IPC분류정보
국가/구분 |
United States(US) Patent
공개
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0486246
(2012-06-01)
|
공개번호 |
US-0072589
(2013-03-21)
|
우선권정보 |
IE-PCT/IE2005/000092 (2005-09-08) |
발명자
/ 주소 |
- Coppock, Vincent
- Zeggelaar, Ruud
- Takahashi, Hiroo
- Kato, Toshiyuki
|
출원인 / 주소 |
- KINGSPAN HOLDINGS (IRL) LIMITED
|
인용정보 |
피인용 횟수 :
0 인용 특허 :
0 |
초록
▼
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 leas
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.
대표청구항
▼
1-40. (canceled) 41. A phenolic foam 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 wherein the blowing agent comprises at least one of butane, pentane, hexane, heptane and isomers thereof, t
1-40. (canceled) 41. A phenolic foam 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 wherein the blowing agent comprises at least one of butane, pentane, hexane, heptane and isomers thereof, the inorganic filler is as metal hydroxide or metal carbonate with an Ionic Equilibrium Solubility (Ksp) less than 10−8 when measured at 25° C. and is present in an amount of from 1 to 10 parts by weight per 100 parts by weight of phenolic resin, wherein the phenolic foam comprises a plasticiser for the phenolic resin, wherein the plasticiser has a molecular structure containing both an ester backbone and a hydroxyl group, an organic modifier for co-reacting with the phenolic resin, and wherein the phenolic foam has a pH of 5 or more, a closed cell content of 90% or more, and an aged thermal conductivity of 0.025 W/m·K or less when measured at a mean temperature of 10° C. after heat ageing for 175±5 days at 70±2° C. in accordance with the procedure specified in European Standard EN13166: 2001, Annex C, Section C.4.2.3. 42. The phenolic foam as claimed in claim 41 wherein the filler comprises a metal carbonate such as calcium carbonate, barium carbonate, zinc carbonate 43. The phenolic foam as claimed in claim 41 wherein the filler comprises calcium carbonate. 44. The phenolic foam as claimed in claim 41 the phenolic resin has a molar ratio of phenol groups to aldehyde groups in the range 1:1 to 1:3, preferably the molar ratio of phenol groups to aldehyde groups is from 1.5 to 2.3. 45. The phenolic foam as claimed in claim 41 wherein the phenolic resin has a weight average molecular weight of from 400 to 3,000, preferably the phenolic resin has a weight average molecular weight of from 700 to 2,000. 46. The phenolic foam as claimed in claim 41 wherein the blowing agent is present in an amount of 1 to 20 parts be weight per 100 parts by weight of phenolic resin. 47. The phenolic foam as claimed in claim 41 wherein the blowing agent comprises cyclopentane and at least one hydrocarbon of isobutene and isopentane. 48. The phenolic foam as claimed in claim 47 wherein the blowing agent comprises 75% or more of cyclopentane. 49. The phenolic foam as claimed in claim 47 wherein the blowing agent comprises 25% or less of at least one hydrocarbon of isobutene and isopentane. 50. The phenolic foam as claimed in claim 41 wherein the acid catalyst is present in an amount of 5 to 25 parts by weight per 100 parts by weight of phenolic resin, preferably the acid catalyst comprises at least one of beneznesulphonic acid, papr-toluenesulphonic acid, xylenesulphonic, naphthalenesulphonic acid, ethylbenzenesulphonic acid and phenolsulphonic acid. 51. The phenolic foam as claimed in claim 41 wherein the plasticiser is present in an amount of 0.1 to 20 parts by weight per 100 parts by weight of phenolic resin, preferably the plasticiser comprises a polyester polyol that is the reaction product of a polybasic carboxylic acid selected from a dibasic to a tetrabasic carboxylic acid with a polyhydric alcohol selected from a dihydric to a pentahydric alcohol, preferably the polyester polyol has a number average molecular weight of 250 to 350 and a weight average molecular weight of 400 to 550. 52. The phenolic foam as claimed in claim 51 wherein the polybasic carboxylic acid used to synthesise the polyester polyol comprises at least one of phthalic acid, isophthalic acid, terephthalic acid, naphthalene-2,3-dicarboxylic acid, naphthalene-1,4-dicarboxylic acid, naphthalene-2,6-dicarboxylic acid, adipic acid, pimeric acid, suberic acid, azelaic acid, sebacic acid, cyclohexane-1,2-dicarboxylic acid, cyclohexane-1,3-dicarboxylic acid, and cyclohexane-1,4-dicarboxylic acid, preferably the polybasic carboxylic acid used to synthesise the polyester polyol comprises one or more of phthalic acid, isophthalic acid, or terephthalic acid. 53. The phenolic foam as claimed in claim 51 wherein the polyhydric alcohol used to synthesis the polyester polyol comprises at least one of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butane diol, 1,5-pentane diol, 1,6-hexane diol, neopentyl glycol, 1,2-cyclohexane dimethanol, 1,3-cyclohexane dimethanol and 1,4-cyclohexane dimethanol. 54. The phenolic foam as claimed in claim 53 wherein the polyhydric alcohol used to synthesise the polyester polyol comprises one or more of diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butane diol. 55. The phenolic foam as claimed in claim 41 comprising a surfactant for the phenolic resin, preferably the surfactant is present in an amount of 1 to 6 parts by weight per 100 parts by weight of phenolic resin, preferably the surfactant is a castor oil-ethylene oxide adduct wherein more than 20 moles but less than 40 moles of ethylene oxide are added per 1 mole of castor oil. 56. The phenolic foam as claimed in claim 41 wherein the modifier is present in an amount of 1 to 10 parts be weight of a compound having an amino group per 100 parts by weight of phenolic resin, preferably at least one amino group containing compound is selected from urea, dicyandiamide and melamine. 57. The phenolic foam as claimed in claim 41 wherein the density of the phenolic foam is from 10 to 100 kg/m3. 58. The phenolic foam as claimed in claim 41 wherein the density of the phenolic foam is from 10 to 45 kg/m3. 59. The phenolic foam as claimed in claim 41 having a limiting oxygen index of 30% or more. 60. The phenolic foam as claimed in claim 41 having a moisture uptake of less than 0.9 kg/m2. 61. The phenolic foam as claimed in claim 41 having a moisture uptake of less than 0.8 kg/m2. 62. The phenolic foam as claimed in claim 41 having a facing on at least one surface thereof, preferably the facing comprises at least one of glass fibre-non woven fabric, spun bonded-non woven fabric, aluminium foil, bonded-non woven fabric, metal sheet, metal foil, ply wood, calcium silicate-board, plaster board, Kraft or other paper product, and wooden board.
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