公开(公告)号：US4539338A

公开(公告)日：1985-09-03

申请号：US634197

申请日：1984-07-27

Applicant: John D. Carlson ,  Edward W. Kifer ,  Vincent J. Wojtyna ,  James P. Colton

Inventor： John D. Carlson ,  Edward W. Kifer ,  Vincent J. Wojtyna ,  James P. Colton

IPC: C08G8/10 ,  C08J9/14

CPC classification number: C08J9/147 ,  C08G8/10 ,  C08J2361/06

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.

Abstract translation: 本发明涉及在制造酚醛泡沫绝缘体中特别适用的苯酚甲醛水溶液。 甲阶酚醛树脂基本上是甲醛与苯酚的摩尔比为约1.7:1至2.3:1，优选1.75:1至2.25:1，最优选约2:1的苯酚甲醛缩聚物。 甲阶酚醛树脂的重均分子量大于800，优选为950-1500。 甲阶酚酸酯还具有大于350，优选约400至约600的数均分子量和大于约1.7，优选1.8至2.6的分散度。 具有这些特性的苯酚甲醛树脂可加工成具有低k值并具有其它物理特性的酚醛泡沫体，其使得酚醛泡沫体作为绝缘材料特别有用。 本发明还涉及由组合物制备的酚醛树脂和酚醛泡沫制备的可发泡酚醛树脂组合物。

公开(公告)号：US4444912A

公开(公告)日：1984-04-24

申请号：US396706

申请日：1982-07-09

Applicant: John D. Carlson ,  Edward W. Kifer ,  Vincent J. Wojtyna ,  James P. Colton

Inventor： John D. Carlson ,  Edward W. Kifer ,  Vincent J. Wojtyna ,  James P. Colton

IPC: C08J9/04 ,  C08J9/14 ,  C08K5/42 ,  C08L61/00 ,  C08L61/04 ,  C08L61/06 ,  C08L61/10

CPC classification number: C08J9/147 ,  C08K5/42 ,  C08J2361/06

Abstract: Closed-cell phenolic foam having a uniform cell structure in which the cell walls are substantially free of both ruptures and perforations is disclosed. The phenolic foam has initial k values of less than 0.15 with substantially no increase of k value over time and good density and compressive strengths. The phenolic foam is prepared by foaming and curing a foamable phenolic resole composition containing an aqueous phenol formaldehyde resole, surfactant, fluorocarbon blowing agent, and optionally other additives with an acid foaming and curing catalyst in a substantially closed mold which exerts a restraining pressure on the foaming composition in excess of ambient atmosphericpressure of greater than about 3 pounds per square inch. The aqueous phenol formaldehyde resole is essentially a phenol formaldehyde condensation polymer having a molar ratio 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 resole has a weight average molecular weight greater than 800 and preferably from 950-1500. The resole also has a number average molecular weight greater than about 350 and preferably from about 400 to about 600 and a dispersivity greater than about 1.7, preferably from 1.8 to 2.6. The acid foaming and curing catalyst is an anhydrous aryl sulfonic acid having a pKa less than about 2.0 and which changes the compatibility of the phenolic resole with water. The preferred anhydrous aryl sulfonic acid is a combination of toluene sulfonic acid and xylene sulfonic acid.

Abstract translation: 公开了具有均匀电池结构的闭孔酚醛泡沫体，其中细胞壁基本上不含破裂和穿孔。 酚醛泡沫体具有小于0.15的初始k值，随着时间的推移基本上不增加k值，并且具有良好的密度和抗压强度。 酚醛泡沫体通过在基本上封闭的模具中发泡和固化含有苯酚甲醛甲苯酚水溶液，表面活性剂，氟碳化合物发泡剂和任选的其它添加剂的可发泡酚醛树脂组合物来制备，所述基本上封闭的模具对所述酚醛树脂施加约束压力 发泡组合物超过环境大气压力大于约3磅/平方英寸。 苯酚甲醛水溶液基本上是甲醛与苯酚的摩尔比为约1.7:1至2.3:1，优选1.75:1至2.25:1，最优选约2:1的苯酚甲醛缩聚物。 甲阶酚醛树脂的重均分子量大于800，优选为950-1500。 甲阶酚醛还具有大于约350，优选约400至约600的数均分子量和大于约1.7，优选1.8至2.6的分散度。 酸发泡和固化催化剂是pKa小于约2.0的无水芳基磺酸，并且改变酚醛树脂与水的相容性。 优选的无水芳基磺酸是甲苯磺酸和二甲苯磺酸的组合。