Synthesis Of Phenolic Resin And Phenolic Foam Board Preparation

In recent years, more and more high-rise buildings are being built with the continuous development of economy. Safety and energy-saving have become important tasks for the sustainable development of society. However, since traditional insulation materials, such as polystyrene (PS) and polyurethane(PU) foam, possess poor flame-retartant performance, they will burn in case of fire or even sparks, and generate toxic gases which is harmful to the environment and human being. Fires caused by the traditional insulation materials occur frequently in recent years. It is urgent to develop new flame-retartant materials. Fortunately, PF(phenolic foam) just meets this requirement.Phenolic foam exsists insulation, flame-retartant, low smoke, excellent heat stability and many other advantages. However, the material itself has the disadvantage of fragility, easy powder and strong acidity. In this thesis, we focused on two major drawbacks of the current market sales phenolic foam. By improving formulation and process of the preparation of phenolic resin and phenolic foam, we obtained the phenolic foam insulation board with excellent comprehensive performance. The ductility of our product is much improved compared with the products on the market. Our products are nearly neutral, avoiding corrosion to the wall. The comprehensive properties reached the national standard completely. In addition, the production process is repeatable, controllable, free of high temparature and high pressure. So this process is suitable for industrial production. The main contents of this thesis are as follows:1. First of all, on the basis of dozens of relative references, this thesis briefly introduced the general situation of the phenolic resin, reaction mechanism, the curing kinetics and heat resistance etc. Then, this thesis described the development and application of phenolic resin. Finally, this thesis concentrated on situation, modified research, development and application of domestic and foreign manufacturers of phenolic foam analysis statements.2. Via systematic experiments and analysis on the factors that influence the synthesis of phenolic resin (temperature, time, material ratio, catalyst and its usage), associated with the feedback information obtained by preparation of phenolic foam, we studied synthesis process for phenolic resin, and optimized the foaming formula. The as-prepared phenolic resin have been characterized by FTIR/GPC etc.3. We developed a process to steadily produce PR suitable for foaming, and further studied the effects of conditions, such as foaming agents, curing temperature, curing time, surfactants, curing agents, on the final foam. And finally, we measured the comprehensive properties of the phenolic resin foam board according to the corresponding standard.4. Finally, on the basis of the simple phenolic foaming technology and process, we tried to improve the ductility of PF by polyurethane prepolymers and investigated the effects in detail.