATERIAL WITHIN A HIGH MODULUS, HIGH STRENGTH COMPACTED MATRIX OF SAID FIBERS AND CEMENTING AGENT.