Closed cell phenolic foam

Claim 2

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material comprising the reaction product of: A. phenolic-resin, B. a blowing agent, C. a surfactant characterized in that it is branched, non-ionic, has a hydroxyl value less than 50 and its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value are capped.

Claim 3

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR5## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR6## hydrogen, or a radical of Formula II of the attached drawings, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:30 to 1:2. C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant, said surfactant characterized in that it: a. is branched, b. is non-ionic, c. has a hydroxyl value less than 50, d. has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped.

Claim 4

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III of the attached drawings wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (c) x is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5, C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant characterized in that it a. is branched, b. is non-ionic, c. has a hydroxyl value less than 50, d. has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped.

Claim 5

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. phenolic-resin B. a blowing agent, and C. a surfactant that is characterized in that it: a. is branched, b. is non-ionic, c. has a hydroxyl value less than 30, d. has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped by a capping agent which forms an ester.

Claim 6

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR7## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR8## hydrogen, or a radical of Formula II of the attached drawings, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:30 to 1:2, C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a minor amount of a surfactant, said surfactant characterized in that it: (a) is branched, (b) is non-ionic, (c) has a hydroxyl value less than 30, and (d) has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped by a capping agent which forms an ester.

Claim 7

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III of the attached drawings wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (c) x is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5. C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a minor amount of a surfactant, said surfactant characterized in that it: (a) is branched, (b) is non-ionic, (c) has a hydroxyl value less than 30, and (d) has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped by a capping agent which forms an ester.

Claim 8

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. phenolic-resin B. a blowing agent, and C. a surfactant that a. is branched, is non-ionic, c. has a hydroxyl value less than 10, d. has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped with an acetate, e. is 0.05 to 10 weight percent of the foam.

Claim 9

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR9## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR10## hydrogen, or a radical of Formula II of the attached drawings, (d) The R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:30 to 1:2, C. a blowing agent, and D. a surfactant that: (a) is branched, (b) is non-ionic, (c) has a hydroxyl value less than 10, (d) has its hydroxyl groups which would otherwise give the surfactant a higher hydroxyl value capped with an acetate, (e) is 0.05 to 10 weight percent of the foam.

Claim 10

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III of the attached drawings wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (c) X is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, and B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5, C. 1:1 weight ratio of CFCl 3 /CF 2 Cl--CCl 2 F wherein its weight percent of the foam is from 5 to 20, D. catalyst of p-toluene sulfonic acid and xylene sulfonic acid and water wherein its weight percent of the foam is from 1 to 15, and E. a surfactant that: a. is branched, b. is non-ionic, c. has a hydroxyl value less than 10, d. has its groups which would otherwise give the surfactant a higher hydroxyl value capped with an acetate, e. is 0.1 to 6 weight percent of the foam, f. and wherein the CFCl 3 /CF 2 Cl--CCl 2 F is contained within the cells, and the process is practiced at atmospheric pressure and at a temperature between 10° and 50° C.

Claim 11

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material comprising the reaction product of: A. phenolic-resin B. a blowing agent, a surfactant which is a surfactant of Formula VI of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 100 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of alkyl, aryl, aralkyl, and alkaryl, (d) X is selected from the group consisting of ##STR11## (e) m is an integer from 1 to 100 inclusive, (f) n is an integer from 3 to 100 inclusive, (g) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 12

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material comprising the reaction product of: A. phenolic-resin B. a blowing agent, a surfactant which is a surfactant of Formula VI of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 100 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of alkyl, aryl, aralkyl, and alkaryl, (d) X is selected from the group consisting of ##STR11## (e) m is an integer from 1 to 100 inclusive, (f) n is an integer from 3 to 100 inclusive, (g) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 13

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR12## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR13## hydrogen, or a radical of Formula II of the attached drawings, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:20 to 1:2. C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant which is a surfactant of Formula VI of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 100 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of alkyl, aryl, aralkyl, and alkaryl, (d) X is selected from the group consisting of ##STR14## (e) m is an integer from 1 to 100 inclusive, (f) n is an integer from 3 to 100 inclusive, (g) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 14

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III of the attached drawings wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (c) x is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5. C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant which is a surfactant of Formula VI of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 100 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of alkyl, aryl, aralkyl, and alkaryl, (d) X is selected from the group consisting of ##STR15## (e) m is an integer from 1 to 100 inclusive, (f) n is an integer from 3 to 100 inclusive, (g) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 15

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. phenolic-resin B. a blowing agent, and C. a surfactant which is a surfactant of Formula IX of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 40 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of lower alkyl, phenyl, naphthyl, and benzyl, (d) m is an integer from 1 to 80 inclusive, (e) n is an integer from 3 to 40 inclusive, (f) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 16

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR16## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR17## hydrogen, or a radical of Formula II of the attached drawings, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:30 to 1:2, C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant which is a surfactant of Formula IX of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 40 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of lower alkyl, phenyl, naphthyl and benzyl, (d) m is an integer from 1 to 80 inclusive, (e) n is an integer from 3 to 40 inclusive, (f) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 17

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III of the attached drawings wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV of the attached drawings, (c) x is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, and B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5, C. a blowing agent in a minor amount sufficient to foam the reaction mixture, D. a surfactant which is a surfactant of Formula IX of the attached drawings wherein: (a) R 5 is an organic radical having 3 to 40 reactive groups, (b) the R 6 's are independently selected from the group consisting of hydrogen and methyl, (c) the R 7 's are independently selected from the group consisting of lower alkyl, phenyl, naphthyl and benzyl, (d) m is an integer from 1 to 80 inclusive, (e) n is an integer from 3 to 40 inclusive, (f) R 8 is independently selected from the group consisting of hydrogen, a copolymer of dialkylmaleate and N-vinyl pyrrolidone and a copolymer of dialkylmaleate and N-vinyl caprolactam wherein the alkyl of the maleate has 1 to 5 carbon atoms.

Claim 18

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. phenolic-resin, B. a blowing agent in a minor amount sufficient to foam the reaction mixture, C. a surfactant which surfactant is the reaction product of I. a polyoxyalkylene ether of Formula VIII of the attached drawings wherein: a. R 5 is an organic radical having 3 to 15 reactive groups, b. the R 6 's are independently selected from the group consisting of hydrogen and methyl, c. m is an integer from 1 to 80 inclusive, d. n is an integer from 3 to 15 inclusive, Ii. a compound selected from the group consisting of N-vinyl pyrrolidone and N-vinyl caprolactam, Iii. di-lower alkyl maleate, wherein II and III form R 8 , Iv. a capping agent selected from the group consisting of acetic acid, acetic anhydride, acetyl chloride and 3,5-dinitrobenzoyl chloride, so that the surfactant has a hydroxyl value less than 10.

Claim 19

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I of the attached drawings wherein: (a) R 1 is ##STR18## hydrogen, or a radical of Formula II of the attached drawings, (b) the R 2 's are independently selected from the group consisting of lower alkyl, phenyl, benzyl, halo, nitro and hydrogen, (c) the R 3 's are independently selected from the group consisting of ##STR19## hydrogen, or a radical of Formula II of the attached drawings, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, or furyl, (e) x is an integer from 2 to 10 inclusive, (f) the phenolic polymer has a molecular weight between 200 and 2000, B. a compound of Formula V of the attached drawings wherein the weight ratio of B:A is 1:30 to 1:2, C. a blowing agent in a minor amount sufficient to foam the reaction mixture, and D. a surfactant which surfactant is the reaction product of I. a polyoxyalkylene ether of Formula VIII of the attached drawings wherein: a. R 5 is an organic radical having 3 to 15 reactive groups, b. The R 6 's are independently selected from the group consisting of hydrogen and methyl, c. m is an integer from 1 to 80 inclusive, d. n is an integer from 3 to 15 inclusive, Ii. a compound selected from the group consisting of N-vinyl pyrrolidone and N-vinyl caprolactam, Iii. di-lower alkyl maleate, wherein II and III form R 8 , Iv. a capping agent selected from the group consisting of acetic acid, acetic anhydride, acetyl chloride and 3,5-dinitrobenzoyl chloride, so that the surfactant has a hydroxyl value less than 10.

Claim 20

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 10 comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV, (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen or a radical of Formula IV, (c) x is an integer from 3 to 6 inclusive, (d) the phenolic polymer has a molecular weight between 300 and 1500, and B. phenol, wherein the weight ratio of B:A is 1:20 to 1:5. C. a blowing agent in a minor amount sufficient to foam the reaction mixture, D. a surfactant which surfactant is the reaction product of: I. a polyoxyalkylene ether of Formula VIII wherein: a. R 5 is an organic radical having 3 to 15 reactive groups, b. the R 6 's are independently selected from the group consisting of hydrogen and methyl, c. m is an integer from 1 to 80 inclusive, d. n is an integer from 3 to 15 inclusive, Ii. a compound selected from the group consisting of N-vinyl pyrrolidone and N-vinyl caprolactam, Iii. di-lower alkyl maleate, wherein II and III form R 8 Iv. a capping agent selected from the group consisting of acetic acid, acetic anhydride, acetyl chloride and 3,5-dinitrobenzoyl chloride, so that the surfactant has a hydroxyl value less than 10.

Claim 21

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 wherein the surfactant is selected from the group consisting of sorbitan (polyoxyethylene acetate) 5 , sorbitan (polyoxypropylene acetate) 5 , glycerol tris (polyoxyethylene acetate), glycerol tris (polyoxypropylene propionate), 1,1,1-trimethylol-propane (polyoxyethylene acetate), pentaerythritol (polyoxyethylene acetate) 3 , polyoxyethylene sorbitan palmitate, polydimethyl siloxane polyalkylene oxide block copolymer esterified with a lower alkyl carboxylic acid, polyethylene glycol adipate (polyoxyethylene acetate), polyethylene glycol tartarate (polyoxyethylene acetate) and mixtures thereof.

Claim 22

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 wherein the closed cell content is 80%.

Claim 23

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 1 wherein the thermal conductivity value of the foam material is 0.1 to 0.2 BTU-inch/Hr-° F-sq. ft. at 24° C.

Claim 24

A laminated structural panel having at least one facing sheet and having adhered to it a closed cell foam material of claim 4 wherein the capping agent is selected from the group of lower alkyl carboxylic acids, lower alkyl carboxylic anhydrides and lower alkyl carboxylic acid chlorides.