Patent US4071481A successfully refreshed from Google Patents.
US4071481A
Expired / Lapsed
US
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Manufacture of phenolic foam
Assignee: Saint Gobain Industries SA
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Filing: 1975-07-11
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Granted: 1978-01-31
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Expires: 1995-07-11
Abstract
Abstract Phenolic foams, mixtures for producing phenolic foams, and processes of manufacturing phenolic foams are disclosed. The resin utilized is a base catalyzed polycondensation product of phenol and formaldehyde which is obtained in a solid, reactive, fusible, substantially anhydrous state. The resin is foamed and hardened by the application of heat without the use of a catalyst. Heat sensitive blowing agents, either in liquid form or in particulate form may be mixed with the resin prior to heating. Surfactants and lubricants may be utilized to enhance the uniformity of the voids in the foam. The resulting foams are non-acidic, are resistant to color changes, and are substantially anhydrous.
Inventors
- 👤 Daniel Hanton
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 22:49
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; C08J9/14; C08J9/142; C08J9/06; C08J9/10; C08J2361/00; C08J2361/04; C08J2361/06
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
68 words
A foamable phenolic resin mixture stable at room temperature from which cured and set foamed articles may be formed by heating alone in the absence of the addition of an agent for setting the resin, comprising a solid, reactive, heat-fusible water-insoluble phenolic resol resin of the resol type in particulate form, a blowing agent, and a surfactant, said mixture being devoid of any agent for setting the resin.
Claim 2
Dependent Claim
68 words
A foamable phenolic resin mixture stable at room temperature from which cured and set foamed articles may be formed by heating alone in the absence of the addition of an agent for setting the resin, comprising a solid, reactive, heat-fusible water-insoluble phenolic resol resin of the resol type in particulate form, a blowing agent, and a surfactant, said mixture being devoid of any agent for setting the resin.
Claim 3
Dependent Claim
18 words
A mixture as in claim 1 wherein the blowing agent is a liquid that vaporizes above 100° C.
Claim 4
Dependent Claim
13 words
A mixture as in claim 2 wherein the blowing agent is an alcohol.
Claim 5
Dependent Claim
27 words
A mixture as in claim 3 wherein the alcohol is of the group consisting of pentanol-1, pentanol-2, pentanol-3, 3-methyl butanol-1, hexanol-1, hexanol-2, 2-methyl hexanol-2, heptanol-2, 2-methyl butanol-2.
Claim 6
Dependent Claim
13 words
A mixture as in claim 2 wherein the blowing agent is a ketone.
Claim 7
Dependent Claim
25 words
A mixture as in claim 5 wherein the ketone is of the group consisting of pentanone-2, 2, 4-dimethyl pentanone-3, hexanone-5 methyl, heptanone-3, or 4-methyl pentanone-2.
Claim 8
Dependent Claim
26 words
A mixture as in claim 1 wherein the blowing agent is a solid in a particulate state which releases nitrogen at temperatures greater than 100° C.
Claim 9
Dependent Claim
29 words
A mixture as in claim 7 wherein the blowing agent releases nitrogen and is of the group comprising nitrogenized or sulfurized solids having azo or nitroso groups and sulfonylhydrazide.
Claim 10
Dependent Claim
11 words
A mixture as in claim 8 which further comprises a lubricant.
Claim 11
Dependent Claim
22 words
A mixture as in claim 1 wherein the surfactant comprises a compound including a polyoxyalkylene chain and an aliphatic or organosilicic chain.
Claim 12
Dependent Claim
27 words
A mixture as in claim 10 wherein the surfactant is of the group consisting of polyethylsorbitol laurate, nonylphenolpolyoxyethylene, and copolymeric silicone oils of diakylsilicones and alkylene oxides.
Claim 13
Dependent Claim
16 words
A mixture as in claim 1 and further comprising a lubricant uniformly distributed throughout the resin.
Claim 14
Dependent Claim
25 words
A mixture as in claim 12 wherein the lubricant is of the group consisting of stearic acid, stearates of heavy metals, and fatty acid amides.
Claim 15
Dependent Claim
26 words
A mixture as in claim 1 wherein the resin is in the form of beads, the beads being coated with the blowing agent and the surfactant.
Claim 16
Dependent Claim
17 words
A mixture as in claim 14 wherein the coating on the resin beads further includes a lubricant.
Claim 17
Dependent Claim
25 words
The composition as in claim 1 wherein the blowing agent is present in the ratio of about 0.5 to 5% by weight of the resin.
Claim 18
Dependent Claim
24 words
The composition as in claim 1 wherein the surfactant is present in the ratio of about 0.2 to 2% by weight of the resin.
Claim 19
Dependent Claim
23 words
The composition as in claim 9 wherein the lubricant is present in the ratio of about 0.5 to 2% by weight of resin.
Claim 20
Dependent Claim
109 words
A process for producing an intermediate phenolic resin product expandable upon the application of heat alone in the absence of an agent for setting the resin, comprising forming a solid, heat-fusible, reactive, water-insoluble phenolic resol resin in a particulate and substantially anhydrous state by the condensation of from 1 to 3.1 moles of an aldehyde with one mole of a phenol in the presence of a basic catalyst, a fusibility agent, a dispersant and a protective colloid, drying said particulate phenolic resin, and thereafter uniformly mixing a blowing agent with the phenolic resin particles, said expandable product being produced in the absence of any agent for setting the resin.
Claim 21
Dependent Claim
109 words
A process for producing an intermediate phenolic resin product expandable upon the application of heat alone in the absence of an agent for setting the resin, comprising forming a solid, heat-fusible, reactive, water-insoluble phenolic resol resin in a particulate and substantially anhydrous state by the condensation of from 1 to 3.1 moles of an aldehyde with one mole of a phenol in the presence of a basic catalyst, a fusibility agent, a dispersant and a protective colloid, drying said particulate phenolic resin, and thereafter uniformly mixing a blowing agent with the phenolic resin particles, said expandable product being produced in the absence of any agent for setting the resin.
Claim 22
Dependent Claim
16 words
A process as in claim 19 which further comprises adding a surfactant to the particulate resin.
Claim 23
Dependent Claim
16 words
A process as in claim 19 which further comprises adding a lubricant to the particulate resin.
Claim 24
Dependent Claim
20 words
A process as in claim 21 wherein the particulate resin, the blowing agent, surfactant and lubricant are simultaneously mixed together.
Claim 25
Dependent Claim
20 words
A process as in claim 19 wherein the resin and blowing agent are mixed at approximately 50° to 80° C.
Claim 26
Dependent Claim
21 words
A process as in claim 23 wherein the mixture is brought to a temperature of between about 65° to 90° C.
Claim 27
Dependent Claim
16 words
A process as in claim 22 wherein the phenolic resin is in the form of beads.
Claim 28
Dependent Claim
16 words
A process as in claim 22 wherein the phenolic resin is in the form of powder.
Claim 29
Dependent Claim
16 words
A process as in claim 19 wherein the blowing agent is a solid in particulate form.
Claim 30
Dependent Claim
14 words
A process as in claim 19 wherein the blowing agent is in liquid form.
Claim 31
Dependent Claim
41 words
A process for producing a foamable article comprising, mixing a fusible, reactive, particulate, phenolic resin of the resol type and a blowing agent, and shaping the mixture to a desired shape in the absence of any agent for setting the resin.
Claim 32
Dependent Claim
41 words
A process for producing a foamable article comprising, mixing a fusible, reactive, particulate, phenolic resin of the resol type and a blowing agent, and shaping the mixture to a desired shape in the absence of any agent for setting the resin.
Claim 33
Dependent Claim
19 words
A process as in claim 29 wherein the shaping step includes extruding the mixture of resin and blowing agent.
Claim 34
Dependent Claim
20 words
A process as in claim 30 wherein the extruded mixture of resin and blowing agent is pressed between cooled rollers.
Claim 35
Dependent Claim
33 words
A process as in claim 31 wherein the extruded and pressed resin is heated in an oven to expand and set the resin in the absence of an agent for setting the resin.
Claim 36
Dependent Claim
37 words
A process as in claim 31 wherein the phenolic resin is introduced into a mold and the mold is subsequently heated to expand and set the resin in the absence of an agent for setting the resin.
Claim 37
Dependent Claim
65 words
An intermediate foamable product, stable at room temperatures, of phenolic resin, from which foamed articles can be formed by heating alone in the absence of an agent for setting the resin, comprising a shaped mass of a solid, reactive, heat-fusible, water-insoluble phenolic resol resin, a blowing agent and a surfactant dispersed throughout the resin, said product being devoid of any agent for setting the resin.
Claim 38
Dependent Claim
65 words
An intermediate foamable product, stable at room temperatures, of phenolic resin, from which foamed articles can be formed by heating alone in the absence of an agent for setting the resin, comprising a shaped mass of a solid, reactive, heat-fusible, water-insoluble phenolic resol resin, a blowing agent and a surfactant dispersed throughout the resin, said product being devoid of any agent for setting the resin.
Claim 39
Dependent Claim
17 words
A product as in claim 34 wherein the mass is in the form of an extruded strip.
Claim 40
Dependent Claim
17 words
A product as in claim 34 wherein the mass is in the form of a pressed strip.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-01-30 | 1981-08-01 | 1982-01-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-01-30 | 1985-08-01 | 1986-01-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-01-30 | 1989-08-01 | 1990-01-31 | $7700.00 | Window Closed / Lapsed |