US4520141A
Expired / Lapsed
US
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Method for manufacturing phenolic resin foam
Assignee: Toyo Quality One Corp
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Filing: 1982-08-31
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Granted: 1985-05-28
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Expires: 2002-08-31
Abstract
Abstract A method for manufacturing a phenolic resin foam is provided which comprises the steps of mixing a composition consisting of 100 parts by weight of a resol-type phenol-formaldehyde resin, 5 to 40 parts by weight of a curing agent consisting of an acid, and a foaming agent consisting of an isocyanate or a mixture thereof with water, and heating the composition for foaming, an amount of the isocyanate being 5 to 30 parts by weight if the foaming agent is the isocyanate alone, and the amount of the isocyanate being not less than its equivalent weight and an amount of water being 5 to 30 parts by weight if the foaming agent is the mixture of the isocyanate with water. If 100 parts by weight of a urethane-modified phenol-formaldehyde resin are used in place of 100 parts by weight of the resol-type phenol-formaldehyde resin, 0.1 to 1.5 parts by weight of a curing agent consisting of a tin compound are used in place of the acid curing agent. The method of the invention allows easy control of the formation of cells and improves the yield of foamed product.
Inventors
- 👤 Sadao Kumasaka
- 👤 Satomi Tada
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 19:22
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/06; C08J9/08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/54; C08G18/542; C08G2110/00; C08G2110/0083; C08J2361/00; C08J2361/04; C08J2361/06
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
75 words
A method for manufacturing a phenolic resin foam, comprising the steps of mixing a composition consisting essentially of 100 parts by weight of a resol-type phenol-formaldehyde resin, 5 to 40 parts by weight of a curing agent consisting of an acid, and a foaming agent consisting of an isocyanate, and heating the composition to foam said composition and form said phenolic resin foam, the amount of the isocyanate being 5 to 30 parts by weight.
Claim 2
Independent Claim
75 words
A method for manufacturing a phenolic resin foam, comprising the steps of mixing a composition consisting essentially of 100 parts by weight of a resol-type phenol-formaldehyde resin, 5 to 40 parts by weight of a curing agent consisting of an acid, and a foaming agent consisting of an isocyanate, and heating the composition to foam said composition and form said phenolic resin foam, the amount of the isocyanate being 5 to 30 parts by weight.
Claim 3
Independent Claim
76 words
A method for manufacturing a phenolic resin foam, comprising the steps of mixing a composition consisting essentially of 100 parts by weight of a urethane-modified phenol-formaldehyde resin, 0.1 to 1.5 parts by weight of a curing agent consisting of a tin compound, and a foaming agent consisting of an isocyanate, and heating the composition to foam said composition and form said phenolic resin foam, the amount of the isocyanate being 5 to 30 parts by weight.
Claim 4
Independent Claim
76 words
A method for manufacturing a phenolic resin foam, comprising the steps of mixing a composition consisting essentially of 100 parts by weight of a urethane-modified phenol-formaldehyde resin, 0.1 to 1.5 parts by weight of a curing agent consisting of a tin compound, and a foaming agent consisting of an isocyanate, and heating the composition to foam said composition and form said phenolic resin foam, the amount of the isocyanate being 5 to 30 parts by weight.
Claim 5
Dependent Claim
27 words
A method according to claim 1, wherein the acid is one member selected from the group consisting of acetic acid, hydrochloric acid, sulfuric acid, and lactic acid.
Claim 6
Dependent Claim
28 words
A method according to claim 2, wherein the tin compound is one member selected from the group consisting of dibutyltin dilaurate, dibutyltin di-2-ethylhexoate, stannous oleate, and stannous 2-ethylhexoate.
Claim 7
Dependent Claim
29 words
A method according to claim 1 or 2, wherein the isocyanate is one member selected from the group consisting of diphenylmethane-4,4'-diisocyanate, xylylene diisocyanate, tolylene diisocyanate, naphthylene-1,5-diisocyanate, and hexamethylene diisocyanate.
Claim 8
Dependent Claim
23 words
A method according to claim 1 or 2, wherein the composition further contains 1 to 5 parts by weight of a foam stabilizer.
Claim 9
Dependent Claim
22 words
A method according to claim 1 or 2, wherein the composition is injected into a mold, and is then heated for foaming.
Claim 10
Dependent Claim
25 words
A method according to claim 3, wherein the isocyanate is selected from the group consisting of diphenylmethane-4,4'-diisocyanate, xylylene diisocyanate, tolylene diisocyanate, naphthylene-1,5-diisocyanate, and hexamethylene diisocyanate.
Claim 11
Dependent Claim
25 words
A method according to claim 4, wherein the isocyanate is selected from the group consisting of diphenylmethane-4,4'-diisocyanate, xylylene diisocyanate, tolylene diisocyanate, naphthylene-1,5-diisocyanate, and hexamethylene diisocyanate.
Claim 12
Dependent Claim
21 words
A method according to claim 3, wherein the composition further contains 1 to 5 parts by weight of a foam stabilizer.
Claim 13
Dependent Claim
21 words
A method according to claim 4, wherein the composition further contains 1 to 5 parts by weight of a foam stabilizer.
Claim 14
Dependent Claim
21 words
A method according to claim 8, wherein the composition further contains 1 to 5 parts by weight of a foam stabilizer.
Claim 15
Dependent Claim
21 words
A method according to claim 9, wherein the composition further contains 1 to 5 parts by weight of a foam stabilizer.
Claim 16
Dependent Claim
20 words
A method according to claim 3, wherein the composition is injected into a mold, and is then heated for foaming.
Claim 17
Dependent Claim
20 words
A method according to claim 4, wherein the composition is injected into a mold, and is then heated for foaming.
Claim 18
Dependent Claim
20 words
A method according to claim 5, wherein the composition is injected into a mold, and is then heated for foaming.
Claim 19
Dependent Claim
20 words
A method according to claim 8, wherein the composition is injected into a mold, and is then heated for foaming.
Claim 20
Dependent Claim
20 words
A method according to claim 9, wherein the composition is injected into a mold, and is then heated for foaming.
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) | 1988-05-27 | 1988-11-26 | 1989-05-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-05-27 | 1992-11-26 | 1993-05-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-05-27 | 1996-11-26 | 1997-05-28 | $7700.00 | Window Closed / Lapsed |