US4698370A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Production of phenolic resin composite foam
Assignee: Sumitomo Durez Co Ltd
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Filing: 1986-04-14
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Granted: 1987-10-06
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Expires: 2006-04-14
Abstract
Abstract A phenolic resin composite foam is disclosed which is prepared by heating and foaming a novolak phenolic resin having a number average molecular weight of 250 to 600 and a bulk density of 0.15 to 0.5, a blowing agent, a blowing auxiliary compound and inorganic foamed particles. Additional materials for flame retardancy can be added. The foam produced has a high compressive strength, a high foaming and rapid curing rates, a low water absorption and a minimum of friability.
Inventors
- 👤 Yukio Saeki
- 👤 Naomitsu Inoue
- 👤 Yukio Tokunaga
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 03:11
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/35; C08J9/0014; C08J9/04; C08J9/06; C08J2361/00; C08J2361/04; C08J2361/06; Y; Y10; Y10S; Y10S521/00; Y10S521/909
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
132 words
A process for producing a phenolic resin composite foam which comprises heating at 100 to 250° C. a phenolic resin composite foam material which is composed of a powdered novolak phenolic resin having a number-average molecular weight of 250 to 600, a bulk density of 0.15 to 0.50 and containing 1 to 10% of free phenol; a chemically decomposing blowing agent; at least one kind of blowing auxiliary selected from the group consisting of urea, formic acid, oxalic acid, maleic acid, fumaric acid, benzoic acid, salicylic acid, p-hydroxybenzoic acid, and phthalic acid incorporated in an amount of 0.1 to 7 parts of weight per 100 parts by weight of the phenolic resin,and inorganic foamed particles incorporated in a ratio of phenolic resin to inorganic foamed particles from 90:10 to 10:90 by weight.
Claim 2
Dependent Claim
132 words
A process for producing a phenolic resin composite foam which comprises heating at 100 to 250° C. a phenolic resin composite foam material which is composed of a powdered novolak phenolic resin having a number-average molecular weight of 250 to 600, a bulk density of 0.15 to 0.50 and containing 1 to 10% of free phenol; a chemically decomposing blowing agent; at least one kind of blowing auxiliary selected from the group consisting of urea, formic acid, oxalic acid, maleic acid, fumaric acid, benzoic acid, salicylic acid, p-hydroxybenzoic acid, and phthalic acid incorporated in an amount of 0.1 to 7 parts of weight per 100 parts by weight of the phenolic resin,and inorganic foamed particles incorporated in a ratio of phenolic resin to inorganic foamed particles from 90:10 to 10:90 by weight.
Claim 3
Dependent Claim
26 words
A process for producing a phenolic resin composite foam according to claim 1, wherein the number-average molecular weight of the novolak rein is 300 to 550.
Claim 4
Dependent Claim
26 words
A process for producing a phenolic resin composite foam according to claim 1, wherein the free phenol present in the novolak resin is 3 to 8%.
Claim 5
Dependent Claim
37 words
A process for producing a phenolic resin composite foam according to claim 1, wherein the chemical decomposing blowing agent is added in an amount of 3-20 parts by weight per 100 parts by weight of phenolic resin.
Claim 6
Dependent Claim
35 words
A process for producing a phenolic resin composite foam according to Claim 1, wherein the inorganic foamed particles have a bulk density of 0.05 to 0.5 and a particle diameter of 0.2 to 7 mm.
Claim 7
Dependent Claim
34 words
A process for producing a phenolic resin composite foam according to claim 1, wherein the inorganic foamed particles have a ratio of phenolic resin to inorganic foamed particles from 70:30 to 30:70 by weight.
Claim 8
Dependent Claim
146 words
A process for producing a phenolic resin composite foam which comprises heating at 100 to 250° C. a phenolic resin composite foam material which is composed of a powdered novolak phenolic resin having a number-average molecular weight of 300 to 550, a bulk density of 0.15 to 0.50 and containing 3 to 8% of free phenol; a blowing agent added in an amount of 3-20 parts by weight per 100 parts by weight phenolic resin; at least one kind of blowing auxiliary selected from the group consisting of urea, formic acid, oxalic acid, maleic acid, fumaric acid, benzoic acid, salicylic acid, p-hydroxybenzoic acid, and phthalic acid incorporated in an amount of 0.1 to 7 parts by weight per 100 parts by weight of the phenolic resin,and inorganic foamed particles incorporated in a ratio of phenolic resin to inorganic foamed particles from 70:30 to 30:70 by weight.
Claim 9
Dependent Claim
146 words
A process for producing a phenolic resin composite foam which comprises heating at 100 to 250° C. a phenolic resin composite foam material which is composed of a powdered novolak phenolic resin having a number-average molecular weight of 300 to 550, a bulk density of 0.15 to 0.50 and containing 3 to 8% of free phenol; a blowing agent added in an amount of 3-20 parts by weight per 100 parts by weight phenolic resin; at least one kind of blowing auxiliary selected from the group consisting of urea, formic acid, oxalic acid, maleic acid, fumaric acid, benzoic acid, salicylic acid, p-hydroxybenzoic acid, and phthalic acid incorporated in an amount of 0.1 to 7 parts by weight per 100 parts by weight of the phenolic resin,and inorganic foamed particles incorporated in a ratio of phenolic resin to inorganic foamed particles from 70:30 to 30:70 by weight.
Claim 10
Dependent Claim
35 words
A process for producing a phenolic resin composite foam according to claim 7, wherein the inorganic foamed particles have a bulk density of 0.05 to 0.5 and a particle diameter of 0.2. to 7 mm.
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) | 1990-10-05 | 1991-04-06 | 1991-10-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-10-05 | 1995-04-06 | 1995-10-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-10-05 | 1999-04-06 | 1999-10-06 | $7700.00 | Window Closed / Lapsed |