JPS5816838A - Manufacture of phenol resin foam - Google Patents

Abstract

PURPOSE:To manufacture foams with improved working efficiency and with no fear of causing big explosion by a method wherein hardened phenol resin foamers including flon gas as a foaming agent are continuously injected onto an endless belt conveyor thereby to effect foaming and curing. CONSTITUTION:A phenol resin material hardened with an acidic catalyzer, an acidic curing solution and flon gas as a foaming agent are mixed in a mixer 11 to obtain foamers. Thus obtained foamers are discharged from a discharge port 7 injected onto craft paper 13 let out by means of a lower conveyor 2. Then, the injected foamers are sent into a space between both conveyors 1, 2 with another craft paper 12 being placed on the upper side thereof. At this time, when a feeding speed of both conveyors 1, 2 is adjusted in accordance with given speed ratios at a proper one matching volumetric expansion per unit time which is determined by the amount of flon gas contained, the formers injected into an inner wall frame are foamed and cured while being fed through the space between both coneyors 1, 2. In this way, a phenol resin foam 15 thus foamed and cured can be attained from an open outlet between both conveyors 1, 2.

Description

[Detailed description of the invention] The present invention relates to a method for producing a phenolic resin foam.

Methods for producing phenolic resin foams used for interior wall panels of buildings and the like are well known. However, these known methods for producing phenolic resin foams generally use liquefied butane gas as a foaming aid. However, butane gas can cause a large explosion if it is accidentally exposed to fire. In addition, butane had the disadvantage that it could not be sent to the mixer without using high pressure, and the phenolic resin could not be foamed and cured unless the temperature was higher than S'o'c.

The present invention aims to provide a method for producing a phenolic resin foam created in view of these circumstances and problems.

The manufacturing method of the present invention is carried out using an apparatus as shown in FIG. In the same figure, (1) and (2) are conveyors that are provided vertically facing each other with an interval equal to the thickness of the inner wall panel, and each conveyor (1) (2) G;i Endless belt conveyor (l a) It consists of a slat type conveyor (lb) inscribed in (2a) and (2b). Although each conveyor can be driven separately, it is difficult to synchronize the conveyance speeds, so in the illustrated example, the lower slat type conveyor (2b
) is driven by a motor (3) or the like, and the other conveyors are rotated by transmitting the rotational driving force of the slat type conveyor (2b). That is, since the lower endless belt conveyor (2a) is circumscribed by the slat type conveyor (2b), it is directly rotationally driven. In addition, the lower endless belt conveyor (2a) is formed thicker on both sides of its conveying surface, and the thicker both sides (4
) is in contact with the conveying surface of the upper endless belt conveyor (la), so the upper endless belt conveyor (la) is in contact with the conveying surface of the upper endless belt conveyor (la).
A rotational driving force is transmitted from the ill m m belt conveyor (2a) through the contact space. Further, since the slat conveyor (1b) is inscribed with the endless belt conveyor (1a), it receives the same rotational driving force from the conveyor (1a) through the inward direction.

Of this pair of upper and lower conveyors (1) (2), the starting end (5) of the upper conveyor is located behind the starting end (6) of the lower conveyor, and the resin is placed between both starting ends (5) (6). A discharge port (7) is provided facing the conveyor surface. The discharge port (7) communicates with the mixer 0υ. This mixer (11
) is a resin tank (8) containing phenolic resin as a raw material, a hardening liquid tank (9), and a fluorocarbon gas tank (e) containing fluorocarbon gas as a foaming aid.
are in communication with each other via pumps (Pl), (P□), and (Ps), respectively. The resin tank (8) contains resol type phenol resin 14F + initial shrinkage material, which is cured with an acidic catalyst, and the curing liquid tank (9) contains l!, such as phosphoric acid. The curing liquid is stored in a Freon gas tank (each tank contains 7p gas as a foaming aid.Each pump (Pl) (
P2) (P3) uses a metering pump that feeds materials and liquids from each tank (8 bars, 9, and 10) in fixed amounts. Further, the mixer 01 is a cylindrical continuous mixer having a stirring shaft such as a pin type with a rotation speed of ♂θθrpm or more. The resin, curing liquid, fluorocarbon gas, etc. are thoroughly stirred in this mixer and discharged from the discharge port (7), but since the pressure of this mixture is decompressed during discharge, the fluorocarbon gas in the mixture immediately vaporizes, and the mixture is It immediately foams into a creamy, uncured foam. Since this foam contains an acidic curing liquid, a condensation reaction occurs, which is further accelerated by the heat generated by this reaction and hardens from the center in a few minutes to several minutes at room temperature. "Discharge 1"
Two or more of (7) may be arranged in parallel in the width direction of the belt.

A roll of kraft paper (6) 03 is supported at the upper front of the upper conveyor starting end (5) and the lower front of the lower conveyor starting end (6).
) By the rotation of (2), it is fed out and conveyed along the feeding surface.

Kraft paper 01 is now being fed out on the lower conveyor (2)
Foamed catalyst-curing resol-based phenolic resin discharged from the discharge port (7) is injected onto the top, and then kraft paper (6) is attached to the top surface while the opposing distance between both conveyors (1) and (2) is adjusted. send it inside. In this case, both conveyors (1)
If the conveyance speed in (2) is adjusted to a speed commensurate with the volumetric expansion per unit time obtained by the Freon gas ratio according to a predetermined magnification, the phenol resin injected into the space within the inner wall frame will be transferred to both conveyors. (1) Foams and hardens while being conveyed within the opposing spacing of (2). The floating of the kraft paper (2) (2) due to the foaming pressure of the phenol resin is prevented by the weight of the conveyor, especially the slat type conveyor (lb) (2b), so the spacing between the two conveyors (1 bar 2) is It hardens as it spreads throughout the space.

In this way, a foamed and hardened phenolic resin foam is obtained from the terminal end side (open end outlet) of the conveyors (1) and (2). In addition, in the drawing, there are 7 knolls 4 between the kraft paper.
! IIIN foam can be obtained directly by conveyor (1) (2) without using this craft 1 ■ 4
It may be possible to obtain a 7-Nol resin foam within the opposing spacing of . In addition, the frame of the inner wall panel (combined with wood) was inserted between the kraft paper (2) (2), foamed phenolic resin was injected into the space inside this frame, and both conveyors (1) were inserted. (2) Foaming may be made to harden inside the frame when passing through the space. In other words, 7 enols 46 in the frame
Interior wall panels filled with 1 Bt# foam can be manufactured directly.

Furthermore, (14a) (14b) GLt: lnveya (i) (
2) is a heater provided so as to surround it. This heater (14a) (14b) connects the conveyor (
1) Heat the phenol resin to about θ゛″C between 1) and 2) to foam the phenol resin.

The method for manufacturing the phenolic resin foam of the present invention as described above uses chlorofluorocarbon gas as a foaming aid, so there is no risk of dust generation, and manufacturing operations can be carried out with peace of mind, greatly increasing manufacturing efficiency. did it. Conventional methods for producing this type of phenolic resin IJH foam have generally used butane gas as a foaming aid.

However, if this butane gas is accidentally exposed to fire, etc., there is a risk of a large explosion. Therefore, they must be handled carefully, which lowers cropping efficiency. Also, butane gas had the disadvantage that it could not be fed to the mixer without using high pressure (5kg/1llt").
Freon gas can be easily and quickly fed to the mixer even at low pressure (7) C2kq/att”.Furthermore, in order to foam and harden phenolic pine resin using butane gas, a high temperature of approximately rθ°C or higher must be applied. However, if fluorocarbon gas is used, foaming and curing can be achieved sufficiently even at low temperatures around θ°C, and fluorocarbon gas is an excellent foaming aid in terms of energy saving. It is also known that foamed books have high bending and compressive strength.

The same amount of illustrative drawings are schematic diagrams illustrating the method for manufacturing the phenolic resin foam of the present invention.

(1) (2)... Conveyor (7
)・-Discharge port (la) (!!a door・・Musui held conveyor (1b) (gb)・・Slat type conveyor (8)・・
・Resin tank (9)...Curing liquid tank (to)...
・Freon gas tank α◇・・・Mixer 0
Uniform...phenolic resin foam

Claims (1)

[Claims] 1) A phenol resin raw material that hardens with an acidic catalyst, an acidic curing liquid such as phosphoric acid, and butane gas as a foaming aid are mixed and stirred in a mixer to form a foam, and the foam is poured into an appropriate space. It is continuously injected into the open end inlet of a pair of upper and lower endless belt conveyors that are set to operate continuously.
While heating before and after C, a phenolic resin foam that foams and hardens in this belt conveyor is pressed and molded, and this hardened phenol resin foam is continuously taken out from the open end exit of the pair of endless belt conveyors. A method for producing a phenolic resin foam, characterized by: