CA1109598A - Process for preparing a composite product constituted by foam particles - Google Patents
Process for preparing a composite product constituted by foam particlesInfo
- Publication number
- CA1109598A CA1109598A CA299,206A CA299206A CA1109598A CA 1109598 A CA1109598 A CA 1109598A CA 299206 A CA299206 A CA 299206A CA 1109598 A CA1109598 A CA 1109598A
- Authority
- CA
- Canada
- Prior art keywords
- particles
- product
- expanded
- volume
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/35—Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
- B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2061/00—Use of condensation polymers of aldehydes or ketones or derivatives thereof, as moulding material
- B29K2061/04—Phenoplasts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
- B29K2105/165—Hollow fillers, e.g. microballoons or expanded particles
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
- C08J2361/04—Condensation polymers of aldehydes or ketones with phenols only
- C08J2361/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The present invention relates to a composite product constituted by virtually contiguous particles of expanded poly-styrene, connected together by an expanded or foamed phenol-formaldehyde resin, of density between 50 and 500 g/l and to a process for preparing said product and to the finished products, in the form of panels or moulded articles, made from said product.
The present invention relates to a composite product constituted by virtually contiguous particles of expanded poly-styrene, connected together by an expanded or foamed phenol-formaldehyde resin, of density between 50 and 500 g/l and to a process for preparing said product and to the finished products, in the form of panels or moulded articles, made from said product.
Description
The presenc invention relates to a composite product comprising a foam polystyrene particle, preferably expanded polystyrel~e balls, and a relatively dense expanded or foamea pllenol-formaldehyde resin. The pxesent invention also relates to the process for preparing said product.
A process for obtaining plates or other shaped articles has already ~een described, whereby expansible granules or beads are moulded in a thermoplastic resin; during moulding, the granules, wilich are possibly preheated, are taken to a sufficiellt temperature to expand and adhere to one another, so as to form a single article.
~ any years ago, a process for preparin~ moulded bodies was also aescribed characterised in that particles of expanded or expansible polystyrene were connected together by means of a suitable adhesive or binder. More than ten years ago, it was proposed to use, as adhesive or binder, heat-settable resins such as "urea-malamine-phenol-formaldehyde resins or cresol -resorcinol formaldehyde resins". I~owever, the products obtained by these processes do not present at the same time, the mechanical insulating properties which are desirable for numerous applications.
A composite product has now been found which presents, with respect to the earlie~ known products of the same type, a remar~able combination of properties, this product being char-acterised in that it is constituted by a foam in the form of individual foam polystyrene particles connected together by a relatively expanded pnenol-formaldehyde resin.
According to the present invention therefore the present invention provides a composite product comprising foamed polystyrene particles whose volume represents 75 to 95% of the apparent volume of said particles and, between said particles, and expanded phenol-formaldehyde resin of density between 50 and 500 g/l the volume of the composite product ~eing 5 to 25%
A process for obtaining plates or other shaped articles has already ~een described, whereby expansible granules or beads are moulded in a thermoplastic resin; during moulding, the granules, wilich are possibly preheated, are taken to a sufficiellt temperature to expand and adhere to one another, so as to form a single article.
~ any years ago, a process for preparin~ moulded bodies was also aescribed characterised in that particles of expanded or expansible polystyrene were connected together by means of a suitable adhesive or binder. More than ten years ago, it was proposed to use, as adhesive or binder, heat-settable resins such as "urea-malamine-phenol-formaldehyde resins or cresol -resorcinol formaldehyde resins". I~owever, the products obtained by these processes do not present at the same time, the mechanical insulating properties which are desirable for numerous applications.
A composite product has now been found which presents, with respect to the earlie~ known products of the same type, a remar~able combination of properties, this product being char-acterised in that it is constituted by a foam in the form of individual foam polystyrene particles connected together by a relatively expanded pnenol-formaldehyde resin.
According to the present invention therefore the present invention provides a composite product comprising foamed polystyrene particles whose volume represents 75 to 95% of the apparent volume of said particles and, between said particles, and expanded phenol-formaldehyde resin of density between 50 and 500 g/l the volume of the composite product ~eing 5 to 25%
- 2 -~ J`~
greater than the apparent expanded volume o~ the foam particles.
The particles of foam or of expanded polystyrene which may be used according to the invention are balls of expanded polystyrene expanded polystyrene balls are preferably used, which are substantially spherical in form and have a diameter of between about 0.8 to 10 mm.
It is possible to use particles of foam of various types ~nixturesof polystyrene balls and of balls of expanded glass) and it is advantageous, for checking the properties of the final product, to use mixtures of particles of different dimensions (average diameter): The use of balls of different dimensions makes it possible to reduce as much as possible the natural gaps (before use of the resin) between the balls.
In the concrete industry, a method is known which allows a suitable selection of the dimensions of the granulates to minimise the quantity of hydraulic binder to be used, so as to obtain a closed concrete with the aid of these granulates.
According to the invention, a mixture of 1 part by volume of expanded polystyrene balls of average diameter 6 mm with 0.4 part by volume of expanded polystyrene balls of average diameter close to 0.8 mm, ~ill preferably be used.
Expanded phenol-formaldehyde resin is a phenol-formaldehyde resin of apparent density ranging from 50 kg per cubic metre to 500 kg per cubic metre. It is generally obtained by limited expansion of a slightly viscous resole containing a porogenic agent such as a Freon (a trade mark) for examplei this resole also advantageously contains a surface-active a~ent making it possible to compl`etely obtain, in an expanded resin with closed cells. Of course, the resole also contains an acid hardener (catalyst) wnicll ensures the reaction of polycondensation of the resole into the expanded resin. The ~xpanded resin fills all the gaps which remain between the particles of pol~styrene foam.
greater than the apparent expanded volume o~ the foam particles.
The particles of foam or of expanded polystyrene which may be used according to the invention are balls of expanded polystyrene expanded polystyrene balls are preferably used, which are substantially spherical in form and have a diameter of between about 0.8 to 10 mm.
It is possible to use particles of foam of various types ~nixturesof polystyrene balls and of balls of expanded glass) and it is advantageous, for checking the properties of the final product, to use mixtures of particles of different dimensions (average diameter): The use of balls of different dimensions makes it possible to reduce as much as possible the natural gaps (before use of the resin) between the balls.
In the concrete industry, a method is known which allows a suitable selection of the dimensions of the granulates to minimise the quantity of hydraulic binder to be used, so as to obtain a closed concrete with the aid of these granulates.
According to the invention, a mixture of 1 part by volume of expanded polystyrene balls of average diameter 6 mm with 0.4 part by volume of expanded polystyrene balls of average diameter close to 0.8 mm, ~ill preferably be used.
Expanded phenol-formaldehyde resin is a phenol-formaldehyde resin of apparent density ranging from 50 kg per cubic metre to 500 kg per cubic metre. It is generally obtained by limited expansion of a slightly viscous resole containing a porogenic agent such as a Freon (a trade mark) for examplei this resole also advantageously contains a surface-active a~ent making it possible to compl`etely obtain, in an expanded resin with closed cells. Of course, the resole also contains an acid hardener (catalyst) wnicll ensures the reaction of polycondensation of the resole into the expanded resin. The ~xpanded resin fills all the gaps which remain between the particles of pol~styrene foam.
- 3 -- .. , - : - .
~r~5~
In the products according to the invention, the foam particles are preferably contiguous or close to one another; in practice, the volume of the final material is 5 to 25~ greater than the apparent expanded volume of the foam polystyrene particles.
Thus, for example, when the finished moulded piece must have a volume of 1 litre, substantially 1 litre ~by apparent expanded volume) o~ expanded polystyrene balls of average diameter 6 mm will be used and, to fill the gaps b~tween these balls, 0.~ to 0.~ litre of expanded polystyrene balls of average diameter 0.8 mm and a sufficient quantity of phenol-formaldehyde resin for all the gaps remaining betweèn the polystyrene balls, after expansion of said resin, to be filled with an expanded resin having a density of between 50 and 500 g/l.
It is possible to obtain products of adjusted apparent d~nsit~, within certain limits; for this! one may: (a) either vary the density of the expanded resin, without changing the quantity and granulometry of the balls; or (b) by maintaining constant the density of the modified resin, vary the granulometry of the balls and the quantity of balls used (by modifying the quantity of small balls with respect to the large ones).
The products according to the invention have remarkable properties of fire resistance, mechanical resistance in view of their density and heat insulation (said latter often being lower than 0.035 kcal/m/hQC). They are in the form of blocks in which there are no intercommunicating gaps, this avoiding any a~sorption of water by these products and allowing the moulding, over all the faces of the product, of charged or non-charged resins, without penetration of said resins inside the products.
The present invention also relates to a process for manufacturing the above-described novel productsin wllicll a g-iven quantity of emulsified resole containing the necessary ingredients '' lncluding nardener, porogenic agent and surface-active agent is injected in~o a bed of foam polys~yrene particles, previously disposed in a mould, t]le temperature of said mould is then raised so as to effect the expansion and poly-condensation of the phenol-formaldehyde resole until the mould is filled, without awaitin~ a temperature which would ~rovoke a possible softening of the foam particles.
It will be noted that the balls of foam polystyrene particles are never subjected to a pressure during manufacture of the products, except, possibly, when the particles are placed in the mould, said (low) pressure then being used to prevent expansion of said particles.
~ lthough non-coated foam particles may be used, the impro~ed process according to the invention consists in effecting a pre-coating of said particles with the aid of a resin emulsion and in introducing said pre-coated particles in the mould in order to effect expansion of the resin therein.
The heating of the phenol-formaldehyde resin to effect expansion and cross-linking of the phenol-formaldehyde resin may be effected by any known means. However, i~t will be noted that, since initially the (coated or uncoated) foam pàrticles fill the whole of the mould, it is possible and even very ad-~antageous to effect said heating by means of a high-frequency current.
On carrying out the invention r it has been noted that the products obtained present/ even when thick, a very high homogeneity; this is to be understood to mean, not only that the foam particles are perfectly and regularly distributed in the whole moulded volume, but also that the cells of the expanded phenol-formaldehyde resin are completely regular; this latter phenomenon probably comes from the fact that said expanded resin is never in very thick form.
- .
.
$~;¢~
Of course, the invention enables moulded pieces of very varied snapes to be product , constituted by the products according to the invention; if in particular glass fabrics or mats llave been disposed inside or on the surface of the mould, the phenol-formaldehyde resin(then used in slightly larger quantities than those previously described) will impregnate said fabrics or mats and a composite material having the advantageous properties will ~e directly obtainedi pieces may also be produced which comprise reinforcing elements or inserts of different nature, 10 located inside or preferably on the surface of the pieces produced ac~ording to the invention. Decorative elements may also be disposed on tlle surface of the products according to the invention.
Expanded pieces have also been advantageously produced by disposing, inside pieces according to the lnvention, rigid or 5ut)~1~, porous panels, themselves made of foam particles (for ~x~mple, panels made by agglomeration of expanded polystyrene be~ds); by using a slight excess of phenol-formaldehyde resin, this latter, during its expansion, penetrates into the gaps in the porous panels, forming a complex composite material having interesting properties.
The following non-limiting examples illustrate the invention.
Exame~: `
A mould is used having an inner volume of 1000 litres ~dimensions being 2.50 metres x 4 metres x 0~10 m); this mould is filled with the aid of "venturis", with a mixture of 1000 litres of expanded polystyrene balls (density 12 kg per m3), of average diameter 6 mm, and of 400 litres of expanded polystyrene balls tdensity 20 kg per m3), of average diameter 0.6 mm; about 40 kg of emulsified phenol-formaldehyde resin constituted by 30 kg of resole, 3 kg of hardener (acid), 7 kg of porogenic agent ~freon~
and 30 g of surface active agent, are injected into this mould.
~b .
The whole is ileated to about 450C for about 1 hour. The panel obtained, when removed from the mould, is left to mature in an oven for a~out 2 hours at around 70C.
Examples 2 to 6 The technique used in these examples is the so-called pre-coating technique which consists, in a preliminary operation, in coating expanded polystyrene balls (density 12 kg/m3) with a certain quantity of phenol-formaldehyde resin in the form of an emulsion and containing a swelling agent (for example 20 to 30~
~y weight of freon with respect to the resin), a surface-active agent (used for exa~ple at a rate of 1 to 3~ by weight with respect to the resin) and an acid catàlyst (used for example at a rate of 2 to 10% by weight with respect to the resin); then in a second operation, these pre-coated balls are introduced into a mould, tlle mould is closed and the material therein is heated with the aid of high frequency ~27 kHz emitted by plates); the duration of heating is considerably shorter than with the con- -ventional technique, since this duration is of the order of one minute.
In this way, by varying the quantities of balls and resin, panels presenting the following prope~ties are obtained:
: .
.. ..
.
, 5'r~3 Polystyrene balls Phenol- Resistance Insulation formal- to compress- coefficienl dehyd~ ion (kg/cm2) (kcal/m/m2, . resin h/Q C) ., 1 m3 of diameter 6mm 0.4 m3 of diameter 0.8 to 2mm 20 kg 1.66 0.0296 1 m3 of diameter 6mm 0.4 m3 of diameter 0.8 to 2mm 30 kg 2.41 0.0292 1 m3 of diarneter 6mm 0. 4 M3 of diameter 0~8 to 2mm 80 kg 2.61 0.032 1 m3 of diameter 6mm 40 kg 2.49 0.0282 1 m3 of diameter 0.8 .
to 2mm 40 kg 3.70 0.0360 Example 7 . . .
A com~osite panel is made comprising, on its two faces, a glass mat and at the centre a ma~erial according to the invention.
A first glass mat (mat of 300 g/m2 and a thickness of about 0.7 mm) is firstly deposited on the bottom of the mould, then the normal quantity, according to the invention, of polystyrene balls precoated with an emulsion of phenol-formaldehyde resin tas described in Example 2) is deposited on this mat and a supple~
mentary quantity of emulsion of phenol-formaldehyde resin equal to about 1.2 ~g of resin per square metre of panel to be produced, is added, a second glass mat identical to the first is deposite~
on the upper surface of the balls, the mould is closed and the whole is su~jected to a heating (for example up to 40-50QC) so as to cause the phenol-formaldehyde resin to foam and cross-link.
..
~r~5~
In the products according to the invention, the foam particles are preferably contiguous or close to one another; in practice, the volume of the final material is 5 to 25~ greater than the apparent expanded volume of the foam polystyrene particles.
Thus, for example, when the finished moulded piece must have a volume of 1 litre, substantially 1 litre ~by apparent expanded volume) o~ expanded polystyrene balls of average diameter 6 mm will be used and, to fill the gaps b~tween these balls, 0.~ to 0.~ litre of expanded polystyrene balls of average diameter 0.8 mm and a sufficient quantity of phenol-formaldehyde resin for all the gaps remaining betweèn the polystyrene balls, after expansion of said resin, to be filled with an expanded resin having a density of between 50 and 500 g/l.
It is possible to obtain products of adjusted apparent d~nsit~, within certain limits; for this! one may: (a) either vary the density of the expanded resin, without changing the quantity and granulometry of the balls; or (b) by maintaining constant the density of the modified resin, vary the granulometry of the balls and the quantity of balls used (by modifying the quantity of small balls with respect to the large ones).
The products according to the invention have remarkable properties of fire resistance, mechanical resistance in view of their density and heat insulation (said latter often being lower than 0.035 kcal/m/hQC). They are in the form of blocks in which there are no intercommunicating gaps, this avoiding any a~sorption of water by these products and allowing the moulding, over all the faces of the product, of charged or non-charged resins, without penetration of said resins inside the products.
The present invention also relates to a process for manufacturing the above-described novel productsin wllicll a g-iven quantity of emulsified resole containing the necessary ingredients '' lncluding nardener, porogenic agent and surface-active agent is injected in~o a bed of foam polys~yrene particles, previously disposed in a mould, t]le temperature of said mould is then raised so as to effect the expansion and poly-condensation of the phenol-formaldehyde resole until the mould is filled, without awaitin~ a temperature which would ~rovoke a possible softening of the foam particles.
It will be noted that the balls of foam polystyrene particles are never subjected to a pressure during manufacture of the products, except, possibly, when the particles are placed in the mould, said (low) pressure then being used to prevent expansion of said particles.
~ lthough non-coated foam particles may be used, the impro~ed process according to the invention consists in effecting a pre-coating of said particles with the aid of a resin emulsion and in introducing said pre-coated particles in the mould in order to effect expansion of the resin therein.
The heating of the phenol-formaldehyde resin to effect expansion and cross-linking of the phenol-formaldehyde resin may be effected by any known means. However, i~t will be noted that, since initially the (coated or uncoated) foam pàrticles fill the whole of the mould, it is possible and even very ad-~antageous to effect said heating by means of a high-frequency current.
On carrying out the invention r it has been noted that the products obtained present/ even when thick, a very high homogeneity; this is to be understood to mean, not only that the foam particles are perfectly and regularly distributed in the whole moulded volume, but also that the cells of the expanded phenol-formaldehyde resin are completely regular; this latter phenomenon probably comes from the fact that said expanded resin is never in very thick form.
- .
.
$~;¢~
Of course, the invention enables moulded pieces of very varied snapes to be product , constituted by the products according to the invention; if in particular glass fabrics or mats llave been disposed inside or on the surface of the mould, the phenol-formaldehyde resin(then used in slightly larger quantities than those previously described) will impregnate said fabrics or mats and a composite material having the advantageous properties will ~e directly obtainedi pieces may also be produced which comprise reinforcing elements or inserts of different nature, 10 located inside or preferably on the surface of the pieces produced ac~ording to the invention. Decorative elements may also be disposed on tlle surface of the products according to the invention.
Expanded pieces have also been advantageously produced by disposing, inside pieces according to the lnvention, rigid or 5ut)~1~, porous panels, themselves made of foam particles (for ~x~mple, panels made by agglomeration of expanded polystyrene be~ds); by using a slight excess of phenol-formaldehyde resin, this latter, during its expansion, penetrates into the gaps in the porous panels, forming a complex composite material having interesting properties.
The following non-limiting examples illustrate the invention.
Exame~: `
A mould is used having an inner volume of 1000 litres ~dimensions being 2.50 metres x 4 metres x 0~10 m); this mould is filled with the aid of "venturis", with a mixture of 1000 litres of expanded polystyrene balls (density 12 kg per m3), of average diameter 6 mm, and of 400 litres of expanded polystyrene balls tdensity 20 kg per m3), of average diameter 0.6 mm; about 40 kg of emulsified phenol-formaldehyde resin constituted by 30 kg of resole, 3 kg of hardener (acid), 7 kg of porogenic agent ~freon~
and 30 g of surface active agent, are injected into this mould.
~b .
The whole is ileated to about 450C for about 1 hour. The panel obtained, when removed from the mould, is left to mature in an oven for a~out 2 hours at around 70C.
Examples 2 to 6 The technique used in these examples is the so-called pre-coating technique which consists, in a preliminary operation, in coating expanded polystyrene balls (density 12 kg/m3) with a certain quantity of phenol-formaldehyde resin in the form of an emulsion and containing a swelling agent (for example 20 to 30~
~y weight of freon with respect to the resin), a surface-active agent (used for exa~ple at a rate of 1 to 3~ by weight with respect to the resin) and an acid catàlyst (used for example at a rate of 2 to 10% by weight with respect to the resin); then in a second operation, these pre-coated balls are introduced into a mould, tlle mould is closed and the material therein is heated with the aid of high frequency ~27 kHz emitted by plates); the duration of heating is considerably shorter than with the con- -ventional technique, since this duration is of the order of one minute.
In this way, by varying the quantities of balls and resin, panels presenting the following prope~ties are obtained:
: .
.. ..
.
, 5'r~3 Polystyrene balls Phenol- Resistance Insulation formal- to compress- coefficienl dehyd~ ion (kg/cm2) (kcal/m/m2, . resin h/Q C) ., 1 m3 of diameter 6mm 0.4 m3 of diameter 0.8 to 2mm 20 kg 1.66 0.0296 1 m3 of diameter 6mm 0.4 m3 of diameter 0.8 to 2mm 30 kg 2.41 0.0292 1 m3 of diarneter 6mm 0. 4 M3 of diameter 0~8 to 2mm 80 kg 2.61 0.032 1 m3 of diameter 6mm 40 kg 2.49 0.0282 1 m3 of diameter 0.8 .
to 2mm 40 kg 3.70 0.0360 Example 7 . . .
A com~osite panel is made comprising, on its two faces, a glass mat and at the centre a ma~erial according to the invention.
A first glass mat (mat of 300 g/m2 and a thickness of about 0.7 mm) is firstly deposited on the bottom of the mould, then the normal quantity, according to the invention, of polystyrene balls precoated with an emulsion of phenol-formaldehyde resin tas described in Example 2) is deposited on this mat and a supple~
mentary quantity of emulsion of phenol-formaldehyde resin equal to about 1.2 ~g of resin per square metre of panel to be produced, is added, a second glass mat identical to the first is deposite~
on the upper surface of the balls, the mould is closed and the whole is su~jected to a heating (for example up to 40-50QC) so as to cause the phenol-formaldehyde resin to foam and cross-link.
..
Claims (9)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A composite product comprising foamed polystyrene particles whose volume represents 75 to 95% of the apparent volume of said particles and, between said particles, an expanded phenol-formaldehyde resin of density between 50 and 500 g/l, the volume of the composite product being 5 to 25% greater than the apparent expanded volume of the foam particles.
2. A product as claimed in Claim 1, wherein said foam polystyrene particles are expanded polystyrene balls.
3. A product as claimed in claim 2, wherein the balls are of at least two different granulometries.
4. A product as claimed in claim 2, in which the balls have a substantially spherical form and have a diameter between about 0.8 and 10 mm.
5. A composite product comprising at least one layer of a product according to claim 1, 2 or 3, and reinforcing elements or inserts, or lightening elements bonded to the product of claim 1, 2 or 3, by the expanded phenol-formaldehyde resin.
6. A composite product comprising at least one layer of a product as claimed in claim 1, 2 or 3, and a glass fabric or mat bonded to said product of claim 1, 2 or 3, by the expanded phenol formaldehyde resin.
7. A process for preparing a composite product comprising polystyrene foam particles whose volume represents 75 to 95% of the apparent volume of said particles and between said particles an expanded phenol-formaldehyde resin of density between 50 and 500 g/l, the volume of the composite product being 5 to 25% greater than the apparent expanded volume of the foam particles, in which process a mould is filled with said foam polystyrene, and with an emulsified phenol formaldehyde resole containing a foaming agent and an acid catalyst in an amount relative to the volume of said mould to achieve said density of said resole resin, and the whole is heated to a temperature sufficient to provoke expansion and polycondensation of said resole resin but lower than the temperature of deformation of said foam polystyrene particles.
8. A process as claimed in claim 7, wherein the polystyrene particles are introduced into the mould in the form of particles coated with an emulsion of the resin.
9. A process as claimed in claim 7 or 8, wherein the heating of the material contained in the mould is effected by high frequency.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR7708250 | 1977-03-18 | ||
| FR7708250A FR2401191A1 (en) | 1977-03-18 | 1977-03-18 | NEW COMPOSITE PRODUCT BASED ON POLYSTYRENE FOAM AND LIGHTENED FORMO-PHENOLIC RESIN |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1109598A true CA1109598A (en) | 1981-09-22 |
Family
ID=9188316
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA299,206A Expired CA1109598A (en) | 1977-03-18 | 1978-03-17 | Process for preparing a composite product constituted by foam particles |
Country Status (19)
| Country | Link |
|---|---|
| JP (1) | JPS53115775A (en) |
| BE (1) | BE865001A (en) |
| BR (1) | BR7801659A (en) |
| CA (1) | CA1109598A (en) |
| DE (1) | DE2811347A1 (en) |
| DK (1) | DK121378A (en) |
| EG (1) | EG13152A (en) |
| ES (1) | ES467991A1 (en) |
| FR (1) | FR2401191A1 (en) |
| GB (1) | GB1601013A (en) |
| GR (1) | GR63108B (en) |
| IT (1) | IT1111452B (en) |
| LU (1) | LU79248A1 (en) |
| NL (1) | NL7802855A (en) |
| NO (1) | NO780972L (en) |
| OA (1) | OA05912A (en) |
| PT (1) | PT67766A (en) |
| SE (1) | SE7803037L (en) |
| ZA (1) | ZA781584B (en) |
Families Citing this family (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2132554B (en) * | 1982-12-17 | 1986-10-01 | British United Shoe Machinery | Shoe insole and the manufacture thereof |
| JPS59155016A (en) * | 1983-02-23 | 1984-09-04 | Sekisui Plastics Co Ltd | Manufacture of composite body that consists of phenolic resin and foam |
| EP0237596A1 (en) * | 1986-03-18 | 1987-09-23 | Benjamin Mosier | Fire retardant polystyrene insulating board |
| USRE33986E (en) * | 1984-05-11 | 1992-07-07 | Method of manufacturing fire retardant polystyrene insulating board | |
| EP0215652A3 (en) * | 1985-09-19 | 1988-07-27 | Geoffrey Crompton | Components that can exhibit low smoke, toxic fume and burning characteristics, and their manufacture |
| DE3545521A1 (en) * | 1985-12-20 | 1987-07-02 | Ipa Bauchemie Gmbh | DEFORMABLE MOLDED BODY AND USE THEREOF AND METHOD FOR THE PRODUCTION THEREOF |
| AT401757B (en) * | 1994-04-07 | 1996-11-25 | Greiner & Soehne C A | MULTI-LAYER COMPONENT MADE OF THERMALLY DEFORMABLE PLASTIC FOAM |
| GB9504028D0 (en) * | 1995-02-28 | 1995-04-19 | Kovacs Laszlo | Additive to expanded foam |
| GB2362586B (en) * | 2000-05-24 | 2003-11-12 | Prometheus Developments Ltd | Fire stable expanded polystyrene foam materials |
| JP2001342281A (en) * | 2000-05-30 | 2001-12-11 | Takashi Fujimori | Molded product composed of resin foam and solid particle and method for producing the same |
| AU2003294511A1 (en) * | 2002-12-23 | 2004-07-14 | Josef Hrovath | Core or support element |
| AU2017381391A1 (en) * | 2016-12-23 | 2019-07-11 | Matrix Composites And Engineering Ltd | Composite material |
-
1977
- 1977-03-18 FR FR7708250A patent/FR2401191A1/en active Granted
-
1978
- 1978-03-13 PT PT67766A patent/PT67766A/en unknown
- 1978-03-14 GR GR55705A patent/GR63108B/en unknown
- 1978-03-15 EG EG175/78A patent/EG13152A/en active
- 1978-03-16 SE SE7803037A patent/SE7803037L/en not_active Application Discontinuation
- 1978-03-16 DE DE19782811347 patent/DE2811347A1/en not_active Withdrawn
- 1978-03-16 LU LU79248A patent/LU79248A1/en unknown
- 1978-03-16 NL NL7802855A patent/NL7802855A/en not_active Application Discontinuation
- 1978-03-17 JP JP3160878A patent/JPS53115775A/en active Pending
- 1978-03-17 OA OA56439A patent/OA05912A/en unknown
- 1978-03-17 BR BR7801659A patent/BR7801659A/en unknown
- 1978-03-17 ES ES467991A patent/ES467991A1/en not_active Expired
- 1978-03-17 ZA ZA00781584A patent/ZA781584B/en unknown
- 1978-03-17 DK DK121378A patent/DK121378A/en unknown
- 1978-03-17 CA CA299,206A patent/CA1109598A/en not_active Expired
- 1978-03-17 NO NO780972A patent/NO780972L/en unknown
- 1978-03-17 BE BE2056775A patent/BE865001A/en not_active IP Right Cessation
- 1978-03-17 IT IT67605/78A patent/IT1111452B/en active
- 1978-03-17 GB GB10752/78A patent/GB1601013A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| FR2401191A1 (en) | 1979-03-23 |
| SE7803037L (en) | 1978-09-19 |
| BE865001A (en) | 1978-09-18 |
| PT67766A (en) | 1978-04-01 |
| FR2401191B1 (en) | 1980-04-18 |
| GB1601013A (en) | 1981-10-21 |
| LU79248A1 (en) | 1978-06-29 |
| ES467991A1 (en) | 1978-12-01 |
| JPS53115775A (en) | 1978-10-09 |
| DK121378A (en) | 1978-09-19 |
| NO780972L (en) | 1978-09-19 |
| EG13152A (en) | 1980-10-31 |
| BR7801659A (en) | 1979-01-02 |
| NL7802855A (en) | 1978-09-20 |
| IT7867605A0 (en) | 1978-03-17 |
| IT1111452B (en) | 1986-01-13 |
| DE2811347A1 (en) | 1978-09-21 |
| GR63108B (en) | 1979-09-05 |
| ZA781584B (en) | 1979-03-28 |
| OA05912A (en) | 1981-06-30 |
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