KR20150134939A - Expandable Phenolic Resin Composition and Phenolic Foam Prepared Thereform - Google Patents

Abstract

The present invention relates to an expandable phenolic resin composition and a phenolic foam manufactured therefrom and, more specifically, to an expandable phenolic resin composition stably applied to a real construction site and various application fields by having excellent strength and density, and leaving almost none of formaldehyde on a phenolic foam itself, thereby being an environmentally-friendly construction material discharging little formaldehyde, and use.

Description

[0001] The present invention relates to a foamable phenolic resin composition, and to a foamable phenolic resin composition comprising the foamable foamable resin composition and an expandable phenolic resin composition and phenolic foam prepared therefrom,

The present invention relates to a foamable phenolic resin composition and a phenol foam prepared therefrom.

Currently, foams of organic compounds such as styrofoam, urethane foam, urea foam and PIR foam are mainly used as insulation materials for construction. These organic compound-based foams have advantages such as ultra light weight, low thermal conductivity, economical efficiency, ease of construction and the like, but generate poisonous soot, carbon monoxide and cyanogen which are harmful to heat and harmful to the human body due to decomposition in case of fire, And the use of this product is being regulated at home and abroad.

As a product that can replace these organic compound-based insulating materials, a glass surface or a rock surface made of fiber glass by melting waste glass or ore at a high temperature is used, but it is advantageous that it is a non-combustible material. However, fine dust There is a problem that the heat conductivity is lowered due to the generation of moisture and moisture, the collapse of shape, the recycling of the shape is not performed, and the secondary environmental pollution is caused.

Phenol foam exhibits flame retardancy, heat resistance, low ductility and lowest thermal conductivity compared with conventional organic compound-based heat insulation materials. When a contact is made with a flame, a carbonized film is formed on the surface to prevent flame propagation. It has the advantage of not changing. In the case of foreign countries, phenol foam is used as a thermal insulation material for buildings, especially ceiling materials. Most phenol resins are produced by using phenol resin, especially with a reaction mole ratio (F / P) of 1.0-3.0 and basic catalysts such as NaOH and NH ₃ Phenolic resins are used.

The phenol foam using such a phenol resin is usually obtained by adding a foaming agent, a plasticizer, a foaming agent, a curing agent, a flame retardant, etc. to a predetermined ratio of phenol resin and stirring. At this time, since the contained phenol resin accounts for 70 to 90% by weight of the total composition, the overall physical properties of the foam are largely influenced.

Further, the phenol foam using the phenol resin was separately subjected to the deaeration process to remove water contained in the phenol resin after the addition and condensation reaction of the phenol resin. However, due to the artificial removal of water in the degassing process, the viscosity of the phenolic resin increases exponentially, so that it is not easy to control in the process, and blending with other additives is not smoothly applied, making it difficult to apply it to the production of phenol foam. Further, there is a problem that it is difficult to obtain stable strength and density depending on the conditions of mixing and processing.

The main object of the present invention is to provide a foamable phenolic resin composition capable of improving the strength and density of phenol foam manufactured so as to be stably applied to actual construction sites and various application fields.

The present invention also solves the problems of phenol foam which has functions as a substitute material for solving the problems of styrofoam, urethane foam and urea foam, which are organic compound-based heat insulating materials currently used by using the foamable phenolic resin composition, To provide a phenol foam.

According to an embodiment of the present invention, there is provided a foamable phenolic resin composition comprising 0.5 to 2 parts by weight of an aramid fiber per 100 parts by weight of a phenolic resin.

In a preferred embodiment of the present invention, the foamable phenolic resin composition further comprises 6 to 12 parts by weight of a curing agent, 2 to 5 parts by weight of a curing agent, and 4 to 8 parts by weight of a blowing agent, based on 100 parts by weight of the phenol resin can do.

In one preferred embodiment of the present invention, the aramid fiber has a breaking strength of 22.0-28.0 g / d measured by the method of ASTM D885, an elongation of 2.5-3.6% as measured by the method of ASTM D885, a method of ASTM D885 (Young's Modulus) of from 650 to 930 g / d.

In a preferred embodiment of the present invention, the phenolic resin has a moisture content of 9.0 wt% or less and a viscosity at 25 DEG C of 10,000 cps or less.

In a preferred embodiment of the present invention, the curing agent is at least one selected from the group consisting of phosphoric acid, arylsulfonic acid, para toluenesulfonic acid, phenolsulfonic acid, benzenesulfonic acid, xylenesulfonic acid and sulfuric acid .

In one preferred embodiment of the present invention, the foam stabilizer is a silicone compound, a polyoxyethylene and a polyoxypropylene derivative, a polyoxyethylene glycol, a polyoxyethylene / polyoxypropylene random copolymer Polyoxyethylene alkylphenol condensation products, polyoxyethylene alkyl ethers, polyethylene fatty acid esters, polyoxyethylene castor ether, polyoxyethylene hydrogenated castor ethers, polyoxyethylene polyoxypropylene block copolymers, , Polyoxyethylene amine (s), and polyoxyethylene lauryl ether (s).

In one preferred embodiment of the present invention, the blowing agent is at least one selected from the group consisting of n-butane, isobutane, n-pentane, isopentane, n-hexane, n-heptane, cyclohexane, cyclopentane, chloropropane, .

Another embodiment of the present invention provides a phenol foam produced by the foamable phenolic resin composition and having a density of 38 to 60 kg / m ³ and an intensity of 0.25 to 0.6 MPa.

Since the phenol foam produced by the present invention has excellent strength and density, it can be stably applied to actual construction sites and various application fields. In addition, the phenol foam itself is environmentally friendly It can be used in all industrial fields as building material.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In general, the nomenclature used herein is well known and commonly used in the art.

Throughout this specification, when an element is referred to as "including " an element, it is understood that it does not exclude other elements unless specifically stated otherwise.

In one aspect, the present invention relates to a foamable phenolic resin composition comprising 0.5 to 2 parts by weight of an aramid fiber per 100 parts by weight of a phenolic resin.

In another aspect, the present invention relates to a phenol foam produced by the foamable phenolic resin composition and having a density of 38 to 60 kg / m ³ and an intensity of 0.25 to 0.6 MPa.

Hereinafter, the present invention will be described in detail.

By containing the aramid fiber in the foamable phenolic resin composition according to the present invention, it is possible to smoothly blend with the phenol resin to improve the strength of the foam, to have a moisture content of 9.0 wt% or less, a viscosity at 25 DEG C of 10,000 cps By weight of the phenol resin is used, it is easy to mix and control easily in the process, and the deterioration of the physical properties of the phenol foam due to the high water content and high viscosity contained in the conventional phenol resin can be prevented.

The aramid fibers of the present invention refer to aromatic polyamide fibers and include para-aramid fibers and meta-aramid fibers. Alternatively, the aramid fiber may be made of poly (para-phenylene terephthalamide), or a commercially available aramid fiber may be used. In particular, since aramid fibers have high strength and abrasion resistance, the strength and wear resistance of the foam can be improved.

Such aramid fibers may be used in the form of pulp or chopped fibers and may have a breaking strength of 22.0-28.0 g / d measured by the method of ASTM D885 and having a tensile strength as measured by the method of ASTM D885 An elongation of 2.5 to 3.6%, and a Young's Modulus of 650 to 930 g / d measured by the method of ASTM D885. At this time, if the physical properties are out of the above range, it is difficult to expect the improvement of physical properties, so the effect on the addition of aramid is insignificant.

The content of the aramid fiber may be 0.5 to 2 parts by weight, more preferably 0.5 to 1 part by weight, based on 100 parts by weight of the phenol resin. If the aramid fibers are used in an amount of less than 0.5 parts by weight based on 100 parts by weight of the phenol resin, the effect of containing the aramid fibers is insignificant. If the aramid fibers are used in an amount exceeding 2 parts by weight, There may be problems in manufacturing the product.

The phenol resin contained in the foamable phenolic resin composition of the present invention is obtained by subjecting phenol and formaldehyde to an addition reaction and condensation reaction at 70 to 80 ° C for 2 to 4 hours in the presence of a catalyst and then reacting with an acid such as sulfuric acid or para- Followed by neutralization. At this time, the phenol resin may be any phenol resin used for foam production, but it is preferably a resol-type phenol resin in terms of strength and density of the phenol foam to be produced.

The addition reaction and the condensation reaction of the resol-type phenol resin can be respectively represented by the following equations (1) and (2).

[Reaction Scheme 1]

[Reaction Scheme 2]

In the above Reaction Scheme 2, m is an integer of 1 to 3, and n is an integer of 2 to 8.

In the above Scheme 1, an addition reaction process of phenol and formaldehyde is briefly shown. In the Scheme 2, trimethylolphenol is excessively produced from the methylolphenol formed through the A reaction according to the present invention, and then B , A phenol resin having a stable weight average molecular weight (500 to 800 g / mol) at a desired level while minimizing the condensation reaction of C and D can be produced.

The addition and condensation reaction is carried out at 70 to 80 ° C for 2 to 4 hours in the presence of a catalyst. If the addition and condensation reaction are carried out at less than 70 ° C, the reaction time becomes too long, Or when the reaction is carried out in excess of 4 hours, the physical properties of the phenol resin produced by over-reaction are deteriorated.

 The molar ratio of phenol to formaldehyde may be 1: 1.8 to 1: 3.9, preferably 1: 2.5 to 1: 3.0 in terms of stable molecular weight and methylolphenol, . If the molar ratio of formaldehyde to 1 mole of phenol is less than 1.8, there may arise a problem that a large amount of trimethylolphenol can not be formed. When the molar ratio exceeds 3.9, unreacted monomers are contained too much, Is too high, it is difficult to control the reaction.

In the present invention, the addition and the catalyst used in the condensation reaction is a one available without If the catalyst capable of producing a phenolic resin limited, preferably NaOH, KOH, Mg (OH) 2, Ba (OH) 2, Ca (OH) ₂ and the like and a nonmetal ionic catalyst such as NH ₄ OH, N (CH ₂ CH ₂ OH) ₃ , N (CH ₂ CH ₃ ) ₃ and the like, more preferably NaOH, Ba ) ₂ , Ca (OH) ₂ , Mg (OH) _2, and KOH.

The catalyst is used in an amount of 2 to 8 parts by weight based on 100 parts by weight of phenol. When the catalyst is added in an amount of less than 2 parts by weight based on 100 parts by weight of phenol, the reaction time is too slow, If the amount is more than 8 parts by weight, the addition and condensation reaction of methylolphenol produced in an excessive amount of the catalyst proceeds unintendedly, resulting in an increase in the molecular weight and a high viscosity-to-moisture ratio.

Further, as the amount of the catalyst remaining in the phenol resin as the final product increases, a water-soluble phenol resin having a high viscosity, which has a low water content, is produced. As a result, a serious problem in storage stability occurs and curing behavior does not occur stably, However, the problem of poor physical properties of the phenolic resin may occur.

As described above, when the addition and condensation reaction is completed, neutralization with an acid such as sulfuric acid, phenolsulfonic acid, or the like is carried out to prevent the self-polymerization of trimethylolphenol in the high-temperature deaeration reaction, It is possible to contain a large amount of roll phenol, thereby maintaining a low viscosity relative to the same moisture.

 The acid such as sulfuric acid, phenolsulfonic acid and the like may be added in an amount sufficient to neutralize the phenol resin as the final product, preferably until the pH of the phenol resin as the final product is 6 to 7, The content of the acid used may be added in an amount of 0.90 to 1 equivalent based on 1 equivalent of the hydroxyl group contained in the catalyst. If it is added in an amount less than 0.90 equivalents based on 1 equivalent of the hydroxyl group contained in the catalyst, there may arise a problem that the resin as the final product is acidified or the resin becomes polymerized during the degassing reaction, The color of the resin may be discolored in a dark state, or the resin may be polymerized in the degassing reaction.

The phenol resin prepared as described above can simultaneously induce an addition reaction and a condensation reaction under stable and specific reaction conditions of phenol and formaldehyde in the presence of a catalyst and neutralize with a specific neutralizing agent to minimize the amount of unreacted monomer, A phenol resin capable of maintaining a low viscosity with respect to the same moisture can be produced by lowering the concentration of hydroxyl groups in the resin and containing a large amount of trimethylolophenol.

The content of trimethylolphenol contained in the phenol resin of the present invention is 10 to 18% by weight. When the content of trimethylolphenol is less than 10% by weight in the formed phenol resin structure, a polymer having 4 or more nuclei is formed, There is a problem that the molecular weight of the phenol resin is too low and the physical properties after the curing are remarkably deteriorated when the content of trimethylolphenol is more than 18% by weight Lt; / RTI >

The content of methylolphenol in the above and below is determined by measuring the retention time value of trimethylolphenol using GPC (gel permeation chromatography) system of Varian Co. The area of trimethylolphenol relative to the total area is measured by an integrator .

In addition, since the phenol resin has a pH of 6 to 7 and neutralizes the resin, it is excellent in storage stability and prevention of autopolymerization in the resin, and has an oligomer having a weight average molecular weight of 500 to 800 g / mol and a repeating unit of 4 or less The water content is 5.0 to 9.0% by weight and the viscosity at 25 ° C is 4,000 to 10,000 cps. Therefore, the viscosity of the conventional phenolic resin is very low compared to the moisture content of the conventional phenol resin, Due to its low viscosity, it is advantageous in process control and its moisture content is low, so it exhibits excellent thermal conductivity and is suitable for insulation.

The foamable phenolic resin composition of the present invention may contain a foam stabilizer in order to uniformly control the shape and size of the foam (foam) in the foam of the phenolic resin, excellent heat insulation, stabilization and uniform distribution of the foam.

The foam stabilizer may be any foam stabilizer that can be used in forming the foam. Examples thereof include silicone compounds such as polydimethylsiloxane, polyoxyethylene and polyoxypropylene, Derivatives, polyoxyethylene glycol, polyoxyethylene / polyoxypropylene random copolymers or polyoxyethylene / polyoxypropylene block copolymers, polyoxyethylene alkylphenol condensation products, polyoxyethylene alkyl ethers, polyethylene fatty acid And at least one member selected from the group consisting of polyoxyethylene alkyl ether, polyoxyethylene castor ether, polyoxyethylene hydrogenated castor ether, polyoxyethylene amine and polyoxyethylene lauryl ether Feature . As the commercially available foam stabilizer, a thickenable nonionic foam stabilizer, a nonionic foam stabilizer of the south-eastern synthesis, and SM3210P of KCC may be used.

Such a foam stabilizer is used in an amount of 2 to 5 parts by weight based on 100 parts by weight of the phenol resin. If the amount of the foam stabilizer is less than the above range, foaming of the foam may not be performed smoothly. There is a problem that the foam is broken and it is difficult to use the foam.

The foamable phenolic resin composition of the present invention may include a curing agent to help the phenol foam maintain its desired foam rate and to cure, to improve the appearance of the product, and to maintain the mechanical strength. The curing agent is not particularly limited as long as it is a curing agent capable of curing the phenolic resin. Examples of the curing agent include phosphoric acid, arylsulfonic acid, paratoluenesulfonic acid, phenol sulfonic acid, benzenesulfonic acid, xylenesulfonic acid, sulfuric acid, etc. As the commercially available curing agent, Toyoura Kasei Co., , Triethylammonium para-toluenesulfonic acid, phosphoric acid, and the like.

In the present invention, the above-mentioned curing agent may be used as the above-mentioned components, but it is preferably a non-aqueous dispersion curing agent, more preferably an arylsulfonic acid system (for example, polyethyleneglycol, ethylene glycol, etc.) aryl sulfonic acid. If the curing agent is dispersed in water or a moisture-containing curing agent is used, the physical properties of the foam (foam) may be lowered by the moisture contained in the curing agent, even if the water content of the phenol resin is low.

The curing agent is used in an amount of 6 to 15 parts by weight based on 100 parts by weight of the phenol resin. When the amount of the curing agent is less than 6 parts by weight, curing and foaming of the phenol foam are not sufficiently performed. Is too fast to control the production of the foamed product, and the foam may corrode.

The foamable phenolic resin composition of the present invention may contain a foaming agent to facilitate foaming of the phenolic resin. Examples of the foaming agent include aliphatic hydrocarbon compounds such as n-butane, isobutane, n-pentane, isopentane, n-hexane and n-heptane; aromatic hydrocarbons such as cyclohexane, cyclopentane and the like; chlorinated aliphatic hydrocarbon compounds such as chloropropane and the like; And 141b may be used. In view of the thermal conductivity of the foam, it may preferably be 141b, n-pentane, and cyclopentane. Particularly, the combination of 141b can further improve the thermal conductivity of the foam, but it should be noted that there is an environmental problem.

Such a foaming agent is used in an amount of 4 to 10 parts by weight based on 100 parts by weight of the phenol resin. When the amount of the foaming agent is less than the above range, foaming is not properly performed. When the amount exceeds this range, the strength of the foam is lowered, Problems may arise.

The foamable phenolic resin composition of the present invention may contain an aliphatic alcohol and polyammonium phosphate (hereinafter referred to as PAP) as additives in order to enhance the cell structure and flame retardancy of the foam more stably. As the aliphatic alcohol, propylene glycol, glycerin and the like can be used. In this case, the content of the additive varies depending on the use of the phenol foam, and the aliphatic alcohol may be used in an amount of 2 to 5 parts by weight based on 100 parts by weight of the phenol resin, and the PAP may be used in an amount of 5 to 8 parts by weight.

Such a foamable phenolic resin composition can be produced by mixing the above-described components. That is, the foamable phenolic resin composition may contain all of the constituent components immediately before preparation of the phenol foam, and the constituent components may be stored separately before the preparation.

The phenol foam according to the present invention can produce a phenol foam by foaming and curing the foamable phenolic resin composition described above.

The foaming and curing of the phenol foam can be carried out at room temperature or by heating, stirring at a constant speed, and then atmospheric pressure or pressure foaming can be employed in the mold. Further, the foam stabilizer, the foaming agent and the additive may be added to the phenol resin in advance or simultaneously with the curing agent. For example, the foamable phenolic resin composition is mixed with the phenolic resin at a temperature of 22 to 25 ° C for 30 seconds at a speed of 2000 to 3000 rpm using a high-speed stirrer. When the stirring speed is out of the above range, mixing of all the components is uneven, so that a foam exhibiting good physical properties can not be obtained.

The mold is designed to be 300 mm × 300 mm × 60 mm in width × height × height, and can be used as a mold when the mold is capable of releasing moisture generated during the curing reaction of the foamable phenolic resin composition to the outside. An SUS steel plate of 400 mm x 400 mm x 1 mm in width × height × height can be placed and cured.

Thus, the mold to which the foamable phenolic resin composition is added is cured and foamed by using a press at 40 to 80 DEG C for 15 to 20 minutes to obtain a phenol foam foam. The curing and foaming may be carried out at room temperature, but foaming is preferably carried out in an oven in order to obtain a yield of the foam, discharge of moisture and formation of a good foam. If the foaming is carried out at a high temperature exceeding 80 캜 The cells of the foam may be poor due to too rapid curing and foaming.

As described above, since the phenol foam produced in the present invention has a density of 38 to 60 kg / m ³ and an intensity of 0.25 to 0.6 MPa, the density and strength of the phenol foam can be variously applied to various applications.

In addition, the appearance of the phenol foam produced in the present invention has a weak red color, and each cell is foamed without a hole in the barrier wall in an independent closed cell state. The foam (foam) means that the larger the bubble size and distribution at the time of foaming, the better the adiabatic property and the low ductility. When the ratio of the bubbles in the foam independently existed without pore (the void ratio) is more than 90% .

The bubble size of the foam is usually 50 to 500 mu m, and the average pore size of the phenol foam produced in the present invention falls within the range of 100 to 400 mu m.

Since the phenol foam according to the present invention is already foamed using a flame retardant phenol resin, the flame retardancy of the foam is exhibited without a separate flame retardant, which is excellent in terms of environment, production process, and production cost. In addition, the phenol foam according to the present invention assists in realizing stable physical properties by synthesizing a stable phenol resin and improves the strength of the phenol foam thus produced, thereby causing problems such as styrofoam and urethane foam insulation widely used as a conventional heat insulating material It can be used as an alternative material to be solved, and various applications of high functional phenol foam to industrial and building materials are expected.

Hereinafter, the present invention will be described in detail with reference to Examples, but the present invention is not limited by these Examples.

[ Manufacturing example  One]

Pure phenol and 40 wt% formaldehyde were charged into a reactor with the molar ratio (formaldehyde / phenol; F / P) shown in Table 1, mixed and stirred, and Ba (OH) ₂ or NaOH as a catalyst was added thereto and mixed and stirred And then neutralized with sulfuric acid (H ₂ SO ₄ ) at 40 ° C for 20 minutes. The neutralized reaction product was subjected to a deaeration process to remove water remaining under a vacuum condition of 740 mmHg, and the reaction was terminated at a desired moisture content.

division phenol Formaldehyde F / P mole ratio catalyst corrector polymerization
Reaction temperature (캜) Reaction time
(hr) NaOH
(g) H ₂ SO ₄
(g) The acid equivalent ratio to the OH equivalent of the catalyst Production Example 1 1600 2425.4 1.9 67.2 38.5 0.95 78 2

[ Example  1 to 4]

The composition obtained by mixing the aramid fiber, the foam stabilizer, the curing agent and the foaming agent in the composition shown in Table 2 in the phenol resin obtained in Preparation Example 1 was injected into a mold (400 mm x 400 mm x 1 mm) at a high temperature of 2500 rpm at room temperature , And then foamed in an oven at 50 DEG C for 5 minutes to prepare a phenol foam. The water content above and below was measured by the Karl Fischer method and the viscosity was measured at 25 ° C using a Brookfield DV-II + Pro Programmable Viscometer using a # 64 Spindle , And the molecular weight was measured using a Varian GPC (gel permeation chromatography) system.

division
Phenolic resin Foaming agent blowing agent Hardener Aramid fiber moisture
(wt%) Viscosity
(cps) content
(Parts by weight) Kinds content
(Parts by weight) Kinds content
(Parts by weight) Kinds content
(Parts by weight) Kinds content
(Parts by weight) Example 1 7 6500 100 PCO 2 Cyclopentane 5 PTSA 10 Staple fiber
(Length: 3mm) 0.5 Example 2 7 6500 100 PCO 2 Cyclopentane 5 PTSA 10 Staple fiber
(Length: 6mm) One Example 3 7 6500 100 PCO 2 Cyclopentane 5 PTSA 10 Staple fiber
(Length: 3mm) 1.5 Example 4 7 6500 100 PCO 2 Cyclopentane 5 PTSA 10 Staple fiber
(Length: 3mm) 2

(PCO): polyoxyethylene castor oil, Koremul-CO25 of Hanjin Chemical Co., Ltd.

PTSA: para toluenesolfonic acid (PTSA) manufactured by Samjung Pure Chemical Co.,

(ASTM D885), elongation: 3.4% (based on ASTM D885), and Young's modulus: 800 g / d (based on ASTM D885)]: aramid fiber (short fiber length 3 mm): Hera Kron HF series of Kolon Industries,

(ASTM D885), elongation: 3.5% (according to ASTM D885) and Young's modulus: 670 g / d (according to ASTM D885)]: aramid fiber (short fiber length 6 mm): HERACRON HF series of Kolon Industries,

[ Comparative Example  One]

Phenol foam was prepared in the same manner as in Example 1 except that no aramid fiber was added.

[ Comparative Example  2]

The aramid fiber was prepared in the same manner as in Example 1 except that 0.3 part by weight of aramid fiber was added to 100 parts by weight of the phenol resin to prepare a phenol foam.

[ Comparative Example  3]

The aramid fiber was prepared in the same manner as in Example 1 except that 3 parts by weight of aramid fiber was added to 100 parts by weight of the phenol resin to prepare a phenol foam.

[ Comparative Example  4]

Kooltherm phenol foam sold by King Span was used.

The physical properties of the phenol foam prepared in the above Examples and Comparative Examples were measured as follows. The results are shown in Table 3 below.

(1) Strength measurement: UTM was measured according to ASTN D1621 measurement method (Lloyd manufacturer).

(2) Density measurement: The value obtained by measuring weight and volume using a phenol foam having a height of 200 mm x 200 mm x 20 mm as a sample, and measured according to JIS A 9511: 2006R.

division Strength (MPa) Density (Kg / cm ³ ) Example 1 0.44 41 Example 2 0.31 38 Example 3 0.30 42 Example 4 0.26 39 Comparative Example 1 0.18 35 Comparative Example 2 0.19 34 Comparative Example 3 - - Comparative Example 4 0.22 38

As shown in Table 3, the phenol foams of Examples 1 to 4 exhibited higher densities and higher strength than Comparative Examples 1 to 4. Particularly, in the case of the phenol foam of Comparative Example 3 in which the aramid staple fibers in an amount larger than the proper amount were mixed, the phenol foam could not be produced due to the small amount of solvent contained in the short fibers itself and the entanglement phenomenon.

Therefore, it has been confirmed that the phenol foam containing aramid fibers and the phenol resin having low water content and low viscosity can be stably supplied to actual construction sites and various application fields due to excellent strength and density.

It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (8)

And 0.5 to 2 parts by weight of an aramid fiber per 100 parts by weight of the phenolic resin.
The foamable phenolic resin composition according to claim 1, wherein the foamable phenolic resin composition further comprises 6 to 12 parts by weight of a curing agent, 2 to 5 parts by weight of a foaming agent, and 4 to 8 parts by weight of a foaming agent based on 100 parts by weight of the phenol resin. Resin composition.
The aramid fiber according to claim 1, wherein the aramid fiber has a breaking strength of 22.0 to 28.0 g / d measured by the method of ASTM D885, an elongation of 2.5 to 3.6% measured by the method of ASTM D885, And a Young's Modulus of 650 to 930 g / d.
The foamable phenolic resin composition according to claim 1, wherein the phenolic resin has a moisture content of 9.0 wt% or less and a viscosity at 25 DEG C of 10,000 cps or less.
The foamable phenolic resin composition according to claim 1, wherein the curing agent is at least one selected from the group consisting of phosphoric acid, arylsulfonic acid, paratoluenesulfonic acid, phenolsulfonic acid, benzenesulfonic acid, xylenesulfonic acid and sulfuric acid.
[5] The composition according to claim 1, wherein the foam stabilizer is selected from the group consisting of a silicone compound, polyoxyethylene and polyoxypropylene derivatives, polyoxyethylene glycol, polyoxyethylene / polyoxypropylene random copolymer or poly An oxyethylene / polyoxypropylene block copolymer, a polyoxyethylene alkylphenol condensation product, a polyoxyethylene alkyl ether, a polyethylene fatty acid ester, a polyoxyethylene castor ether, a polyoxyethylene hydrogenated castor ether, a polyoxyethylene Wherein the foamable phenolic resin composition is at least one selected from the group consisting of polyoxyethylene amines, polyoxyethylene lauryl ethers, and polyoxyethylene lauryl ethers.
The blowing agent according to claim 1, wherein the foaming agent is at least one selected from the group consisting of n-butane, isobutane, n-pentane, isopentane, n-hexane, n-heptane, cyclohexane, cyclopentane, chloropropane, Phenolic resin composition.
A phenol foam produced by the foamable phenolic resin composition of any one of claims 1 to 7, having a density of 38 to 60 kg / m ³ and an intensity of 0.25 to 0.6 MPa.