US4119584A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Phenolic foam modified with phosphorus-containing isocyanate-terminated prepolymers
Assignee: Union Carbide Corp
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Filing: 1977-03-25
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Granted: 1978-10-10
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Expires: 1997-03-25
Abstract
Abstract This invention provides a low density (<2 pcf.) modified phenolic foam produced by combining a resole resin with a phosphorus-containing isocyanate-terminated prepolymer in the presence of a minor amount of a surfactant, a catalytic amount of an organotin catalyst, and a halocarbon blowing agent. Foam products producted by the method of the invention have a good combination of low combustibility, friability resistance and compressive strength.
Inventors
- 👤 Anthony Joseph Papa
- 👤 Richard Lee Rollins
- 👤 Frank Edward Critchfield
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 02:16
CPC Classifications
C; C08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/54; C08G18/542; C08G18/08; C08G18/10; C08G18/48; C08G18/50; C08G18/5075; C08G18/5081; C08G18/5084; C08G2110/00; C08G2110/0025; C08G2110/0041; C08G2110/005
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
130 words
A process for producing a rigid phenolic foam having a density of up to about 2 pcf. which comprises forming and curing a reaction mixture containing: (a) a liquid phenol-aldehyde resole having a viscosity from 200 to 500,000 centipoises at 25° C., (b) from 35 to 75 parts by weight of a phosphorus-containing isocyanate terminated prepolymer per hundred parts of said resole and said isocyanate terminated prepolymer, (c) a catalytic amount of an organotin catalyst for the curing of the reaction mixture to produce the elastomer, (d) from 0.5 to 5.0 parts by weight of a surface active agent per hundred parts by weight of said resole and said isocyanate terminated prepolymer, and (e) a halocarbon blowing agent in an amount sufficient to produce a cellular structure in the foam.
Claim 2
Dependent Claim
130 words
A process for producing a rigid phenolic foam having a density of up to about 2 pcf. which comprises forming and curing a reaction mixture containing: (a) a liquid phenol-aldehyde resole having a viscosity from 200 to 500,000 centipoises at 25° C., (b) from 35 to 75 parts by weight of a phosphorus-containing isocyanate terminated prepolymer per hundred parts of said resole and said isocyanate terminated prepolymer, (c) a catalytic amount of an organotin catalyst for the curing of the reaction mixture to produce the elastomer, (d) from 0.5 to 5.0 parts by weight of a surface active agent per hundred parts by weight of said resole and said isocyanate terminated prepolymer, and (e) a halocarbon blowing agent in an amount sufficient to produce a cellular structure in the foam.
Claim 3
Dependent Claim
9 words
A foam produced by the process of claim 1.
Claim 4
Dependent Claim
14 words
The process as claimed in claim 1 wherein the organotin catalyst is dibutyltin dilaurate.
Claim 5
Dependent Claim
9 words
A foam produced by the process of claim 3.
Claim 6
Dependent Claim
15 words
The process as claimed in claim 1 wherein the halocarbon blowing agent is a chlorofluorocarbon.
Claim 7
Dependent Claim
9 words
A foam produced by the process of claim 5.
Claim 8
Dependent Claim
14 words
The process as claimed in claim 1 wherein the halocarbon blowing agent is trichloro-monofluoromethane.
Claim 9
Dependent Claim
9 words
A foam produced by the process of claim 7.
Claim 10
Dependent Claim
14 words
The process as claimed in claim 1 wherein the halocarbon blowing agent is 1,1,2-trichloro-1,2,2-trifluoroethane.
Claim 11
Dependent Claim
9 words
A foam produced by the process of claim 9.
Claim 12
Dependent Claim
36 words
The process as claimed in claim 1 wherein there is also present 0.05 to 1.0 parts by weight of an acyl chloride inhibitor per 100 parts by weight of said resole and said isocyanate terminated prepolymer.
Claim 13
Dependent Claim
9 words
A foam produced by the process of claim 11.
Claim 14
Dependent Claim
13 words
The process as claimed in claim 11 wherein the inhibitor is benzoyl chloride.
Claim 15
Dependent Claim
9 words
A foam produced by the process of claim 13.
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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) | 1981-10-09 | 1982-04-10 | 1982-10-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-10-09 | 1986-04-10 | 1986-10-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-10-09 | 1990-04-10 | 1990-10-10 | $7700.00 | Window Closed / Lapsed |