US4353994A
Expired / Lapsed
US
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Low-density, furfuryl benzylic phenolic thermosetting foam product and method of preparing same
Assignee: LINAMAR MACHINE Ltd
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Filing: 1981-12-14
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Granted: 1982-10-12
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Expires: 2001-12-14
Abstract
Abstract A low-density, low-friability, furfuryl-phenol thermosetting foam product is prepared by reacting, in the presence of a blowing agent and an acid catalyst, a furfuryl-alcohol monomer or polymer and a benzylic-ether phenol-formaldehyde resin, having a mole ratio of benzylic-ether phenol to formaldehyde of from about 1:3 to 1:11, which reaction provides a closed-cell, thermosetting foam product having a foam density of 0.5 pound per cubic foot or less.
Inventors
- 👤 Stuart B. Smith
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 06:02
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0061; C08G; C08G2110/00; C08G2110/0025; C08G2110/0041; C08G2110/005; C08G2110/0058; C08J2205/00; C08J2205/04; C08J2205/052; C08J2361/00; C08J2361/04; C08J2361/06; C08J2371/00; C08J2371/08; C08J2371/10; C08J2371/12; C08J2371/14; C08J2461/00; C08J2461/04; C08J2461/06; C08J2471/00; C08J2471/08; C08J2471/10; C08J2471/12; C08J2471/14
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
114 words
A method of preparing an ultralow-density thermosetting foam product composed substantially of closed cells and characterized by low friability, which method comprises: reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol mnomer, a furfuryl-alcohol polymer or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resole resin, the benzylic-ether resole resin having a mole ratio of formaldehyde to benzylic-ether phenol of from about 3:1 to 1:1, the reaction carried out in the presence of a sufficient amount of a blowing agent to form a low-density foam and a catalytic amount of a strong acid catalyst, to provide a thermosetting foam product having a foam density of less than about 0.5 pound per cubic foot.
Claim 2
Independent Claim
114 words
A method of preparing an ultralow-density thermosetting foam product composed substantially of closed cells and characterized by low friability, which method comprises: reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol mnomer, a furfuryl-alcohol polymer or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resole resin, the benzylic-ether resole resin having a mole ratio of formaldehyde to benzylic-ether phenol of from about 3:1 to 1:1, the reaction carried out in the presence of a sufficient amount of a blowing agent to form a low-density foam and a catalytic amount of a strong acid catalyst, to provide a thermosetting foam product having a foam density of less than about 0.5 pound per cubic foot.
Claim 3
Dependent Claim
36 words
The method of claim 1 wherein the furfuryl-alcohol polymer comprises an acid-catalyzed furfuryl-alcohol polymer which generally comprises a head-to-tail polymerization of the furfuryl alcohol in the polymer chain, and having reactive hydroxyl groups in the polymer.
Claim 4
Dependent Claim
29 words
The method of claim 1 wherein the benzylic-ether phenolic-formaldehyde resin comprises a single-stage resin, and wherein the mole ratio of phenol to formaldehyde ranges from about 1:1 to 1:1.6.
Claim 5
Dependent Claim
13 words
The method of claim 1 wherein the acid catalyst comprises a sulfonic-acid catalyst.
Claim 6
Dependent Claim
19 words
The method of claim 4 wherein the sulfonic-acid catalyst comprises an alkene sulfonic acid or a toluene sulfonic acid.
Claim 7
Dependent Claim
18 words
The method of claim 1 which includes, in the reaction mixture, a cell-control amount of a silicone surfactant.
Claim 8
Dependent Claim
22 words
The method of claim 1 wherein the reaction is carried out at a temperature ranging from about 60° F. to 180° F.
Claim 9
Dependent Claim
32 words
The method of claim 1 wherein the amount of the furfuryl-alcohol polymer and the amount of the benzylic-ether phenolic-formaldehyde resin range from about 10% to 90% by weight of the reaction mixture.
Claim 10
Dependent Claim
31 words
The method of claim 1 wherein the blowing agent is present in an amount ranging from about 1 to 15 parts by weight of the polymer resin in the reaction mixture.
Claim 11
Dependent Claim
34 words
The method of claim 1 wherein the acid catalyst is present in an amount ranging from about 0.05 to 10 parts per 100 parts by weight of the resin polymer in the reaction mixture.
Claim 12
Dependent Claim
29 words
The method of claim 1 which includes adding from about 0.1 to 8.0 weight percent of the reaction mixture of a styrene monomer, to provide a closed-cell foam product.
Claim 13
Dependent Claim
22 words
The method of claim 1 which includes from about 10% to 40% by weight of the resin of a resole phenol-formaldehyde resin.
Claim 14
Dependent Claim
43 words
The method of claim 1 wherein the benzylic-ether phenolic resin has the general formula: ##STR4## wherein R is hydrogen, the sum of m and n is at least 2, the ratio of m to n is at least 1 and X is hydrogen.
Claim 15
Independent Claim
167 words
A method of preparing a thermosetting foam product, which method comprises: reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol polymer, a furfuryl alcohol or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resin, having 4 to 10 phenolic rings and having a mole ratio of phenol to formaldehyde of from about 1:1 to 1:2, in the presence of from about 1 to 15 parts per 100 parts of polymer and resin of a blowing agent and of from about 0.05 to 10 parts per 100 parts of polymer and resin of a catalytic amount of a sulfonic-acid catalyst and a small cell-control amount of a silicone surfactant, to effect the generally simultaneous condensation of the phenol-formaldehyde resin and the condensation of the furfuryl compound, the amount of the polymer and the resin ranging from about 10% to 90% by weight of the reaction mixture, to provide an integral thermosetting foam product characterized by a low density of about 0.5 pcf or less and low friability.
Claim 16
Independent Claim
167 words
A method of preparing a thermosetting foam product, which method comprises: reacting a furfuryl compound, selected from the group consisting of a furfuryl-alcohol polymer, a furfuryl alcohol or mixtures thereof, with a benzylic-ether phenolic-formaldehyde resin, having 4 to 10 phenolic rings and having a mole ratio of phenol to formaldehyde of from about 1:1 to 1:2, in the presence of from about 1 to 15 parts per 100 parts of polymer and resin of a blowing agent and of from about 0.05 to 10 parts per 100 parts of polymer and resin of a catalytic amount of a sulfonic-acid catalyst and a small cell-control amount of a silicone surfactant, to effect the generally simultaneous condensation of the phenol-formaldehyde resin and the condensation of the furfuryl compound, the amount of the polymer and the resin ranging from about 10% to 90% by weight of the reaction mixture, to provide an integral thermosetting foam product characterized by a low density of about 0.5 pcf or less and low friability.
Claim 17
Dependent Claim
30 words
The method of claim 14 which includes adding from about 0.5 to 5.0 weight percent of the reaction mixture of a styrene monomer, to provide a substantially closed-cell foam product.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1985-10-11 | 1986-04-12 | 1986-10-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-10-11 | 1990-04-12 | 1990-10-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-10-11 | 1994-04-12 | 1994-10-12 | $7700.00 | Window Closed / Lapsed |