WO2000001761A1 - Mousse phenolique - Google Patents
Mousse phenolique Download PDFInfo
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- WO2000001761A1 WO2000001761A1 PCT/JP1999/003567 JP9903567W WO0001761A1 WO 2000001761 A1 WO2000001761 A1 WO 2000001761A1 JP 9903567 W JP9903567 W JP 9903567W WO 0001761 A1 WO0001761 A1 WO 0001761A1
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- 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
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
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- 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
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/149—Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143
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- 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
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/141—Hydrocarbons
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- 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
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
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- 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
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
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- 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
Definitions
- the present invention relates to a phenolic foam for heat insulation having excellent heat insulating performance, excellent mechanical strength, and suitable for the global environment.
- phenol foam is particularly useful for various building materials because of its excellent flame retardancy, heat resistance, low smoke emission, dimensional stability, solvent resistance, and workability.
- the general method for producing phenolic foam is foaming and curing a foamable mixture in which a resole resin obtained by polymerizing phenol and formalin with an alkaline catalyst, a foaming agent, a surfactant, a curing catalyst, and other additives are uniformly mixed. It is to let.
- CFCs such as trichloro mouth trifluorofluoroethane (CF C-113) and trichloro mouth monofluoromethane (CFC-11), and dichloro trifluorofluoroethane (HCFC—) 123
- HCF Cs such as dichlorofluorene (HCF C-141 b), 1,1,1,2-tetrafluo ore (HF C-134a;), 1,1-difluorene HFCs (HFC-152a) and hydrocarbons such as cyclohexane, cyclopentane and normal pentane (hereinafter referred to as HCs) are known.
- CFCs are excellent in safety during production, have low thermal conductivity of gas itself, and also have excellent foaming properties in resin resin, so that fine closed cells can be easily formed by foaming.
- the obtained foam has an advantage that the thermal conductivity can be lowered, it has been preferably used.
- HFCs and HCs which do not destroy the ozone layer, have attracted attention as blowing agents. Furthermore, the use of H Cs as foaming agents has received special attention because of their lower global warming potential than HFCs.
- HFCs and HCs are difficult to use industrially due to their poor foaming performance as phenolic foam blowing agents. "” Especially when using HC blowing agents, the thermal conductivity of the blowing agents themselves Therefore, it was not possible to obtain a phenol form showing good heat insulation performance.
- WO 97/08230 proposes a method for producing a phenolic foam of a hydrocarbon blowing agent having a low thermal conductivity using a resin resin substantially free of free formaldehyde. It is described that a phenolic foam having a conductivity of 0.0181 (kcal / m'hr '° C) was obtained. However, although the phenol foam is described in the specification as having a small increase in thermal conductivity, it increases by more than 10% to 0.020 (kca 1 / m ⁇ hr ⁇ ° C) after 200 days. Further, as shown in Comparative Example 7 of the present specification, fine pores exist in the cell wall. It is speculated that this large change with time in the thermal conductivity is due to the gradual replacement of the blowing agent with air through the fine holes present in the cell walls.
- Japanese Patent Publication No. 4-503829 discloses that a phenol form having good heat insulating properties can be produced by adding fluorcarbon to a hydrocarbon blowing agent, and in Examples of the publication, perfluoroca is added to pentane.
- a phenol foam having a thermal conductivity of 0.0186 W / m-K obtained using a foaming agent to which bon is added is described.
- the phenol foam produced according to the formulation of this example has fine pores in the cell wall as shown in Comparative Example 8 of the present specification.
- perfluorocarbon is expensive, there is a problem that the production cost increases when added to a foaming agent.
- phenolic foams that have exhibited good heat insulating performance, have excellent mechanical strength such as compressive strength, and have improved brittleness by using a hydrocarbon-containing blowing agent as a blowing agent so far. Had not been obtained.
- An object of the present invention is to use HCs as a foaming agent while having a low thermal conductivity, Another object of the present invention is to provide a phenolic foam having little mechanical change in thermal conductivity with time, excellent mechanical strength such as compressive strength, and improved brittleness. Disclosure of the invention
- the present inventors have found that, in order to achieve the above object, when phenolic foams having a cellular structure according to the present invention are produced under specific foaming and curing conditions using a resin having a specific range of reactivity, As a result, they have found that the objects of the present invention can be achieved, and have completed the present invention.
- the present invention is as follows.
- the hydrocarbon is a mixture of 95 to 5% by weight of butanes selected from isobutane, normal butane and cyclobutane and 5 to 95% by weight of pentanes selected from normal pentane, isopentane, cyclopentane and neopentane.
- the hydrocarbon is 95-5% by weight of isobutane
- the fluorocarbon is one or more selected from 1,1,1,2-tetrafluoroethane, 1, 1, -difluorene and benzofluorene. 5, phenolic foam,
- the rate of viscosity increase is 0.005 to 0. 5, a resole resin having a water content of 4 to 12% by weight and a viscosity at 40 ° C. of 1,000 to 30,000 cps, a surfactant, a hydrocarbon-containing blowing agent, and a curing catalyst.
- the temperature is 10 to 70 ° 0, the vapor pressure of the pressure the blowing agent, were mixed in the vapor pressure + 5 kg / cm 2 or less in the mixer of the blowing agent, foamed, stepwise in a subsequent curing reaction stage
- a method for producing phenolic foam which comprises raising the temperature;
- FIG. 1 is a schematic diagram for explaining the cell wall structure of phenol foam.
- Fig. 1a is a schematic diagram of a cell wall structure of the present invention in which pores do not substantially exist in the cell wall
- Fig. 1b is a schematic diagram of a cell wall structure of the prior art in which holes or dents exist.
- FIG. 2 is an electron micrograph of the cut surface of the bubble wall in Example 1 having no holes or dents.
- FIG. 3 is an electron micrograph of the cut surface of the bubble wall having holes or dents in Comparative Example 1.
- Fig. 4 is an electron micrograph of a cut section of a bubble wall having holes or dents in Comparative Example 7. It is.
- FIG. 5 is an electron micrograph of a cut section of a bubble wall having holes or dents in Comparative Example 8.
- FIG. 6 is a photograph of the cross section for void measurement of Example 1 in a range of 100 mm ⁇ 150 mm.
- FIG. 7 is a photograph of the cross section for void measurement of Comparative Example 1 in a range of 100 mm ⁇ 150 mm.
- 1 indicates a bubble wall surface
- 2 indicates a cut surface of the bubble wall
- 3 indicates a hole or a dent.
- the phenolic foam of the present invention is a phenolic foam produced using a hydrocarbon-containing blowing agent.
- the hydrocarbon content of the foaming agent is preferably at least 50% by weight, more preferably at least 70% by weight, particularly preferably at least 90% by weight. If the hydrocarbon content is less than 50% by weight, the global warming potential of the blowing agent is undesirably large.
- cyclic or linear alkanes, alkenes and alkynes having 3 to 7 carbon atoms are preferred, and the foaming performance and chemical stability are preferred.
- Alkanes or cycloalkanes having 4 to 6 carbon atoms are more preferable from the viewpoints of the properties (having no double bond) and the thermal conductivity of the compound itself.
- normal butane, isobutane, cyclobutane, normal pentane, isopentane, cyclopentane, neopentane, normal hexane, isohexane, 2,2-dimethylbutane, 2,3-dimethylbutane, cyclohexane, etc. Can be mentioned.
- normal pentane, isopentane, cyclopentane, pentanes of neopentane and butanes of normal butane, isobutane, and cyclobutane have good foaming properties in the production of the phenol foam of the present invention, and furthermore, have a good thermal conductivity.
- these hydrocarbons may be used as a mixture of two or more kinds. Specifically, a mixture of 5 to 95% by weight of pentanes and 95 to 5% by weight of butanes is preferable because it shows good heat insulating properties over a wide temperature range. More preferably pen evenings 2 It is a mixture of 5-75% by weight and butanes in a range of 75-25% by weight.
- the combination of normal pentane or isobentan and isobutane can be used in a wide temperature range from low temperature range (for example, insulation material for freezer at about -80 ° C) to high temperature range (for example, heat insulation material for heating body at about 200 ° C).
- the amount of the HFCs in the present invention is 100 parts by weight or less, preferably 90 parts by weight or less, 0.1 parts by weight or more, preferably 5 parts by weight or more with respect to 100 parts by weight of the hydrocarbon blowing agent. is there. If the amount of HFC is more than 100 parts by weight, the global warming potential of the mixed foaming agent increases, which is not preferable. If the amount is less than 0.1 part by weight, the effect of improving the low-temperature characteristics is small.
- a low-boiling substance such as nitrogen, air, helium, or argon may be added to the foaming agent as a foaming nucleating agent as long as the cell structure is not damaged.
- a preferable addition amount of the foaming nucleating agent is 0.05 to 5 mol% based on the foaming agent. If the addition amount of the foam nucleating agent is more than 5 mo 1%, the foaming tends to be uneven or the void amount tends to be large.
- Density of phenol foams according to the present invention is 10 kg / m 3 or more, preferably 15 kg / m 3 or more, more preferably 2 Okg / m 3 or more, 100 kg / m 3 or less, preferably 7 Okg / m 3 Below, more preferably 5 Okg / m 3 or less c If the density is less than 10 kg / m 3 , mechanical strength such as compressive strength will be reduced, and it will be easier to break during handling, brittleness will increase, and practical Problems tend to occur. Conversely, when the density exceeds 100 kg / m 3 , heat transfer in the resin part increases and the heat insulation performance decreases.
- the phenol foam of the present invention has substantially no pores in the cell wall and has a specific cell structure having fine cells having an average cell diameter of 5 ⁇ m or more and 200 / m or less. Since the phenol foam of the present invention has substantially no pores in the cell wall, the phenol form contains a hydrocarbon used as a foaming agent during production.
- the hydrocarbon content in the phenol foam of the present invention is preferably 35% by weight or less, more preferably Is 20% by weight or less, preferably 0.05% by weight or more, more preferably 0.1% by weight or more.
- a foam is composed of fine spaces created in a resin by vaporization of a foaming agent, and a resin portion existing between the spaces.
- the space portion is called a bubble
- the resin portion is called a bubble wall.
- bubbles are about 5 ⁇ m to lmm in size.
- the phenol foam of the present invention has an average cell diameter of 5 Aim or more, preferably 1 Ozm or more, and 200 m or less, preferably 150 m or less. If the average cell diameter is less than 5 m, there is a limit to the thickness of the cell wall, so the foam density inevitably increases, and as a result, the heat transfer ratio of the resin in the foam increases, and the phenol foam The insulation performance becomes insufficient. On the other hand, when the average cell diameter exceeds 200 ⁇ m, heat conduction by radiation increases, and the heat insulation performance of the phenol foam decreases.
- the phenol form has a relatively large void (usually about 1 mm or more in diameter) with a spherical or amorphous void (hereinafter referred to as a void) inside.
- voids are considered to be formed by coalescence of air bubbles, uneven vaporization of a foaming agent, or by entrainment of air during the foaming process, which causes a decrease in compressive strength and unfavorable appearance.
- the void is defined as follows.
- a cross section parallel to the front and back surfaces of the phenol form is cut out, and voids existing in the cross section are measured by a method described later, and a void having an area of 2 mm 2 or more for each void is defined as a void.
- the phenol foam of the present invention such voids are extremely small, and the total area of the voids is 5% or less of the total area of the cross section. Therefore, the phenolic foam according to the present invention has the characteristic that the dispersion of the compressive strength is small, and it is also particularly susceptible to the influence of the void, and even a thin foam having a thickness of 10 mm or less, which was difficult to handle in construction. It has an extremely excellent effect that it can be easily handled. In terms of appearance, it is almost inferior to thermal insulation made of other materials.
- the preferred void content is 3% or less, more preferably 1% or less.
- the cell wall refers to a phenol resin portion that forms cells.
- Figure 1 shows a schematic diagram of the bubble wall structure.
- the phenol foam according to the invention has a cell wall structure schematically shown in FIG.
- Fig. 1b schematically shows the phenolic foam used.
- the cell wall cut surface Fig. 1
- Many holes or dents (3 in Fig. 1) are observed in 2)
- the cell wall surface 1 in Fig. 1
- These holes or dents are usually 50-100 nm in diameter and often penetrate the cell wall.
- the phenolic foam according to the present invention has substantially no pores or dents on the cut surface of the cell wall and the surface of the cell wall as shown in Fig. 1a.
- substantially no pores exist in the cell wall means that the cell wall cut surface is observed with an electron microscope, and the number of holes or dents per cell wall cut surface is 10 or less, preferably 5 or less. It is in the following state.
- the mechanism of the formation of pores or dents is that volatile components such as water separate in the phenol resin when the phenol resin cures to form lumps and evaporate after the phenol resin cures. It is believed to form by. In particular, it is said that when these holes or dents are formed, the replacement of the blowing agent with air is promoted to increase the thermal conductivity.
- the present inventors believe that the presence of the pores or dents forms at least one of the major causes of reduced mechanical strength and increased brittleness of the phenol form.
- foaming agents are CFCs.
- Japanese Patent Application Laid-Open No. Sho 53-36969 Japanese Patent Publication No. Sho 63-2
- Japanese Patent Publication No. 0460 There is Japanese Patent Publication No. 0460.
- JP-A-53-13669 the amount of water in the resole resin is extremely limited, and in Japanese Patent Publication No. 63-240660, a high-molecular-weight resole resin is used. Accordingly, techniques have been proposed for increasing the viscosity of the foamable composition, improving the cell wall strength, and eliminating holes or dents in the resin portion. According to the study of the present inventors, these methods have problems such as difficulty in handling and further increasing the expansion ratio when an HC foaming agent is applied because the viscosity of the foamable composition increases. was there. In a phenol foam using HCs as a foaming agent, a pore or dent is substantially absent, and a high-performance foam has not been known.
- the phenolic foam structure of the present invention can be obtained for the first time by foaming and curing a resol resin having a specific reactivity under specific conditions. That is, in the present invention, when the foamable composition obtained by mixing in the mixer is out of the mixer, the foaming is already in a state where foaming has already progressed to some extent, and then the foaming proceeds, and the process proceeds to the curing reaction step. By gradually raising the temperature and releasing the volatile components to the gaseous phase to complete the curing, there is substantially no pore or dent on the cut surface of the bubble wall and the bubble wall surface, and the void volume is reduced. It is possible to obtain a phenolic foam having a small and fine and uniform cell structure.
- the closed cell rate is preferably 80% or more, more preferably 85% or more, and particularly preferably 90% or more. If the closed cell rate is less than 80%, not only may the replacement rate of the foaming agent in the cells with air increase, the thermal insulation performance deteriorates with time, but also the brittleness of the foam increases to increase the mechanical strength. May not satisfy the target practical performance.
- the initial thermal conductivity of the phenol foam of the present invention is preferably not more than 0.022 kcal / m'hr ° C, more preferably not more than 0.020 kcal / m'hr ° C. l Okc al / m 'hr' ° C or more. Furthermore, the phenolic foam of the present invention has a small increase in thermal conductivity over time, which is an important property as a heat insulating material.
- the increase in the thermal conductivity of the phenolic foam according to the invention after 300 days is less than 0.002 kca1 / m ⁇ hr ⁇ ° C, preferably 0.001 kca1 / 1 / m ⁇ hr ⁇ .
- the phenol foam according to the present invention has excellent heat insulating performance.
- the phenol foam of the present invention preferably has a brittleness of 30% or less. More preferably, it is 20% or less and 1% or more. Thus, the phenol form according to the present invention has remarkably improved brittleness.
- the resole resin used in the production of phenolic foam is polymerized by heating phenol and formalin as raw materials in a temperature range of 40-: L 00 ° C using an alcohol catalyst. C If necessary, urea is added during polymerization of the resin resin. May be added. When adding urine, it is more preferable to mix urea, which has been methylated with an alcohol catalyst, in advance into a resole resin.
- the amount of methylolated urea contained in the resin is usually 1 to 30% by weight based on the resin.
- the resole resin after synthesis is usually Because it contains excess water, it is adjusted to the amount of water suitable for foaming when foaming.
- the water content is adjusted to 4% by weight or more, preferably 5% by weight or more, and 12% by weight or less, preferably 9% by weight or less.
- the preferred viscosity of the resole resin subjected to foaming is at least 100 cps at 40 ° C., preferably at least 300 cps, and at most 300 cps, preferably at 250 cps. It is as follows. When an additive such as urea is added to the resole resin, the viscosity of the resole resin containing the additive must satisfy the above range.
- the curing reactivity of the resin resin (including the case where an additive is added) as a raw material is important. That is, the viscosity rise rate constant of the resin obtained by the method described later in the present invention is 0.05 or more, preferably 0.01 or more, and 0.5 or less, and preferably 0.5 or less. 3 5 or less. If the viscosity increase rate constant is less than 0.05, the reactivity is too low, and the viscosity rise of the foamable mixture is slowed down, the cell diameter increases, and in some cases, foam breakage occurs, and the foam performance deteriorates. cause.
- the viscosity rise rate constant exceeds 0.5, pores will be formed in the cell wall, or the curing will be too fast and the viscosity will rise too much during mixing with a mixer, etc., and the internal pressure of the mixer will increase, making it impossible to operate. In some cases, the resin resin may be completely solidified in the mixer and damage the mixer.
- the phenol foam of the present invention can be obtained by introducing a resin resin having a proper viscosity and a proper curing reactivity, a foaming agent, a surfactant, and a curing catalyst into a mixer and mixing them uniformly. Foamed composition can be obtained by foaming and curing.
- the thermal insulation performance and mechanical performance of a foam largely depend on the form of the fine bubbles that compose it. That is, it is important that the closed cell ratio is high and the average cell diameter is in the range of 5 to 200111. In order to form these fine bubbles, it is important that foaming starts at the same time and in a short time. Foaming starts when the foaming agent vaporizes due to heat of reaction when the resin is mixed with the foaming agent and the curing catalyst or mechanical heat generation during mixing. Thereafter, the bubbles grow and a bubble structure is formed. At this time, the bubble shape is greatly affected by the compatibility of the foaming agent, the degree of progress of the vaporization of the foaming agent, or the degree of progress of the crosslinking reaction of the resin resin.
- the foaming starting point and the subsequent growth process it is important to control the foaming starting point and the subsequent growth process. It is.
- the start of foaming occurs promptly after the foamable composition is mixed, and it is preferable that foaming has already progressed to some extent when the foamable composition leaves the mixer.
- the state in which foaming has already occurred upon exiting the mixer is known as floss foaming.
- This foaming state is controlled by the temperature and pressure of the mixed state of the foamable composition. Generally mixed: It is said that the pressure inside the machine requires higher pressure to prevent premature foaming.
- the pressure in the mixer is controlled to an appropriate range in consideration of the vapor pressure and the boiling point of the blowing agent used.
- the pressure in the mixer is equal to or higher than the vapor pressure of the blowing agent at the temperature in the mixer (if the blowing agent is a mixture, the vapor pressure of the mixture) and equal to or lower than the vapor pressure +5 kg / cm 2 . If the pressure in the mixer is lower than the vapor pressure of the foaming agent, the foaming proceeds too much in the mixer, causing an increase in the bubble diameter, breakage of the bubbles, or coalescence of the bubbles to grow into a void.
- the pressure exceeds the vapor pressure of the foaming agent + 5 kg / cm 2 the start of foaming or the growth of bubbles will be uneven, resulting in an increase in the variation of the bubble diameter or an increase in voids, resulting in a good foam. It is difficult to get.
- it is controlled to a blowing agent vapor pressure +0.5 kg / cm 2 or more and a blowing agent vapor pressure +3 kg / cm 2 or less.
- the temperature in the mixer is 10 ° C or higher, preferably 20 ° C or higher, 70 ° C or lower, preferably 60 ° C or lower. If the temperature of the mixer exceeds 70 ° C, the number of voids may increase even in the appropriate pressure range, or the pressure inside the mixer may increase, making it impossible to operate.
- a low-boiling substance such as nitrogen, helium, argon, or air may be added to the foaming agent in advance as foam nuclei.
- Initial curing time is 1 minute to 1 hour at 70 to 90 ° C, and 90 to: L 10 minutes to 5 hours at 00 ° C, and 10 minutes to 3 hours at 100 to 130 ° C as needed.
- the temperature difference between the stages is at least 5 ° C, preferably at least 10 ° C.
- aromatic sulfonic acids such as toluenesulfonic acid, xylenesulfonic acid, benzenesulfonic acid, phenolsulfonic acid, styrenesulfonic acid, and naphthalenesulfonic acid are used alone or in combination of two or more. Can be used You.
- the usual amount of the curing catalyst used is in the range of 1 to 30 parts by weight per 100 parts by weight of the resole resin.
- resorcinol, cresol, saligenin (0-methylol phenol), p-methyl mono-l-phenol and the like may be added as a curing aid.
- the usual addition amount of the curing aid is in the range of 1 to 300 parts by weight based on the curing catalyst.
- these curing catalysts can be used after being diluted with a solvent such as diethylene glycol or ethylene glycol.
- a nonionic surfactant is effective, for example, an alkylene oxide which is a copolymer of ethylene oxide and propylene oxide, or an alkylene oxide.
- These surfactants may be used alone or in combination of two or more.
- the amount of the surfactant used in the present invention is preferably in the range of 0.3 to 10 parts by weight per 100 parts by weight of the resin.
- the density in the present invention is a value obtained by measuring the weight and apparent volume of a 20 cm square phenol foam sample, removing the face material, siding material, etc., from the sample, if any. And measured according to JISK 7222.
- the number of holes or dents in the cell wall in the present invention was measured as follows. Test—The specimen was cut to a thickness of about 2 to 3 mm and a thickness of about 1 cm 2 with a trimming cutter from a cross section substantially parallel to the front and back surfaces in the center in the thickness direction of the foam. The test piece fixed on the sample stage was subjected to gold sputtering (15 mA, 3 minutes), and a 500 ⁇ magnification photograph of the cut surface of the bubble wall was taken with a scanning electron microscope (Hitachi S-800). I took a picture and observed it. The cut surface at 10 places was observed, and the number of holes or dents was counted and averaged.
- the void in the present invention was measured as follows. Cut approximately the center of the phenolic foam sample in the thickness direction parallel to the front and back surfaces, and enlarge the range of 100 mm x 150 mm by 200% color copy (each length is twice as long, that is, the area is 4 times) Then, the area fraction was calculated by integrating the void area of 8 squares or more with lmmx 1 mm square using transparent grid paper. That is, since the enlarged copy is taken, these 8 squares correspond to an area of 2 mm 2 in the actual cross section of the foam.
- the closed cell ratio was measured as follows. Cylindrical specimens of diameter 35 to 36 mm cut out from phenolic foam with a cork borer are cut at heights of 30 to 40 mmC, and the sample volume is measured using the standard method of an air-comparison hydrometer 1000 (manufactured by Tokyo Science). I do. The value obtained by subtracting the cell wall volume calculated from the sample weight and the resin density from the sample volume was divided by the apparent volume calculated from the outer dimensions of the sample, and measured in accordance with ASTM D2856. However, the density of the phenol resin was 1.27 g / cm 3 .
- the average cell diameter of the phenol foam in the present invention is a length of 9 cm, excluding voids, on a 50-fold enlarged photograph of a cross section of a test piece cut substantially parallel to the front and back surfaces in the thickness direction of the form.
- the compressive strength was measured according to JIS K 7220 using a 50 mm square sample with a specified strain of 0.05.
- Thermal conductivity was measured according to the plate heat flow meter method of JIS A 1412 at a sample of 200 mm square, a low temperature plate at 5 ° C, and a high temperature plate at 35 ° C.
- test pieces for the brittle test were cut out of 12 cubes of 25 mm 1.55 mm on a side so as to include a molded skin or face material on one side. However, when the thickness of the foam was less than 25 mm, the thickness of the test piece was the thickness of the foam.
- Room temperature-dried 24 oak cubes measuring 1 9 ⁇ 08 mm and 12 test specimens can be sealed to prevent dust from coming out of the box. Place in an oak wooden box and spin 600 ⁇ 3 at 60 ⁇ 2 revolutions per minute.
- the contents of the box are transferred to a mesh of nominal size 9.5 mm, sieved to remove small pieces, the weight of the remaining test piece is measured and determined, and the rate of decrease from the weight of the test piece before the test is determined.
- the calculated value is brittle and was measured according to JISA 951.
- Hydrocarbons and fluorocarbons present in phenolic foam are: Measurement. The phenol foam sample is placed in a closed mixer and ground so that the cell is broken. The gas phase is replaced with nitrogen and introduced into a gas absorption tube containing pyridine to dissolve hydrocarbons and fluorocarbons in pyridine. And measured by gas chromatography.
- the viscosity increase rate constant which is an index of curing reactivity, was determined by the following method.
- a curing catalyst of 70% by weight of toluenesulfonic acid and 30% by weight of ethylene glycol was precisely weighed and added to 5 parts by weight of the resin, and 1 Mix well for a minute. This is set on a rotary viscometer (R10.0 type viscometer RE type, manufactured by Tonen Sangyo Co., Ltd.), and the viscosity at 40 ° C is measured at 30 second intervals. The semi-logarithmic plot is plotted with the X-axis of the measurement results as time and the Y-axis as logarithm of viscosity. The time is regarded as a straight line between 4 minutes and 10 minutes, and this “slope (1 / min)” is calculated. This “tilt” was defined as “viscosity increase rate constant”.
- the viscosity of the resole resin was measured at 40 ° C with a rotary viscometer.
- the water content of the resole resin was measured as follows.
- the resole resin is dissolved in dehydrated methanol (manufactured by Kanto Chemical Co., Ltd.) in the range of 3% to 7% by weight, and the water content of the solution is measured.
- a Karl Fischer moisture meter MKC—210 manufactured by Kyoto Electronics Industry Co., Ltd. was used for the measurement.
- the reactor was charged with 350 g of 50% by weight formalin (manufactured by Mitsubishi Gas Chemical Co., Ltd.) and 300 g of 99% by weight of phenol (manufactured by Wako Pure Chemical Industries, Ltd.) The mixture was stirred by a rotating rotary stirrer, and the temperature inside the reactor was adjusted to 40 ° C by a temperature controller. Next, 66 g of a 50% by weight aqueous solution of caustic soda was added, the reaction solution was gradually increased from 40 ° C. to 85 ° C., and kept at 85 ° C. for 120 minutes. Thereafter, the reaction solution was cooled to 5 ° C. This is designated as resol resin A-1.
- Resin resin A_1 was neutralized with a 50% by weight aqueous solution of paratoluenesulfonic acid monohydrate until the pH reached 6, and the reaction solution was dehydrated at 60 ° C. This is referred to as a resol tree S purse B.
- resole resin C For the synthesis of resole resin C, the weight of 50% by weight formalin was changed to 320 g, and the weight of methylol urea U to be added was changed to 7700 for 600 g of resole resin. Was carried out in the same manner as in Resin Resin A.
- resole resin D For the synthesis of resole resin D, except that the weight of 50% by weight formalin was changed to 420 g, and the weight of methyl urea U to be added was changed to 6100 for 500 g of resole resin was carried out in the same manner as for resol resin A.
- Resole resin E was synthesized in the same manner as resin resin C, except that it was neutralized and dehydrated without adding methylol urea U.
- Resin Resin F was synthesized as follows. A reactor was charged with 436.0 g of 50% by weight formalin and 300 g of 99% by weight phenol, and was stirred with a propeller rotary stirrer, and the temperature inside the reactor was adjusted with a temperature controller. The temperature was adjusted to 40 ° C. Then, 66 g of 50% aqueous sodium hydroxide solution was added and heated.When the solution viscosity at 25 ° C reached 62 cst, the reaction solution was cooled to 30 ° C, and paratoluenesulfonic acid monohydrate was added. And neutralized with a 50% by weight aqueous solution until the pH reached 6. Urea equivalent to 77% mol of the unreacted formaldehyde in the reaction solution was added and dehydrated.
- resol resin G was synthesized as follows. 37 7% by weight of formaldehyde aqueous solution (special grade reagent manufactured by Wako Pure Chemical Industries, Ltd.) 3850 g and 99% by weight of phenol 30000'g are mixed, and an aqueous solution of sodium hydroxide (1 ON) 85 g And heated to 60 ° C over 40 minutes and kept at 60 ° C for 30 minutes. The temperature was then raised to 80 ° C and held for 30 minutes. The temperature was further raised and refluxed for 40 minutes. Subsequently, the water was dehydrated under reduced pressure, and thereto was added 727 g (a concentration of 13% by weight in the resin resin) of monoethylene glycol to obtain a resole resin G.
- formaldehyde aqueous solution special grade reagent manufactured by Wako Pure Chemical Industries, Ltd.
- Table 1 shows the water content, viscosity, and viscosity increase rate constant of the resole resin.
- Silicone surfactant (polyalkylsiloxane-polyoxyalkylene copolymer: Paintaid 32 manufactured by Dow Corning Asia Co., Ltd.) was added to resole resin A at a ratio of 3.5 g to 100 g of resole resin. And dissolved.
- the resol resin mixture normal pentane (manufactured by Wako Pure Chemical Industries, Ltd. 9 9 +%) as a foaming agent 5 0 wt 0/0, isobutane (Esukei Sangyo Co., Ltd.
- the mixer temperature was 58 ° C.
- the mixer pressure was 6.8 kg / cm 2 in absolute pressure.
- the mixture coming out of the mixer was already foaming and was in a so-called floss state.
- the cloth is poured into a formwork on which a nonwoven fabric (Spunbond E10040 manufactured by Asahi Kasei Kogyo Co., Ltd.) is laid, and the thickness is uniformly adjusted. With a lid.
- the mold is designed to release the moisture generated during the curing reaction to the outside.
- Table 3 shows the measurement results of the obtained phenol form.
- Figure 2 shows a 5000x electron micrograph of the hole or dent measurement.
- Figure 6 shows a photograph of the cut surface for void measurement. Examples 2 to 13 and Comparative Example 1
- Example 2 The procedure was performed in exactly the same manner as in Example 1 except that the resol resin, the foaming agent composition, the mixer temperature and the mixer pressure were changed as shown in Table 2.
- Table 3 shows the physical properties of the obtained foam.
- FIG. 3 shows a 5,000-fold electron micrograph of the hole or dent measurement of Comparative Example 1.
- FIG. 7 shows a photograph of the cut surface for void measurement of Comparative Example 1. Comparative Example 2
- Example 2 The procedure was the same as in Example 1 except that the resin resin, the composition of the foaming agent, the mixer temperature and the mixer pressure were changed as shown in Table 2, and the curing step was further changed to 80 ° C for 5 hours.
- Table 3 shows the physical property results of the obtained foam. Comparative Example 3
- Paraffin as a blowing agent (Wako Pure Chemical Industries, Ltd., melting point 44 ° C to 46 ° C, first-class reagent) Weight ratio of normal pentane and isobutane in which 5% by weight and 0.3% by weight of nitrogen are dissolved 1: 1 mixture using by changing the mixer temperature 74 ° C, the mixer pressure 8. 5 kg / cm 2, is carried out in the same manner as in example 1 except for changing the curing step to 5 hours at 80 ° C of Was. Table 3 shows the physical property results of the obtained foam. Comparative Example 4
- Example 2 The procedure was performed in exactly the same manner as in Example 1 except that the resin resin, the mixer temperature and the mixer pressure were changed as shown in Table 2, and the curing step was changed to 110 ° C. for 3 hours.
- Table 3 shows the physical property results of the obtained foam. Comparative example ⁇
- Resin Resin F 47.75 g of Resin Resin F was weighed, and this was mixed with an alkylphenol ethoxylate (Harf 0 am PI, manufactured by Huntsman Chemical Co.) and ethylene oxide.
- alkylphenol ethoxylate Hardf 0 am PI, manufactured by Huntsman Chemical Co.
- ethylene oxide ethylene oxide
- a mixture of propylene oxide block copolymer (Pluronic F 127 from BASF) at a weight ratio of 1 to 1 was mixed in a 2.25 g cup.
- 4.5 g of normal pentane was mixed into a cup of this mixture while stirring at room temperature.
- Castor oil ethoxylate X (54 moles of ethylene oxide per mole of castor oil) with respect to 100 parts by weight of resole resin G 4.0 parts by weight of castor oil ethoxylate Y (54 moles of ethylene oxide per mole of castor oil) 8. 0 parts by weight added.
- PF-5050 perfluoropentane
- the phenol foam according to the present invention has a thermal conductivity of not more than 0.022 kcal / m-hr ⁇ ° C using a hydrocarbon blowing agent and hardly changes with time. It has excellent heat insulation performance and has a small number of voids, so it can handle even thin plates of 10 mm or less stably.
- the phenol foams shown in Comparative Examples 2 to 4 exhibited excellent initial heat insulation performance with 10 or less pores or dents in the cell wall, but showed a temporal change.
- the compressive strength was low, the dispersion of the compressive strength was large, and in the case of a thin plate having a thickness of 10 mm or less, a phenomenon that the plate was easily broken was observed.
- the foaming ratio is larger than that of the floss method, so that the cell diameter is larger.
- foaming is not performed uniformly, it is considered that pores or dents are generated in the cell wall.
- the phenol foam of the present invention has excellent heat insulating performance, excellent mechanical strength such as compressive strength, and has significantly improved surface brittleness. It is suitable for the global environment because it uses a blowing agent with a low global warming potential.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (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)
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/720,925 US6476090B1 (en) | 1998-07-03 | 1999-07-02 | Phenolic foam |
JP2000558158A JP3813062B2 (ja) | 1998-07-03 | 1999-07-02 | フェノールフォーム |
CA002336374A CA2336374C (en) | 1998-07-03 | 1999-07-02 | Phenolic foam |
EP99926890A EP1095970B1 (en) | 1998-07-03 | 1999-07-02 | Phenolic foam |
DE69924253T DE69924253T2 (de) | 1998-07-03 | 1999-07-02 | Phenolhaltiger schaum |
AU43960/99A AU4396099A (en) | 1998-07-03 | 1999-07-02 | Phenolic foam |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP10/189314 | 1998-07-03 | ||
JP18931498 | 1998-07-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000001761A1 true WO2000001761A1 (fr) | 2000-01-13 |
Family
ID=16239290
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP1999/003567 WO2000001761A1 (fr) | 1998-07-03 | 1999-07-02 | Mousse phenolique |
Country Status (9)
Country | Link |
---|---|
US (1) | US6476090B1 (ja) |
EP (1) | EP1095970B1 (ja) |
JP (1) | JP3813062B2 (ja) |
KR (1) | KR100429437B1 (ja) |
CN (1) | CN1128836C (ja) |
AU (1) | AU4396099A (ja) |
CA (1) | CA2336374C (ja) |
DE (1) | DE69924253T2 (ja) |
WO (1) | WO2000001761A1 (ja) |
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EP1186627A1 (en) * | 2000-09-06 | 2002-03-13 | Atofina Chemicals, Inc. | Blowing agent blends |
EP1229069A2 (fr) * | 2001-02-02 | 2002-08-07 | Atofina | Agent d'expansion à base de HFC-134A et de cyclopentane |
JP2002309030A (ja) * | 2001-04-11 | 2002-10-23 | Asahi Kasei Corp | フェノール樹脂発泡体 |
JP2002338784A (ja) * | 2001-05-18 | 2002-11-27 | Asahi Organic Chem Ind Co Ltd | 発泡性フェノール系レゾール樹脂組成物 |
JP2005054371A (ja) * | 2003-08-05 | 2005-03-03 | Okabe Co Ltd | 耐震用スリット材 |
WO2009110587A1 (ja) | 2008-03-07 | 2009-09-11 | 東レ株式会社 | 断熱材 |
WO2012053493A1 (ja) | 2010-10-18 | 2012-04-26 | 旭化成建材株式会社 | フェノール樹脂発泡板 |
WO2012072769A1 (en) | 2010-12-01 | 2012-06-07 | Novartis Ag | Pneumococcal rrgb epitopes and clade combinations |
WO2014092086A1 (ja) * | 2012-12-11 | 2014-06-19 | 旭化成建材株式会社 | フェノール樹脂発泡体とその製造方法 |
WO2016152154A1 (ja) * | 2015-03-24 | 2016-09-29 | 旭化成建材株式会社 | フェノール樹脂発泡体及びその製造方法 |
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US6358434B1 (en) * | 2001-05-21 | 2002-03-19 | Ato Fina Chemicals, Inc. | Blowing agent blends |
CN100413922C (zh) * | 2003-06-27 | 2008-08-27 | 上海尖端工程材料有限公司 | 一种酚醛泡沫制品的制造工艺 |
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US20050261387A1 (en) * | 2004-05-20 | 2005-11-24 | Stevenson James F | Noise suppression structure manufacturing method |
CA2621512C (en) | 2005-09-08 | 2014-03-25 | Kingspan Holdings (Irl) Limited | A phenolic foam |
US20070155848A1 (en) * | 2005-12-29 | 2007-07-05 | Miller Douglas J | Oxidation resistant carbon foam |
KR101515265B1 (ko) * | 2012-01-19 | 2015-05-06 | (주)엘지하우시스 | 페놀 폼을 이용한 hvac 덕트 및 그 제조 방법 |
US9688831B2 (en) | 2013-12-27 | 2017-06-27 | Asahi Kasei Construction Materials Corporation | Phenol resin foam |
WO2015194174A1 (ja) * | 2014-06-18 | 2015-12-23 | 旭化成建材株式会社 | フェノール樹脂発泡体及びその製造方法 |
GB2553072B (en) * | 2015-05-22 | 2021-07-07 | Linde Ag | Blowing agent |
KR20230095122A (ko) | 2018-04-27 | 2023-06-28 | 아사히 가세이 겐자이 가부시키가이샤 | 난연성 페놀 수지 발포체 |
GB2575988B (en) * | 2018-07-30 | 2020-07-22 | Kingspan Holdings Irl Ltd | Phenolic foam and method of manufacture thereof |
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- 1999-07-02 WO PCT/JP1999/003567 patent/WO2000001761A1/ja active IP Right Grant
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- 1999-07-02 AU AU43960/99A patent/AU4396099A/en not_active Abandoned
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- 1999-07-02 CA CA002336374A patent/CA2336374C/en not_active Expired - Lifetime
- 1999-07-02 EP EP99926890A patent/EP1095970B1/en not_active Revoked
- 1999-07-02 KR KR10-2001-7000039A patent/KR100429437B1/ko not_active IP Right Cessation
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Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2002249758A (ja) * | 2000-09-06 | 2002-09-06 | Atofina Chemicals Inc | 発泡剤ブレンド |
EP1186627A1 (en) * | 2000-09-06 | 2002-03-13 | Atofina Chemicals, Inc. | Blowing agent blends |
EP1229069A2 (fr) * | 2001-02-02 | 2002-08-07 | Atofina | Agent d'expansion à base de HFC-134A et de cyclopentane |
FR2820427A1 (fr) * | 2001-02-02 | 2002-08-09 | Atofina | Agent d'expansion de polymere a base de hfc-134a et de cyclopentane |
US6624208B2 (en) | 2001-02-02 | 2003-09-23 | Atofina | Blowing agent based on HFC-134a and cyclopentane for the expansion of polymers |
EP1229069A3 (fr) * | 2001-02-02 | 2003-10-15 | Atofina | Agent d'expansion à base de HFC-134A et de cyclopentane |
KR100839399B1 (ko) * | 2001-02-02 | 2008-06-19 | 아르끄마 프랑스 | HFC-134a 및 시클로펜탄을 기재로 하는, 중합체발포용 발포제 |
JP2002309030A (ja) * | 2001-04-11 | 2002-10-23 | Asahi Kasei Corp | フェノール樹脂発泡体 |
JP4601855B2 (ja) * | 2001-05-18 | 2010-12-22 | 旭有機材工業株式会社 | 発泡性フェノール系レゾール樹脂組成物 |
JP2002338784A (ja) * | 2001-05-18 | 2002-11-27 | Asahi Organic Chem Ind Co Ltd | 発泡性フェノール系レゾール樹脂組成物 |
JP2005054371A (ja) * | 2003-08-05 | 2005-03-03 | Okabe Co Ltd | 耐震用スリット材 |
WO2009110587A1 (ja) | 2008-03-07 | 2009-09-11 | 東レ株式会社 | 断熱材 |
US9096728B2 (en) | 2008-03-07 | 2015-08-04 | Toray Industries, Inc. | Heat insulating material |
WO2012053493A1 (ja) | 2010-10-18 | 2012-04-26 | 旭化成建材株式会社 | フェノール樹脂発泡板 |
KR20130041955A (ko) | 2010-10-18 | 2013-04-25 | 아사히 가세이 겐자이 가부시키가이샤 | 페놀 수지 발포판 |
US9976026B2 (en) | 2010-10-18 | 2018-05-22 | Asahi Kasei Construction Materials Corporation | Phenol resin foamed plate |
WO2012072769A1 (en) | 2010-12-01 | 2012-06-07 | Novartis Ag | Pneumococcal rrgb epitopes and clade combinations |
WO2014092086A1 (ja) * | 2012-12-11 | 2014-06-19 | 旭化成建材株式会社 | フェノール樹脂発泡体とその製造方法 |
JPWO2014092086A1 (ja) * | 2012-12-11 | 2017-01-12 | 旭化成建材株式会社 | フェノール樹脂発泡体とその製造方法 |
JP2017206714A (ja) * | 2012-12-11 | 2017-11-24 | 旭化成建材株式会社 | フェノール樹脂発泡体とその製造方法 |
US10253151B2 (en) | 2012-12-11 | 2019-04-09 | Asahi Kasei Construction Materials Corporation | Phenolic resin foam and method for producing the same |
WO2016152154A1 (ja) * | 2015-03-24 | 2016-09-29 | 旭化成建材株式会社 | フェノール樹脂発泡体及びその製造方法 |
Also Published As
Publication number | Publication date |
---|---|
US6476090B1 (en) | 2002-11-05 |
AU4396099A (en) | 2000-01-24 |
JP3813062B2 (ja) | 2006-08-23 |
CN1128836C (zh) | 2003-11-26 |
CA2336374A1 (en) | 2000-01-13 |
KR100429437B1 (ko) | 2004-05-03 |
EP1095970A4 (en) | 2003-02-05 |
DE69924253T2 (de) | 2005-12-22 |
CN1307607A (zh) | 2001-08-08 |
DE69924253D1 (de) | 2005-04-21 |
EP1095970A1 (en) | 2001-05-02 |
EP1095970B1 (en) | 2005-03-16 |
CA2336374C (en) | 2004-06-01 |
KR20010053372A (ko) | 2001-06-25 |
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