Abstract:
A process for the continuous manufacture of phenolic resin foam in an endless sheet which includes mixing expandable liquid phenolic resin with a blowing agent and an acid-containing curing agent, optionally with the addition of additives, and processing of the mixture in a temperature-controllable double belt press. The process also comprises cooling the phenolic resin to a temperature of from about 8* to 15*C., admixing a blowing agent under a high pressure with said resin to form a resin premix, mixing said resin premix with a curing agent resin to form a resin premix, mixing said resin premix with a curing agent and other foam additives to form a curable reaction mixture, continuously applying said mixture uniformily onto a moving substrate, covering the mixture on said substrate with a continuous protective layer, passing the covered mixture into the double belt press, and foaming the mixture under pressure until a desired sheet thickness has been obtained.