US3885010A — Process and apparatus for the continuous manufact…

Claim 1

Independent Claim 131 words

IN A PROCESS FOR THE CONTINUOUS MANUFACTURE OF PHENOLIC RESIN FOAM IN AN ENDLESS SHEET BY MIXING A LIQUID PHENOLIC RESIN WITH A BLOWING AGENT AND AN ACID-CONTAINING CURING AGENT AND BY PROCESSING OF THE MIXTURE IN A TEMPERATURE-CONTROLLABLE DOUBLE BELT PRESS, THE IMLPROVEMENT WHICH COMLRISES COOLING THE LIQUID PHENOLIC RESIN TO A TEMPERATURE OF FROM ABOUT 8* TO ABOUT 15*C., ADMIXING A BLOWING AGENT UNDER A HIGH PRESSURE WITH SAID RESIN TO FORM A RESIN PREMIX, MIXING SAID RESIN PREMIX WITH A CURING AGENT TO FORM A CURABLE REACTION MIXTURE, CONTINUOUSLY APPLYING SAID MIXTURE UNIFORMLY ONTO A MOVING SUBSTRATE, COVERING THE MIXTURE ON SAID SUBSTRATE WITH A CONTINUOUS PROTECTIVE LAYER, PASSING THE COVERED MIXTURE IN THE DOUBLE BELT PRESS, AND FOAMING THE MIXTURE UNDER PRESSURE UNTIL SAID SHEET IS FORMED.

Claim 2

Dependent Claim 131 words

IN A PROCESS FOR THE CONTINUOUS MANUFACTURE OF PHENOLIC RESIN FOAM IN AN ENDLESS SHEET BY MIXING A LIQUID PHENOLIC RESIN WITH A BLOWING AGENT AND AN ACID-CONTAINING CURING AGENT AND BY PROCESSING OF THE MIXTURE IN A TEMPERATURE-CONTROLLABLE DOUBLE BELT PRESS, THE IMLPROVEMENT WHICH COMLRISES COOLING THE LIQUID PHENOLIC RESIN TO A TEMPERATURE OF FROM ABOUT 8* TO ABOUT 15*C., ADMIXING A BLOWING AGENT UNDER A HIGH PRESSURE WITH SAID RESIN TO FORM A RESIN PREMIX, MIXING SAID RESIN PREMIX WITH A CURING AGENT TO FORM A CURABLE REACTION MIXTURE, CONTINUOUSLY APPLYING SAID MIXTURE UNIFORMLY ONTO A MOVING SUBSTRATE, COVERING THE MIXTURE ON SAID SUBSTRATE WITH A CONTINUOUS PROTECTIVE LAYER, PASSING THE COVERED MIXTURE IN THE DOUBLE BELT PRESS, AND FOAMING THE MIXTURE UNDER PRESSURE UNTIL SAID SHEET IS FORMED.

Claim 3

Dependent Claim 36 words

The process of claim 1, wherein the phenolic resin is mixed with the blowing agent in a first premixing chamber and thereafter is further intermixed in a second premixing chamber with simultaneous cooling of the mixture.

Claim 4

Dependent Claim 34 words

The process of claim 1, wherein the substrate and cover layer contacting phenolic resin foam are treated, immediately prior to coming into contact with the curable reaction mixture, with an adhesive or release agent.

Claim 5

Dependent Claim 32 words

The process of claim 1, wherein the blowing pressure of the foam during foaming is maintained to within a predetermined pressure range by varying the sheet thickness of the foaming reaction mixture.

Claim 6

Dependent Claim 18 words

The process of claim 4, wherein the blowing pressure is from about 0.1 to about 0.3 atmosphere gauge.

Claim 7

Dependent Claim 22 words

Process of claim 1, wherein the substrate and the top Cover layer surround the expanded sheet on all sides of the foam.

Claim 8

Dependent Claim 20 words

The process of claim 6, wherein the top cover layer is disposed within a U-shaped channel formed by the substrate.

Claim 9

Dependent Claim 154 words

A process for the continuous production of phenolic resin foam in endless sheets comprising cooling a liquid phenolic resin to 8* to 15*C, mixing the thus cooled liquid phenolic resin with a blowing agent to form a premix, mixing a curing agent for the phenolic resin with said premix to form an expandable and hardenable liquid phenolic reaction mixture, continuously applying said liquid phenolic reaction mixture onto a continuously moving lower cover layer from a nozzle reciprocating transversely to the direction of movement of said lower cover layer, covering the reaction mixture on said lower cover layer with an upper cover layer, passing the covered mixture between the belts of a double belt press, and heating the covered mixture while between the belts of said double belt press so that said reaction mixture is foamed under pressure and at least partially cured whereby a phenolic resin foam sheet having a predetermined thickness is formed.

Claim 10

Dependent Claim 154 words

A process for the continuous production of phenolic resin foam in endless sheets comprising cooling a liquid phenolic resin to 8* to 15*C, mixing the thus cooled liquid phenolic resin with a blowing agent to form a premix, mixing a curing agent for the phenolic resin with said premix to form an expandable and hardenable liquid phenolic reaction mixture, continuously applying said liquid phenolic reaction mixture onto a continuously moving lower cover layer from a nozzle reciprocating transversely to the direction of movement of said lower cover layer, covering the reaction mixture on said lower cover layer with an upper cover layer, passing the covered mixture between the belts of a double belt press, and heating the covered mixture while between the belts of said double belt press so that said reaction mixture is foamed under pressure and at least partially cured whereby a phenolic resin foam sheet having a predetermined thickness is formed.

Claim 11

Dependent Claim 25 words

The process according to claim 8, wherein modifiers or fillers are added to the liquid phenolic resin simultaneously with the addition of the curing agent.

Claim 12

Dependent Claim 54 words

The process according to claim 8, wherein said lower cover layer is bent upwardly in a U-shape so that said lower cover layer defines upwardly extending edges on each lateral side thereof, said process further comprising inwardly bending the ends of said upwardly extending edges about the lateral edges of said upper cover layer.

Claim 13

Dependent Claim 43 words

The process according to claim 8, wherein the blowing pressure of said reaction mixture as it foams is maintained to within a predetermined range by controlling the distance between the belts in said double belt press and hence the thickness of said sheet.

Claim 14

Dependent Claim 41 words

The process according to claim 11, wherein the blowing pressure of said reaction mixture during foaming is maintained between about 0.1 and 0.3 atmosphere gauge by controlling the thickness of the sheet produced with the belts of said double belt press.

Claim 15

Dependent Claim 22 words

The process according to claim 8, wherein said covered mixture is heated in said double belt press by means of hot air.

Claim 16

Dependent Claim 33 words

The process according to claim 13, wherein the temperature of said hot air is maintained such that the temperatures of the belts in said double belt press are between about 50* to 80*C.

Claim 17

Dependent Claim 27 words

The process according to claim 8, wherein said blowing agent is fed to said liquid phenolic resin at a pressure sufficiently high so that it is atomized.

Claim 18

Dependent Claim 25 words

The process according to claim 15, wherein said blowing agent is fed to said liquid phenolic resin at a pressure of about 50 atmospheres gauge.

Claim 19

Dependent Claim 29 words

The process according to claim 8, wherein said blowing agent and said liquid phenolic resin are mixed in a chamber cooled to a temperature of about +4*C to -4*C.

Claim 20

Dependent Claim 33 words

The process according to claim 8, wherein said blowing agent is mixed with said liquid phenolic resin in two pre-mixing chambers, at least one chamber being cooled to between about +4*C and -4*C.

Claim 21

Dependent Claim 21 words

The process according to claim 8, wherein said blowing agent is homogeneously mixed with said liquid phenolic resin in a chamber.

Claim 22

Dependent Claim 15 words

The process according to claim 8, wherein said reaction mixture further includes modifiers or fillers.

Claim 23

Dependent Claim 28 words

The process according to claim 8, wherein said reaction mixture after being deposited on said lower cover layer is uniformly distributed thereon by means of a guide roll.

Claim 24

Dependent Claim 17 words

The process according to claim 21, wherein said upper cover layer is guided by said guide roll.

Claim 25

Dependent Claim 28 words

The process according to claim 8, wherein the temperature of said reaction mixture is no more than about 30*C as it is applied to said lower cover layer.

Claim 26

Dependent Claim 26 words

The process according to claim 23, wherein said reaction mixture is maintained between about 28* and 30*C as it is applied to said lower cover layer.

Claim 27

Dependent Claim 21 words

The process according to claim 8, wherein the weight flow rate of the reaction mixture is about 1 to 5 kg/min.

Claim 28

Dependent Claim 23 words

The process according to claim 8, further comprising forming grooves in the phenolic resin foam sheet passing out of the double belt press.

Claim 29

Dependent Claim 28 words

The process according to claim 8, wherein the phenolic resin foam sheet passing out of said double belt press has a thickness of at least about 20 min.

Claim 30

Dependent Claim 21 words

The process according to claim 27, wherein the phenolic resin foam sheet has a thickness of about 20 to 100 mm.

Claim 31

Dependent Claim 91 words

In a process for the continuous production of a phenolic resin foam in endless sheet form by continuously feeding a mixture of a liquid phenolic resin, a blowing agent and an acid-containing curing agent between the belts of a double belt press and heating the mixture while in said press to cause the mixture to foam and cure between the belts in said press, the improvement comprising cooling said liquid phenolic resin to a temperature of between about 8* to 15*C prior to mixing with the blowing agent and curing agent.

Claim 32

Dependent Claim 91 words

In a process for the continuous production of a phenolic resin foam in endless sheet form by continuously feeding a mixture of a liquid phenolic resin, a blowing agent and an acid-containing curing agent between the belts of a double belt press and heating the mixture while in said press to cause the mixture to foam and cure between the belts in said press, the improvement comprising cooling said liquid phenolic resin to a temperature of between about 8* to 15*C prior to mixing with the blowing agent and curing agent.

Claim 33

Dependent Claim 180 words

In a process for the continuous production of phenolic resin foam in endless sheet form by mixing a liquid phenolic resin with the blowing agent and subsequently with the acid-containing curing agent, feeding the mixture so obtained in a transversely reciprocating manner between the belts of a double belt press, and continuously foaming and curing the mixture as it travels through said press, the improvement comprising cooling said liquid phenolic resin to a temperature of about 8* to 15*C prior to admixture with said blowing agent, continuously applying said mixture in a transversely reciprocating manner onto a lower cover layer having a U-shaped cross section and defining upwardly extending lateral edges, applying an upper cover layer to the mixture on said lower cover layer in such a way that said mixture uniformly distributed on said lower cover layer, bending the ends of the upwardly extending edges of the lower U-shaped cover layer inwardly about the lateral edges of the upper cover layer, and maintaining the foaming pressure of the mixture as it vertically foams to within a predetermined pressure range.

Claim 34

Dependent Claim 180 words

In a process for the continuous production of phenolic resin foam in endless sheet form by mixing a liquid phenolic resin with the blowing agent and subsequently with the acid-containing curing agent, feeding the mixture so obtained in a transversely reciprocating manner between the belts of a double belt press, and continuously foaming and curing the mixture as it travels through said press, the improvement comprising cooling said liquid phenolic resin to a temperature of about 8* to 15*C prior to admixture with said blowing agent, continuously applying said mixture in a transversely reciprocating manner onto a lower cover layer having a U-shaped cross section and defining upwardly extending lateral edges, applying an upper cover layer to the mixture on said lower cover layer in such a way that said mixture uniformly distributed on said lower cover layer, bending the ends of the upwardly extending edges of the lower U-shaped cover layer inwardly about the lateral edges of the upper cover layer, and maintaining the foaming pressure of the mixture as it vertically foams to within a predetermined pressure range.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1978-05-19	1978-11-18	1979-05-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1982-05-19	1982-11-18	1983-05-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1986-05-19	1986-11-18	1987-05-20	$7700.00	Window Closed / Lapsed

Process and apparatus for the continuous manufacture of phenolic resin foam in endless sheets

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