Phenolic foam

Claim 1

A RIGID RESOLE PHENOLIC FOAM WHICH IS NON-CORROSIVE, FREE FROM PUNKING, NON-FRIABLE AND OF UNIFORM AND STRONG CELL STRUCTURE WITH A DENSITY OF UP TO ABOUT 1.5 LBS/FT3, SAID FOAM BEING OBTAINED BY FOAMING AND CURING AT A TEMPERATURE BELOW 90*F, A REACTION MIXTURE EXPRESSED ON THE BASIS OF WEIGHT PERCENTAGES OF THE REACTION MIXTURE CONSISTING OF FROM ABOUT 15% TO ABOUT 55% OF A RESOLE RESIN; FROM ABOUT 6% TO ABOUT 20% OF AN ALKYLENE GLYCOL SELECTED FROM THE GROUP CONSISTING OF ETHYLENE GLYCOL, BUTYLENE GLYCOL, PROPYLENE GLYCOL, DIETHYLENE GLYCOL AND DIPROYLENE GLYCOL; FROM ABOUT 3% TO ABOUT 25% OF A HALO-ORGANIC PHOSPHATE PLASTICIZER-FLAME RETARDANT WHICH HAS A BOILING POINT ABOVE THE REACTION TEMPERATURE AND A HALOGEN/CARBON RATIO SUFFICIENTLY HIGH TO POSSESS FIRE RETARDANT PROPERTIES; FROM ABOUT 0.01% TO ABOUT 3% OF STANNOUS CHLORIDE OR NON-ACIDIC ORGANOTIN CATALYST; FROM ABOUT 0.01% TO ABOUT 20% OF A SURFACTANT; FROM ABOUT 30% TO ABOUT 60% OF A DIFUNCTIONAL DIISOCYANATE; AND FROM ABOUT 1% TO ABOUT 30% OF A BLOWING AGENT WHICH IS A HALOGENATED ALKANE HAVING 1 TO 3 CARBON ATOMS AND A BOILING POINT BELOW 90*F.

Claim 5

A method of making a rigid resole phenolic foam which is non-corrosive, free from punking, non-friable and of uniform and strong cell structure with a density of up to about 1.5 lbs/ft3, said method comprising: first, mixing a reaction mixture expressed on the basis of weight percentages of the reaction mixture comprising from about 15% to about 55% of a resole resin; from about 6% to about 20% of an alkylene glycol selected from the group consisting of ethylene glycol, butylene glycol, propylene glycol, diethylene glycol and dipropylene glycol; from about 3% to about 25% of a halo-organic phosphate plasticizerflame retardant which has a boiling point above the reaction temperature and a halogen/carbon ratio sufficiently high to possess fire retardant properties; from about 0.01% to about 3% of stannous chloride or non-acidic organotin catalyst; from about 0.01% to about 20% of a surfactant; from about 30% to about 60% of a difunctional isocyanate; and from about 1% to about 30% of a blowing agent which is halogenated alkane having 1 to 3 carbon atoms and a boiling point below 90*F, and allowing the mixture to foam and cure at a temperature below 90*F.

Claim 6

A method of making a rigid resole phenolic foam which is non-corrosive, free from punking, non-friable and of uniform and strong cell structure with a density of up to about 1.5 lbs/ft3, said method comprising: first, mixing a reaction mixture expressed on the basis of weight percentages of the reaction mixture comprising from about 15% to about 55% of a resole resin; from about 6% to about 20% of an alkylene glycol selected from the group consisting of ethylene glycol, butylene glycol, propylene glycol, diethylene glycol and dipropylene glycol; from about 3% to about 25% of a halo-organic phosphate plasticizerflame retardant which has a boiling point above the reaction temperature and a halogen/carbon ratio sufficiently high to possess fire retardant properties; from about 0.01% to about 3% of stannous chloride or non-acidic organotin catalyst; from about 0.01% to about 20% of a surfactant; from about 30% to about 60% of a difunctional isocyanate; and from about 1% to about 30% of a blowing agent which is halogenated alkane having 1 to 3 carbon atoms and a boiling point below 90*F, and allowing the mixture to foam and cure at a temperature below 90*F.