Patent US3745286A successfully refreshed from Google Patents.
US4539338A
Expired / Lapsed
US
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Phenol formaldehyde resoles for making phenolic foam
Assignee: DOMTAR INSULATION PRODUCTS Inc 1020 WILLIAM PITT WAY PITTSBURGH PA 15238
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Filing: 1984-07-27
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Granted: 1985-09-03
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Expires: 2004-07-27
Abstract
Abstract The present invention is directed to aqueous phenol formaldehyde resoles that have particular application in manufacturing phenolic foam insulation. The resoles are essentially phenol formaldehyde condensation polymers having molar ratios of formaldehyde to phenol of from about 1.7:1 to 2.3:1, preferably from 1.75:1 to 2.25:1 and most preferably about 2:1. The resoles have a weight average molecular weight greater than 800 and preferably from 950-1500. The resoles also have a number average molecular weight greater than 350 and preferably from about 400 to about 600 and a dispersivity greater than about 1.7, preferably from 1.8 to 2.6. Phenol formaldehyde resoles having these characteristics are processable into phenolic foams having a low k value and having other physical characteristics which make the phenolic foam especially useful as an insulation material. The present invention is also directed to foamable phenolic resole compositions prepared from the phenolic resoles and phenolic foams prepared from the compositions.
Inventors
- 👤 John D. Carlson
- 👤 Edward W. Kifer
- 👤 Vincent J. Wojtyna
- 👤 James P. Colton
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 17:24
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; C08J9/14; C08J9/143; C08J9/147; C08G; C08G8/00; C08G8/04; C08G8/08; C08G8/10; C08J2361/00; C08J2361/04; C08J2361/06
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
109 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to about 2.3:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 2
Dependent Claim
109 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to about 2.3:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 3
Dependent Claim
24 words
An improved process as in claim 1 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 4
Dependent Claim
24 words
An improved process as in claim 1 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 5
Dependent Claim
111 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to 2.3:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 6
Dependent Claim
111 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to 2.3:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 7
Dependent Claim
24 words
An improved process as in claim 4 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
Claim 8
Dependent Claim
109 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to about 2.25:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 9
Dependent Claim
109 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to about 2.25:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 10
Dependent Claim
24 words
An improved process as in claim 6 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 11
Dependent Claim
24 words
An improved process as in claim 6 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 12
Dependent Claim
111 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersitivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 13
Dependent Claim
111 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersitivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 14
Dependent Claim
24 words
An improved process as in claim 9 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
Claim 15
Dependent Claim
105 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 16
Dependent Claim
105 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 17
Dependent Claim
24 words
An improved process as in claim 11 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 18
Dependent Claim
24 words
An improved process as in claim 11 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 19
Dependent Claim
108 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 20
Dependent Claim
108 words
An improved process for preparing closed cell phenolic foam having entrapped fluorocarbon blowing agent comprising preparing a foamable phenolic resole composition comprising aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent and acid catalyst, and foaming and curing said composition in a substantially closed mold wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 21
Dependent Claim
24 words
An improved process as in claim 14 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
Claim 22
Dependent Claim
89 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to about 2.3:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 23
Dependent Claim
89 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to about 2.3:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 24
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 16 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 25
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 16 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 26
Dependent Claim
91 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to 2.3:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 27
Dependent Claim
91 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.7:1 to 2.3:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 28
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 19 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
Claim 29
Dependent Claim
88 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 30
Dependent Claim
88 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 31
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 21 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 32
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 21 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 33
Dependent Claim
90 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight between 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 34
Dependent Claim
90 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of from about 1.75:1 to 2.25:1, a weight average molecular weight between 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 35
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 24 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
Claim 36
Dependent Claim
85 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 37
Dependent Claim
85 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight greater than about 800, a number average molecular weight greater than about 350, a dispersivity greater than about 1.7 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 38
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 26 wherein the weight average molecular weight of the phenol formaldehyde resole is between about 950 and 1500.
Claim 39
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 26 wherein the number average molecular weight of the phenol formaldehyde resole is between about 400 and 600.
Claim 40
Dependent Claim
88 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 41
Dependent Claim
88 words
An improved foamable phenolic resole composition for preparing closed cell phenolic foam comprising an aqueous phenol formaldehyde resole, surfactant, blowing agent and acid catalyst wherein the improvement comprises a phenol formaldehyde resole having a molar ratio of formaldehyde to phenol of about 2:1, a weight average molecular weight between about 950 and 1500, a number average molecular weight between about 400 and 600, a dispersivity between about 1.8 and 2.6 and wherein the content of free formaldehyde and free phenol are each less than 7 percent by weight.
Claim 42
Dependent Claim
27 words
An improved foamable phenolic resole composition as in claim 29 wherein the content of free formaldehyde and free phenol are each less than 4 percent by weight.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-09-02 | 1989-03-04 | 1989-09-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-09-02 | 1993-03-04 | 1993-09-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-09-02 | 1997-03-04 | 1997-09-03 | $7700.00 | Window Closed / Lapsed |