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Phenolic Foam

a technology of phenolic foam and cell walls, applied in the field of phenolic foam, can solve the problems of metals being susceptible to corrosion, reducing the flexibility of the cell walls of phenolic foam with time, and degrading thermal insulation performan

Inactive Publication Date: 2010-01-14
KINGSPAN HLDG (IRL) LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0001]Phenolic foam is used in insulation applications for construction materials because of its superior thermal insulation and fire resistance characteristics.
[0002]It is known that the thermal conductivity of polymeric thermal insulation materials including phenolic foam can change with time. This phenomenon is caused by the gradual diffusion out of gas from inside the foam cells. The gas present inside the foam cells is the blowing agent used in the foaming process. The gas in the foam cells is slowly replaced by air from the atmosphere. As a result, the thermal conductivity of phenolic foam can increase with time.
[0003]It is highly desirable to achieve long-term stability for the thermal insulation performance of phenolic foam products. It is believed that one of the causes for the degradation of thermal insulation performance is the reduction in the flexibility of the cell walls of phenolic foam with time. Therefore, an object of the present invention is to impart flexibility to the cell walls and thereby maintain closed cell structure in the phenolic foam. Stable closed cell structure provides a means for maintaining stable thermal conductivity for the phenolic foam over an extended time period.
[0005]Accordingly, an object of the invention is to provide phenolic foam that has excellent thermal insulation performance, yet also has a higher pH value when compared to conventional phenolic foam. Such a phenolic foam when in contact with metal would have significantly reduced potential to induce metallic corrosion.

Problems solved by technology

It is believed that one of the causes for the degradation of thermal insulation performance is the reduction in the flexibility of the cell walls of phenolic foam with time.
This could cause a problem when metallic materials are in contact with the phenolic foam, as metals could be susceptible to corrosion.

Method used

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Examples

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Effect test

example 1

[0083]104 parts by weight (pbw) of Resin A at 20° C. is mixed with 5 pbw of powdered urea and 5 pbw of plasticiser. The resin is allowed to stand for 1 hour at 20 C. Next is added 5.3 pbw of calcium carbonate (Durcal 130 from Omya), with average particle size 170 μm. The resin is mixed at 300 rpm until calcium carbonate is uniformly dispersed. Resin A, (containing urea and calcium carbonate filler), is then cooled to between 17° C. and 21° C. The said phenolic resin mixture is pumped to a high speed peg mixer where 9 parts by weight of cyclopentane / isopentane (85 / 15 by weight) is added as blowing agent, and 20 parts by weight liquid para-toluene sulphonic acid / xylene sulphonic acid blend (65 / 35 w / w) at 92% concentration is added as catalyst. In the peg mixer, intimate mixing is achieved to give a foamable phenolic resin composition. The resin composition is discharged on to the lower non woven mat facing material which is carried on a running conveyor into a foam lamination machine....

example 2

Here There is a Reduced Amount of Plasticiser (2.5 Parts Per Weight Instead of 5 Parts Per Weight)

[0085]104 parts by weight (pbw) of Resin A at 20° C. is mixed with 5 pbw of powdered urea and 2.5 pbw of plasticiser. The resin is allowed to stand for 1 hour at 20 C. Next is added 5.3 pbw of calcium carbonate, (Durcal 130 from Omya). The resin is mixed at 300 rpm until calcium carbonate is uniformly dispersed. Resin A, (containing urea and calcium carbonate filler), is then cooled to between 17° C. and 21° C. The said phenolic resin mixture is pumped to a high speed peg mixer where 9 parts by weight of cyclopentane / isopentane (85 / 15 by weight) is added as blowing agent, and 20 parts by weight liquid para-toluene sulphonic acid / xylene sulphonic acid blend (65 / 35 w / w) at 92% concentration is added as catalyst. In the peg mixer, intimate mixing is achieved to give a foamable phenolic resin composition. The resin composition is discharged on to the lower non woven mat facing material whic...

example 3

Here There is a Reduced Amount of Urea (2.5 Parts Per Weight Instead of 5 Parts Per Weight)

[0087]104 parts by weight (pbw) of Resin A at 20° C. is mixed with 2.5 pbw of powdered urea and 5 pbw of plasticiser. The resin is allowed to stand for 1 hour at 20 C. Next is added 5.3 pbw of calcium carbonate (Durcal 130 from Omya). The resin is mixed at 300 rpm until calcium carbonate is uniformly dispersed. Resin A, (containing urea and calcium carbonate filler), is then cooled to between 17° C. and 21° C. The said phenolic resin mixture is pumped to a high speed peg mixer where 9 parts by weight of cyclopentane / isopentane (85 / 15 by weight) is added as blowing agent, and 20 parts by weight liquid para-toluene sulphonic acid / xylene sulphonic acid blend (65 / 35 w / w) at 92% concentration is added as catalyst. In the peg mixer, intimate mixing is achieved to give a foamable phenolic resin composition. The resin composition is discharged on to the lower non woven mat facing material which is car...

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Abstract

A phenolic foam is made by foaming and curing a foamable phenolic resin composition that comprises a phenolic resin, a blowing agent, an acid catalyst and an inorganic filler. The blowing agent comprises an aliphatic hydrocarbon containing from 1 to 8 carbon atoms and the inorganic filler is at least one selected from a metal hydroxide, a metal oxide, a metal carbonate and a metal powder. The phenolic foam has a pH of 5 or more. The phenolic foam has a higher pH value compared with conventional phenolic foam and reduces corrosion risk when in contact with metallic materials. The phenolic foam maintains excellent long-term stable thermal insulation performance, low water uptake and fire resistance performance and by using a hydrocarbon blowing agent, does not harm the environment as an ozone depleting or global warming material.

Description

[0001]Phenolic foam is used in insulation applications for construction materials because of its superior thermal insulation and fire resistance characteristics.[0002]It is known that the thermal conductivity of polymeric thermal insulation materials including phenolic foam can change with time. This phenomenon is caused by the gradual diffusion out of gas from inside the foam cells. The gas present inside the foam cells is the blowing agent used in the foaming process. The gas in the foam cells is slowly replaced by air from the atmosphere. As a result, the thermal conductivity of phenolic foam can increase with time.[0003]It is highly desirable to achieve long-term stability for the thermal insulation performance of phenolic foam products. It is believed that one of the causes for the degradation of thermal insulation performance is the reduction in the flexibility of the cell walls of phenolic foam with time. Therefore, an object of the present invention is to impart flexibility ...

Claims

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Application Information

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IPC IPC(8): C08L61/06
CPCC08J9/0066C08L71/08C08J2361/06C08J9/141
Inventor COPPOCK, VINCENTZEGGELAAR, RUDDTAKAHASHI, HIROOKATO, TOSHIYUKI
Owner KINGSPAN HLDG (IRL) LTD
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