Process for producing amine formaldehyde resin foam

Claim 1

A process for producing amine formaldehyde resin foam by using a precondensate for the amine formaldehyde resin, foaming agent, a surfactant and a curing agent, characterized in that the foaming agent is selected from the group consisting of aliphatic hydrocarbons, halogenated aliphatic hydrocarbons having a boiling point in the range of from about -30° C. to about 30° C. or mixtures thereof, and the foaming agent being used in amount of from about 0.07 mol to about 1.0 mol per 100 g of solid content of the precondensate for amine formaldehyde resin, and wherein the foaming system further contains at least one modifier selected from the group consisting of a compound represented by the formula: ##STR2## wherein R 1 , R 2 and R 3 are independently selected from the group consisting of hydrogen and alkyl having 1-3 carbon atoms, and R 4 is selected from the group consisting of hydroxyl, hydrogen and alkyl having 1-3 carbon atoms; mixtures of the compounds of formula I; a condensate of each of the compounds of formula I and formaldehyde; and mixtures of the condensate and the compound of formula I, the process comprising mixing the precondensate, the foaming agent, the modifier and the surfactant under such conditions that the foaming agent is maintained liquid, emulsifying the resulting mixture at a temperature which is at least 0° C. and higher than the boiling point of the foaming agent by 5°-50° C. and at such a pressure that the foaming agent is maintained liquid at said temperature, while or after mixing the resulting emulsified mixture with the curing agent, transferring the resulting mixture to an environment having atmospheric pressure or depressurizing the mixture to atmospheric pressure at a temperature which is between 0° and 35° C. and higher than the boiling point of the foaming agent to foam the mixture.