Phenolic foam and surfactant useful therein

Claim 2

A closed cell foam material comprising the reaction product of: A. phenolic-resin foam forming reactants, B. a blowing agent, C. a surfactant which is the reaction product of: I. an alkoxylated amine of Formula VI ##STR3## wherein: (a) R 5 is an alkoxylated chain of Formula VII, having terminal hydroxyl groups, ##STR4## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 15:85 to 85:15 with Ii. a copolymerizable mixture of dialkyl maleate and a member selected from the group consisting of N-vinyl-2-pyrrolidone and N-vinyl caprolactam, and Iii. a capping agent for the terminal hydroxyl groups.

Claim 3

The closed cell foam material of claim 1 wherein the phenolic resin foam forming reactants comprise phenol and an ortho-cresol-phenol block copolymer.

Claim 4

The closed cell foam material of claim 2 wherein the ratio of phenol to ortho-cresol in the phenolic resin is 1:1.5 to 10:1.

Claim 5

The closed cell foam material of claim 1 wherein the capping agent is acetic anhydride.

Claim 6

The closed cell foam material of claim 1 wherein the surfactant has a hydroxyl value of less than 50.

Claim 7

The closed cell foam material of claim 1 wherein the blowing agent is present in an amount sufficient to give the resultant foam a density of 0.5 to 10 pounds per cubic foot.

Claim 8

The closed cell foam material of claim 1 wherein the blowing agent comprises 1 to 30 weight percent of the foam material.

Claim 9

The closed cell foam material of claim 1 wherein the surfactant comprises from 0.05 to 10 weight percent of the foam material.

Claim 10

The closed cell foam material of claim 1 wherein the alkoxylated amine has a molecular weight between 1500 and 6000.

Claim 11

The closed cell foam material of claim 1 wherein the copolymerizable mixture comprises 5 to 40 weight percent based on the weight of the surfactant.

Claim 12

The closed cell foam material of claim 1 wherein the alkyl of the dialkyl maleate has 1 to 5 carbon atoms.

Claim 13

A closed cell foam material comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I ##STR5## wherein: (a) R 1 is ##STR6## hydrogen, or a radical of Formula II, ##STR7## (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, and a radical of Formula II, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, and 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 ##STR9## 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 the reaction product of I. an alkoxylated amine of Formula VI ##STR10## wherein: (a) R 5 is an alkoxylated chain of Formula VII, having terminal hydroxyl groups, ##STR11## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 15:85 to 85:15, (d) the molecular weight of the alkoxylated amine is 1500 to 6000, and Ii. a copolymerizable mixture of dialkyl maleate and a member selected from the group consisting of N-vinyl-2-pyrrolidone and N-vinyl caprolactam, Iii. a capping agent for the terminal hydroxyl groups 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 14

A closed cell foam material comprising the reaction product of: A. an alkylol group containing phenolic polymer of Formula I ##STR5## wherein: (a) R 1 is ##STR6## hydrogen, or a radical of Formula II, ##STR7## (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, and a radical of Formula II, (d) the R 4 's are independently selected from the group consisting of lower alkyl, hydrogen, phenyl, benzyl, and 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 ##STR9## 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 the reaction product of I. an alkoxylated amine of Formula VI ##STR10## wherein: (a) R 5 is an alkoxylated chain of Formula VII, having terminal hydroxyl groups, ##STR11## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 15:85 to 85:15, (d) the molecular weight of the alkoxylated amine is 1500 to 6000, and Ii. a copolymerizable mixture of dialkyl maleate and a member selected from the group consisting of N-vinyl-2-pyrrolidone and N-vinyl caprolactam, Iii. a capping agent for the terminal hydroxyl groups 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 15

A closed cell foam material comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III ##STR12## wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV, ##STR13## (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen and 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, 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 the reaction product of: I. an alkoxylated amine of Formula VI ##STR14## wherein: (a) R 5 is an alkoxylated chain of Formula VII, ##STR15## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 20:80 to 60:40, (d) the molecular weight of the alkoxylated amine is 1800 to 2800, Ii. a copolymerizable mixture of dibutyl maleate and N-vinyl-2-pyrrolidone wherein the copolymerizable mixture comprises 20 weight percent based on the weight of the reaction product, and the molar ratio of dibutyl maleate to N-vinyl-2-pyrrolidone is 1:1, Iii. acetic anhydride, wherein the surfactant has a hydroxyl value less than 10.

Claim 16

A closed cell foam material comprising the reaction product of: A. a methylol group containing phenolic polymer of Formula III ##STR12## wherein: (a) R 1 is HOCH 2 --, hydrogen or a radical of Formula IV, ##STR13## (b) the R 3 's are independently selected from the group consisting of HOCH 2 --, hydrogen and 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, 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 the reaction product of: I. an alkoxylated amine of Formula VI ##STR14## wherein: (a) R 5 is an alkoxylated chain of Formula VII, ##STR15## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 20:80 to 60:40, (d) the molecular weight of the alkoxylated amine is 1800 to 2800, Ii. a copolymerizable mixture of dibutyl maleate and N-vinyl-2-pyrrolidone wherein the copolymerizable mixture comprises 20 weight percent based on the weight of the reaction product, and the molar ratio of dibutyl maleate to N-vinyl-2-pyrrolidone is 1:1, Iii. acetic anhydride, wherein the surfactant has a hydroxyl value less than 10.

Claim 17

A process for producing a closed cell foam material, said process comprising reacting phenolic-resin foam forming reactants in the presence of a blowing agent and a surfactant which is the reaction product of: I. an alkoxylated amine of Formula VI ##STR16## wherein: (a) R 5 is an alkoxylated chain of Formula VII, having terminal hydroxyl groups, ##STR17## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 15:85 to 85:15 with Ii. a copolymerizable mixture of dialkyl maleate and a member selected from the group consisting of N-vinyl-2-pyrrolidone and N-vinyl caprolactam, and Iii. a capping agent for the terminal hydroxyl groups.

Claim 18

A process for producing a closed cell foam material, said process comprising reacting phenolic-resin foam forming reactants in the presence of a blowing agent and a surfactant which is the reaction product of: I. an alkoxylated amine of Formula VI ##STR16## wherein: (a) R 5 is an alkoxylated chain of Formula VII, having terminal hydroxyl groups, ##STR17## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 15:85 to 85:15 with Ii. a copolymerizable mixture of dialkyl maleate and a member selected from the group consisting of N-vinyl-2-pyrrolidone and N-vinyl caprolactam, and Iii. a capping agent for the terminal hydroxyl groups.

Claim 19

A process for producing a closed cell foam material, said process comprising reacting phenolic-resin foam forming reactants in the presence of a blowing agent and a surfactant which is the reaction product of: I. an alkoxylated amine of Formula VI ##STR18## wherein: (a) R 5 is an alkoxylated chain of Formula VII, ##STR19## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 20:80 to 60:40, (d) the molecular weight of the alkoxylated amine is 1800 to 2800, Ii. a copolymerizable mixture of dibutyl maleate and N-vinyl-2-pyrrolidone wherein the copolymerizable mixture comprises 20 weight percent based on the weight of the reaction product, and the molar ratio of dibutyl maleate to N-vinyl-2-pyrrolidone is 1:1, Iii. acetic anhydride, wherein the surfactant has a hydroxyl value less than 10.

Claim 20

A process for producing a closed cell foam material, said process comprising reacting phenolic-resin foam forming reactants in the presence of a blowing agent and a surfactant which is the reaction product of: I. an alkoxylated amine of Formula VI ##STR18## wherein: (a) R 5 is an alkoxylated chain of Formula VII, ##STR19## (b) n is an integer from 2 to 10 inclusive, (c) the ratio p:q is 20:80 to 60:40, (d) the molecular weight of the alkoxylated amine is 1800 to 2800, Ii. a copolymerizable mixture of dibutyl maleate and N-vinyl-2-pyrrolidone wherein the copolymerizable mixture comprises 20 weight percent based on the weight of the reaction product, and the molar ratio of dibutyl maleate to N-vinyl-2-pyrrolidone is 1:1, Iii. acetic anhydride, wherein the surfactant has a hydroxyl value less than 10.