Note: Descriptions are shown in the official language in which they were submitted.
'~itle of tbe Invention
~`IIOD FOR ~RODUCI~G Pl-~NOL FOA~ P~AS'~IC
Field o~ the Invention
The present invention relates to methods f'or produc-
ing phenol ~'oam plastics. ~he phenol foa~ plastic pro-
duced accordin~ ~o the invention can be used as a beat-
insulating material in con~truction~ ship building;
machine b~ilding, cb~mical ind~stry~ and refrigeratin~
engineering.
Description of the Prior Ar~
~ nown in the art is a metbod ~or prod~cing a pbenol
foam plastic by mising resol pbenol-formaldehyde resin
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wit~ a foaming agent and an acid catal~st. I~ tbis
case9 foami~g and curin~ of tbe mi~tl~re take place after
a certain period of time (1,5 to 10 minutes).
A serious disadvantage of tbe prior art metbod is
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tbe necessity t~ obtain, in advance~ tbe resol phenol-
formaldebyde resi~O Tbis resin is produc~d in several
stages, namely:
(1) polgcondensation of p~enols witb formaldebyde
in tbe presence of a catalys~, at elevated temperatures
(j5 to 90C)~ for a long period of time (1~5 to 3 bours);
; (2) cooling and ne~trali~atio~ of tbe resulting
product;
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'i (3) separation of tbe resi~ e.g., by vacuum distilla-
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~ o prod~ce ~sol phenol-foI~aldebyde resin takes mucb
time, r1~uires spcci~ll eq~ipment~ cons~Mes ~ucb heat and
labor, wbile tbe stora~;e li~2 of resol phenol-formal-. dehyde resin i5 limltod (~p to 2 to 4 month~ and, at
bigh tamperat~res, ~p to a rnonth)D
Wben a phenol ~oam plaskic is produced on the basis
~ of said resin7 curing ta]~es a long period of time
(1 5 to 10 min~tes) and requires an acid catalyst.
'~he ph~sico-mecbanical properties of tbe p~enol
~oa~ plastic produced by tbe prior art method are not
s~fficiently bigb, for example:
apparent density, kg/c~.m 50-100
stress at lO~o linear compression st.rain, kg~/sq cm
., . 0.5-2.0
: . sorptlon moisture co~tent after 24 bours of expos~re
to air witb a relative b~midity o~ 98~2~o9 % by mass
25-20
heat-conductivit~ coefficient at 20~5C, kcal/~sb-C
0-035-0~040
. Summary of tbe Invention
It is an object of tbe present inve~tion to provide a
simple metbod ~or producing a pbenol ~oa~ plasticD
.~ Another object o~ tbe invention is to provide
a method permitting a pbenol ~oam plastlc ~ith improved
. pbysico-mecbanical properties to be obtained.
:~ With these and other objects in view, the invention
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resi~l~s in ~ raet~od for producing a phenol ~oam pl~stic,
consi3ting in th~t polycon~ensation OL` phenols with for-
maldehyde i5 conductecl siraulta~eously witb ~oaming and
curin~ in tbe presence Or a foamin~ a~ent and an acid
or alkaline catalys~ the phenols bein~ pyrocat~chol,
hydroquinone, resorcinol, 5-metb~l resorcinol~ sbale
alkyl resorcinols, shale total resorcinols~ or ~arious
combinations of said pbenols~
Owing to:
(1) the use of t~e above pbenols;
(2) tbe introd~ction of a foaming a~ent into tbe
starting mixture of monomers; and
(3) the introd~ction o~ an acid or alkaline catalys~
into the starting mi~ture of monomers 9 it bas become
possible to conduct t~e processes o~ pol~condensation,
foaming and curing in a single stage.
Tbe proposed method fox producin~ a pbenol foam
plastic is quite simple. ~he necessity to obtain an
intermediate product, i.e., resol phenol-formaldehyde
xesin, is ruled o~t3 bence9 no special eguipment is
required to produce it. In addition, tbe method can be car~
ried out in a broad temperature range (from 10 ~o 90C)
witbin a much sborter period o~ time (~rom 5 to 60 se-
conds). ~be above ~actors permit the prod~ctio~ o~ a
pbenol ~oam plastic to be substantially inte~si~ied.
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In tbe proposed metbod, the process of curing ca~
be conducted in the presence of botb an acid and
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- alk~line catalysl; (said catal~1sli serv~s, at tbe same
time, as the polycondensation catalyst). In tbe latter
c~s~, an acid-Iree phenol ~oam plastic¦is produced,
whicb contributes to its low corrosion activit~r
~he phenol foam plastic produced b~ the proposed
method ~eatures i~proved physico-~echa~ical cbaracte-
ristics, namely:
apparent densit~ kgJc~.m 50-100
stress at 10% li~ear compression strain, k~Jsq.crn
~ 1.0-6~3
heat-cond~ctivity coef~icien~ at 20~5C~ kcalJm-b~C
0~031-0.037
sorption moist~re conte~t after 24 bo~rs of exposure
to air witb a relative b~midiky of 98~2%, % by mass
2~ 0-1.0
water absorptio~ duri~g 24 ho~rs, % by vol~me
3L~"O~.l.
It is expedie~t bo ~se, in tbe proposed metbod9
sbale alkyl resorcinols of tbe followi~g composition
(% by wei~at):
~ 5-metbyl resorcinol 46-58
.: 2,5-dimetbyl resorcinol 9-12
:` :
5~d~ ~etbyl resorcinol 10-12
5-etbyl resorcinol 10-12
. other alkyl resorci~ols . 13~18,
or sbale ~otal resorcinols o~ the following composition
(% by weight):
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5-me~hyl :reso:rcinol 25~4-29.4
: ~,5-dimetbyl resorcinol ~0-10.
5-eth~l resorcinol '~5-9.5
2,5-dimetbyl resorcinol 5.4-7.0
monohydric pbenols 1,0-11.4
` resorcinol 1.6-2.6
~-methyl resorcinol 1.2~.0
5-n-propyl rssorcinol 1~2-lo~
2-metbyl resorcinol 1.0-104
496-dimeth~l resorcinol . 0~8-1.0
5-n-butyl resorcinol 0.5-0.7
other alk~l resorcino~ 34.0-34.8
. Wi.tb a view to i~tensi~ying the process of foaming
and obtaini~g a more structurally bomogeneo~s foam
plastic~ the polyco~densation to~etber witb ~oaming
and c~ring sbould preferably be conducted in the pre-
sence of a non-ionic sur~actant taken in an amount
~- of 1 to 5% of the weight o~ the starting pbenols.
In order to enbance the mechanical strengtb of tbe
pbenol foam plastic, the polycondensation togetber witb
foaming and c~ri~g sbo~ld ad~isably be co~d~cted in
the presence o~ powdered boro~ ~aken.in an a~ount o~
1 to 5~0 of tbe weigbt of ~he starting pbenols.
~o red~ce the sorptio~ mois~ure content a~d mini~ize
water absorption of tbe desired foam plasticl tbe poly-
condensa~ion together with ~oaming and curing sbould
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pref`e~ably be conducted in tbe presence o~ polyvinyl
alcobol takcn in an amo~nt of 1 to 2~o 4f' the w~ight
of the starting phenols~ or in tbe presence o~ poly-
ethylene glycol taken in an amo~nt of 0.5 to 2.5~o o~
tbe wai~bt o~ the starting phenols.
Debailed Description of the Inve~tion
The proposed method for producin~ a phenoL foa~
plastic is realized as ~ollows:
Phenols (pyrocatechol, hydroquinone, resorcinol,
5-metbyl resorcinol; shale alk~l resorci~ols, shale
~otal pbenols, or various combinations o~ tbese pbenols~
are introduced into a 34-40~0 a~ueous sol~tion o~ formal-
debyde. ~be resulti~g ~ixture is thoroughly stirred till
complete dissolution Oe the pbenols. Tben, introduced
into the solution is a foaming agent and, i~ necessar~,
the appropriate addi~ivesg namely: a no~-ionic sureac-
tant, powdered boron, poly~inyl alcohol, polyetbylene
glycol. Tbe mixture is tboroughly stirred~ and an acid
or alkaline catalyst is added tbereto. '~he above compo-
nents may be mixed simultaneously, or in any otber se-
guence~ in a broad ~emperature range (~rom 10 to 60C)~
A~ber all tbe components ba~e been mixed~ sponta~eo~s
beating o~ tbe mixture begins with simultaneous polycon-
densation, :eoaming and curing~ wbich processes are
over in 5 to 60 seconds.
~ be ~bale al~gl resorcinols and sbale total phenols
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used in the proposcd method are produc~ of` ~rocessing
oil shales. The composit:Lon of` tbe sbale alkyl re30I-
cinols and sbale total phe~ols ~sed in tbe metbod may
vary according to the oil sbale deposits and the tech-
nigues of processing shales, which, bowe~er, does not
in a~y way af~ect th~ proposed metbod and properties
of the end product
~ s the acid catalyst9 ~se may be made, in tbe proposed
method, o~, ~or e~ample, mineral and oxganic acids, as
well as acid salts.
As tbe alkaline catalyst, use may be made, ~or example,
of an alkali metal bydroxide.
As tbe ~oaming agent~ a n~mber o~ compounds can be
used9 s~c~ as: carbonates and bicarbonates o~ alkali
metals, alkali-eartb me~als and ammoni~m; powders of me-
tals standing, in tbe electromotive series, bigher tha~
bydrogen; and liquids boiling or vigoro~sly evaporating
at temperat~res below 80C.
As tbe sur~actants, s~ch non-ionic s~r~ace-active
agents are ~sed as cellulose esters~ silicone oils,
and prod~cts of treatment o~ alkyl pbenols witb etbylene
oxide.
For a better ~nderstanding o~ th~ invention, tbe
~ollowin~ examples o~ its practical embodi~ent are give~
by way o~ tration. ~be properties of tbe phanol
foam plastic prod~ced according to eacb example are
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listcd in tbe table ~ollowin~ the examples.
$xample 1
100 parts by weight of :resorcinol are mi~ed, at 20C,
wi~-h 100 par~s by weigh~ o:~ a 34% aqueous sol~tion of
~ormaldehyde~ 2 parts by weight o~ calci~m carbonate,
and 2 parts by weight of polyhydroxy etbylene ester
of iso-oc~yl pbenol, of the following formula;
C H - C6H - O(CII2CH20)n l C~2CH2 3
As tbe resulting mixture is bei~g stirred, added thereto
are 50 parts bg weight o~ s~lfuric acid baving a speci~ic
gravity of 1.12. A~ter said components hava been mixed,
tbe processes of polycondensation, foaming and curing are
conducted simultaneo~sly to yield a pbe~ol foam plastic.
It takes 15 seconds ~or tbe foam plastic to form.
Example 2
100 parts bg weight of p~rocatecbol are mi~ed~ a~
18C, witb 100 parts by weight of a 34% agueo~s solution
of formaldehyde, 1 part by weigbt of the surfacta~t
o~ Example 1, and 3 parts by weigbt of powdered al~
n~m. Added to tbe resulting mixture~ witb stirring,
are 80 parts by weigbt o~ sulf~ric acid ha~ing a speci-
~ic gravity of 1.49. hfter said components bave been
mixed, tbe processes of polycondensation, foaming and
c~ring are conducted simul~aneo~sly to yield a pbenol
foam plastic~
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Example 3
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~ 100 parts by weight of 5-metbyl resoxcinol are mi~e~,,,, ~
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at 15 C, with 100 parts b9 ~eight of a 34% aq~eo~s
sol~-tion of formalde~yda and 20 parts b~ wei~bt o~ a
lig~id foaming agerlt~ name:L~ isopentane~ ~d~ed to ~be
res~lting mix~ro, witb stirring, are 50 parts by weigbt
of s~lfuric acid baving a specific gravit~ of` 1.52.
As a result, a phenol foam plastic is obtained
Example 4
100 parts by weigbt o~ hydroguinone axe mixed, at
60C, wi~b 100 parts by weigbt o~ a 34% aqueous solu-
tion of ~ormaldehyde and 3 parts by weigbt o~ calci~m
bicarbonate. Added to the resulting mixture, witb stir-
ring; are 80 part~ by weig~t o~ s~l~uric acid having a
speci~ic gravity o~ 1.52. 5 seconds a~ter bbe components
have be~n mixed, ~oxmation of a pbe~ol ~oam plastic is
completed.
EXample 5
s 100 parts by waigbt of resorcinol.are mixed; at 20C,
with 120 parts b~ wei~bt o~ a 34~ aqueous solution o~
~ormaldebyde, 3 parts b~ weigbt of polybydroxy etbylene
ester of isooctyl pbenol, of tbe following ~ormula:
C E~ - C6H4 - 0(CH2CH2)n.l ~ CH2CH2H'
and 3 parts by weigbt of ammoni~m carbonate. Added to
. tbe res~lting mixt~re, witb stirring~ are 83 parts by
~:~ weigbt of a 20% a~ueo~s solution o~ sodi~m bydroxide.
As a res~l~ o~ simultaneous pol~conde~sation, foaming
: and curi~V a phenol ~oam plastic is produced, wbose
~: ~ormation i.s completed a~ter 30 seco~dsO
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~xample G
100 par~ by weig~t ot 5-me~hyl xesorcinol are mi~od
with 90 pclrt~ by weight of a 40% aqueows solution of
~ormaldehyde, 3 parts by we:Lgbt of powdered alumin~m~
and 3 parts by weigbt ot` the sur~actant of Example 1.
Added to th~ res~lting mi~tllre, witb stirri~3 are
~0 parts by weight of a 20% aqueous solution of potas-
sium bydroxide After intensive stirrin~ o~ ~he compo-
~ents, tbe process of for~atiion o~ a pbe~ol foam plastic
is completed. It takes 60 seco~ds ~or the ~oam plastic
to form.
Example 7
100 parts by weigbt of sbale alkyl resorcinols
(composition, in % by weigbt: 5-metbyl resorci~ol - 46;
: 2,5-dimet~yl resorcinol - 12~ 4,5-dimethyl resorcinol -
12; 5-etbyl resorcinol - 12; otber alkyl re~orci~ols
are mix~d~ at 30C, witb 100 parts by wel~bt o~ a 34Y0
; aq~eo~s solution o~ ~ormaldebyde and 3 parts b~ weigh~
o~ calcium carbonate. Added to tbe resulting mixture,
witb s~irring, are ~5 parts by weight o~ sul~uric acid
bavi~g a specific gravi~y o~ 1.09. A~ter intensive
.; stirri~ of tbe components, the process o~ formabion
.. - o~ a phe~ol foa~ plastic is over. It takes 15 seconds
. ~or tbe foam plastic to form.
Example 8
100 parts by weigbt o~ ~bale aIk~l resorci~o~s
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(composi~ion, in % by wei~ht: 5-methyl resorcinol - 5~;
2,5-~ime~yl r~sorcinol - 9; 4,5-dimet~yl resorcinol 10;
5-ethyl resorcinol - 10; otber alkyl resorcinols - 13)
are Inixed, a~ 20C, with 100 parts b~ weigbt of a 34~o
aqweous solution oY formaldebyde~ 2 parts by weigbt o~
powdered aluminum~ and 5 parts by weight of tba sur~ac-
s
tant of Example 1. Added to the resul~ing mixtur~,
witb stirring, are 45 parts by weight of phosphoxic acid
t bavin~ a speci~ic gravity o:E 1.08. As a result of mixin~,
a pbenol ~oam plastic i5 obtained. It takes 40 seconds
for tbe foam plas~ic to ~orm.
Example 9
100 parts bg weight of shale alkyl resorcinols (compo-
,.
sitionj in % by weigbt: 5-methyl resorcinol - 50;
2,5-dimetbyl re40rcinol - 10.5; 495-dimetbyl resorcinol -
;- .
12; 5-etbyl resorcinol - 10.5; otber alkyl resorcinols -
17) are mixed, at 20C, with 130 parts by weight of a
3~% aq~eo~s sol~tio~ oY formaldebyde and 10 parts by
weigbt of a liquid ~oaming agent, namely, difluorodicblo-
romethane. Added to tbe resulting mi~t~re~ witb stirring,
are 50 parts by weigbt of byd~ochloric acid baving a
speci~ic gravity of 1.09. As a result of sim~ltaneo~s
polycondensation, foa~ing and c~ring~ a pbenol ~oam
plastic is obtained.
Example 10
100 parts by weight of s~ale alkyl resoroinols (com-
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position, in % by weigbt: 5-m~tbyl r~sorcinol - 52;
2,5-dime~byl resorcinol - 10.5; 475-di~etbyl resorcinol -
11; 5-ethyl resorcinol 11; other alkyl resorcinols
15.5) are f~ixed, at 25C, witb ~0 parts by weigbt of a
40~o agueous solution of' formaldebyde, 3 parts by weiæbt
of powdered alumi~um, and 3 parts by weigbt of the ~r-
factant o~ Exa~ple 5. ~d~ed to ~he resulting mixt~re,
witb s~irring, are ~5 parts by weight of a 20% aq~eous
sol~tion of sodium bydroxide. ~s a result o~ simultaneo~s
polycondensation~ foa~ing and curin~9 a pbenol foa~
plastic is obtained. It takes ~5 seconds for tbe foa~
plastic to for~.
:E~ample 11
100 parts by weigbt o~ s~ale total pbe~ols (co~posi-
tionjin % by weight: 5-metbyl resorcinol - 25~4;
4,5-dimatbyl resorcinol - 10.8; 5-etbyl resorcinol - 9.5;
2,5-dimet~yl resorcinol - 7.0; monoh~dric pne~ols - 3.0;
resoxcinoL - 2.6; 4-~ethyl resorcinol - 2~0; 5-n-propyl
; ~
; resorcinol - 108; 2-metbyl resorcinol - 1.4; 4,6-dimetbyl
resorcinol - 1.0; 5-n-butyl resorcinol - 0.7; other
alkyl resorcinols 3~.8) are mixed, at 10C, witb 80
parts by ~eigbt of a 34Y0 aqueo~s sol~tion of for~alde-
-~ byde, 5 parts by weigbt of calciu~ carbonate 3 an~ 5 part3
by weight of tbe surfactant of Example 1. ~dded to tbe
resulting mixture, with stirri~gt are 40 parts by weigbt ~ -
~: of sul~uric acid baving a specific gravity of 1.18.
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A~7 a result o~7 simLIlt,anco~s polycon/le~6~tion, ~70~ming
and curing7 ~ pt~enol ~70am plastic is prod~ced. Ik ta~es
15 seconds for tbe t70am plastic to form.
Example 12
100 parts by weight of 7hale total phenols (composi-
tion, in ~0 by ~vei~rbt: 5~metbyl resorcinol 29.4;
4,5-dlmethyl resorcinol - 8,0; 5-etbyl resorci~ol - 7.5;
2,5-dimetbyl resorci~ol - 5.4; monohySlric phenol~ - 9.4;
resorcinol - 1.6; ~-metbyl resorcinol _ 1.2; 5-n-propyl
resorcinol - 1.2; 2-metbyl resor¢inol l.Oi
4,6-dimetbyl resorcinol - 0.8; 5-n-butyl resorcinol - 0~5;
otber alkyl resorcinol~ - 34.0) are mixedg at 20C,
witb 60 parts by weigbt of7 a 40Y0 agueous solutio~ of
formaldebyde and 3 parts by weigbt o~7 powder~d aluminum.
Added to tbe resulting mix~ure, witb stirring, are
50 parts by weigbt of pbosphoric acid having a specific
gravity of 1.19. As a res~lt of sim~lta~eo~s polgconde~-
sa~ion, foaming and curing, a pbenol foam plastic is
obt a ined O
Example 13
100 parts by weigbt o~ sbale total phe~ols (composi-
tion, in ~0 by weigbt: 5-me~byl resorcinol - 27.4;
435-dimetbyl resorcinol - 9~4; 5-etbyl resorci~ol - 8.59
2,5-dimetbyl resorci~ol - 6.2; mo~obydric pbenol~ - 6.2;
resorcinol - 2.1; 4-metbyl resorcinol - 1.6; 5-n-p~opyl
resorcinol - 1.5; 2-metbyl resorcinol - 1.2;
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~,6 dirnethyl r~sorcinol - 0 9; 5~-butyl resorcinol - 0~6;
othar alkyl resorcinols _ 34.4) aro mixed, at 20C7 with
100 parts by ~veigh~ of a 37% agueous solution of formal-
deb~de and 4 parts by weigbt of ammoni~m carbonate.
Added to the resulting mixbllre, witb stixring, are
20 parts by weight o~ a 20~o agueo~s solution o~ sodium
hydroxide A~ter mixin~ all o~ the above components, tbe
processes of polycondensation, ~oaming and c~ri~g are
conducted simultaneously to yield a phenol foam plastic.
Example 14
100 parts by weigbt o~ sbale total pbenols (composi-
tion, in % by weight: 5-methyl resorcinol - 29.0;
4,5-dimebbyl resorcinol - 10~8; 5-ethyl resorcinol - 9.5;
2,5-dimetbyl resorcinol - 6.~, monobydric phenols - 1.0;
resorcinol - 2.3i 4~m0th~1 resorci~ol _ 1.7; 5-n-propyl
resorcinol - 1~6i 2-metbyl resorcinol - 1.3; 4,6-dime~thyl
resorcinol - 1.0; 5-~-butyl resorci~ol - 007; obher alkyl
resorcinols - 34.3) arc mixed, at 20C, witb 120 parts by
weigbt of a 34% agueous solution of ~ormaldehyde, 1.5 parts
by woight of calcium carbona~e, 3 parts by weight o~ t~e
s~rfactant of Exa~ple 5~ and 1 part by weigbt o~ powdered
boron. Added to tbe resulting mixture, witb st1rring,
are 20 parts by weigbt o~ sulf~ric acid baving a specific
gravity of 1,12. ~fter ~ixi~g all o~ tbe above components,
the processes of pol~condensation9 foaming and curi~g
aro conducted simultaneously to gield a pbenol ~oa~
plastic,
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~ample 15
100 par~s by weight of shale ~otal pbenols ol~ the
compo~ition of ~xample 12 are mixed, at 20C~ with
80 parts by weight of a 34~, aqueous solu~ion of formal-
dehyde, 2 parts by weight c,~ calcium carbonate, a~d
5 parts by weight of powdered boron. Added to tbe re-
- sulting ~ixture, with stirring, are 20 parts by weight
of s~lf~ric acid ha~in~ a speci~ic gra~itg o~ 1~12.
After mixing all o~ tbe above compone~ts, the processes
o~ polycondensation~ foaming and curing are conducted
simulta~eously to yield a pbenol foam plastic.
Example 16
100 parts by ~ei~ht of sbale total phe~ols of tbe
compo~itionbf Example 11 are mixed witb 100 parts by
weigbt o~ a 34% aqueous solutio~ of ~ormaldehyde,
2 parts by ~/eigbt of calci~m carbonate~ 2 parts by
weigbt of the sur~actant of hxample 5, and 2,~ parts
by weig~t o~ powdered boron~ Added to tbe resultin~
mixture, witb stirri~g, are 20 parts bg weighb of s~l-
furic acid baving a ~pecific gravity of 1.12 Aa a
resulb, a pbenol foam plastic is obtained.
Example 17
100 parts by weight o~ sbale total phenols o~ tbe
compo ition of Example 12 are mixed with 70 parts by
weight o~ a 40Yo agueous sol~tion of formaldebyde, 3 parts
by weigbt of calcium carbonateJ a~d 1 part by weigbt o~
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polyvinyl alcobol, Added to tbe rcs~lting mixtur-~) rJith
s~ixring, arq 30 part~ by wcigbt o~ sulfuric acid havin~
a specific gravi~y o~ 1.12. ~s a result, a phenol ~oa~
plastic i5 obtainod~
E~a~ple 18
100 parts by ~eight o~ sbale total phenolq o~ tbe
composition of Example 13 ar~ mixed with 200 parts bg
weight of a 40% agueous so~ution o~ ~oxmaldeb~de,
4 parts by weight of calcillm carbonat~/ 3 parts by
weigbt of the surfactant o~ Example 1, a~d 2 parts by
weight of polyvinyl alcohol. Added to tbe r~s~lting
mixt~re~ witb stirring, are 40 parts by ~eight of sul-
furic acid bavi~g a speci~ic gra~ity of 1~120 A~ter
mixlng all of tbe above components, tbe processes of
polycondensatio~, foami~g and curing are conductod
simulta~eously to yield a pbe~ol ~oam plastic.
Example 19
100 parts by weigbt of sbale total phenols of tbe
composition o~ Example 13 are mixed with 100 parts by
weigbt of a 3~% aq~eo~s solu~io~ of ~ormaldebyde, 3 parts
bg weight o~ calcium carbonate, 3 parts by weigbb of
the sur~acta~t o~ Example 5, and 0~5 parbs b~ weigbt
of polyetbylene glycol. Added to tbe resulting mixture~
with s~irri~, are 30 parts by weight o~ s~lfuric acid
having a ~pecific gravity of 1.120 ~B a res~lt, a phe~ol
~oam plas~ic is obtained.
s~ ,
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EX~mple 20
100 parts by weigbt of sbale ~otal phenols of tbe co0-
position o~ ~xa~le 11 are mixed witb 150 parts by weigh~
of a 40% aqueous solutio~ o~` ~orm~ldeb~de, 4 parts by
weigbt o~ calcium carbonate 7 and 2.7 par~s by wei~bt of
polyetbyl~ne glycol~ Added to tbe re~lti~g mixt~re,
with stirring, are 40 parts by weigbb of sulf~ric acid
ba~ing a speci~ic gra~i-ty of 1.12~ As a result~ a pbenol
~oam pla~tic i9 obtained.
Example 21
100 par~s by weigbt o~ sbale total pbenols of tbe com-
position of Example 12 are mixed with ~0 parts by weigbb
of a 37% agueous solution of formaldebyde, 3 parts by
weigbt o~ calcium carbonate, 3 parts by weigbt o~ the
sur~ac~ant of Example 1, and 1.5 parts by weight of
polyetbylene glycol~ Added to the resulting mixture~
with stirring, are 30 parts by weigbt o~ sul~uric acid
baving a specific gravity o~ 1.12~ A~ter mixing all o~
tbe above components, tbe processes o~ polycDndensation~
foa~ing and curing are conducbed simultaneously to
gield a pbenol ~oa~ plastic.
Example 22
50 part~ by weight of resorcinol and 50 parts by weigbt
o~ 5-metbyl resorcinol are ~ixed witb 100 parts by weigbt
o~ a 37% aqueous ~olution of ~or~aldebyde and 3 parbs by
weighb o~ calciu~ car~ona~e~ A~ded to tbe resulting mix-
- 18
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t~re, witb stirrin~, are 30 parts by weight o~ sul~ric
~cid bavin~ a spocific ~ravity of 1.14. A~t0r mixing
all of the above componentc;, the processe~ o~ poly-
co~densation, ~oaming and curing are co~d~ct.ed 9im~1ta
neo~qly to yield a pbenol foa~ plastic.
Example 23
~ 30 parts by weight of pyroeateebol, 30 parts by weight
of bydroguinone and 40 parts by weight of 5-methyl re-
soreinol are mixed witb 1~0 parts by weight o~ a 40%
ag~eou~ solution of formaldebyde, 2 parts by weigbt of
tbe sur~aetant of Examplo 1~ 3 parts by weight o~ cal-
eium earbonate, a parts by wei~hb of.powdered boron,
and 1 part bg weight of polyvinyl alcobolO Added to tbe
~ . res~ltin~ mixt~re~ witb stirring, are 40 parts by weigbb
.~ of sulfuric aeid baving a speci~ic gravitg o~ 1012.
After mixing all of tbe abo~e components, tbe proeesses o~
;~ polyeondensa~ion, ~oaming and euring are eondueted
simultaneouslg ~o yield a pbenol ~oa~ pla~ti¢0
Exampl~ 24
: . For eo~parison, this example illuitra~es bow p~enol
- ~oam plastie i~ obtained by the prior art met~od~
First~ ~ liguid resol. pbenol-~ormaldehyde resin is
obtained by way o~ polyeondensation of pbenol ~94 parts
., -; , ,
.: by weigbt) witb ~ormaldeh~de (130 parts by weigbt o~ a
37% agueou~ solution) in tbe presenee of 1.5 parts by
~ ~ weigbt of ~lodi~ b~droxideO ~he polyeonden~ation i8
:. eondueted at 75 ~o 80C ~or 2.5 to 3.hours.
19 -
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Tbe rosulting product ls neutralized with bo.ric acid
to pH - 7.0-7.3 and conce~brated by distilling off
wa~er and vola~ile compounds under vacuum (ultimate
pressure of 100 to 160 mm Hg) ~o a spoci~ic gravity of
: 1.24 g/cu.cm, ab 20C.
~ ~ Tbe obtained resol pb~nol-formaldebyde resin is raixed
witb 1.4 parts b~ weight of powdered al~min~m, 4 parbs
by weight 4f ths surfactant o~ Example 1, a~d added to
tho mixture are 17 parts by weight o~ bhe produ~ o~
polyconden~ation of sulfopbenol urea with formaldebyde
and 42 parts by wei~ht o~ orthophospboric acid. 1.5 to
2 ~in~.tes after bbe components bave been mixed, foaming
and curing of bbe mixture start. As a result, a pbenol
foam plastiG ia obtained.
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