New Synthetic Technology For High-Performance Foamable Phenolic Resin And Its Application

Composed of thermosetting phenolic resin and various additives, phenolic foam is a kind of macromolecular organic rigid foam product. Phenolic foam is an ideal building insulation material, which has a series of superiorities, such as light weight, non-toxic, fire safety, chemical resistance and so on. But its defects, like easy pulverization of material surface, osteoporosis of internal structure, poor mechanical properties greatly limits its application.In consideration of phenolic foam’s defects, firstly, this paper examined polyurethane pre polymers modified pure phenolic resin foam and its effect on the properties of foam. And we also carried on a study on the modification of pure phenolic resin foam adopting pre polymers blocked by-OH, studied the effects of the variety of polyether polyol and the additives amount of polyurethane polymer on the properties of pure phenolic foam. This paper determined the optimum preparation conditions of the pure phenolic resin foam polyurethane pre polymers modifying process. The pre polymers additive amount of phenolic resin is 10%. The preparation material of polyurethane pre is 330N polyether polyols and MDI-50. The results show that the preparation of polyurethane pre polymers will effectively improve the pure phenolic resin foam bubble pore structure, greatly improve the toughness of the pure phenolic resin foam, and significantly reduce its pulverization rate while polyurethane pre polymers can interpenetrate network structure with phenolic resin in foaming process of hydroxyl methyl ether bond. The modified phenolic foam compressive strength is 0.22 MPa; the bending strength is 0.12 MPa; the pulverization rate is 2.17%; the resilient rate is 49.5%; the oxygen index is 44, which is a genera flame retardant grade.And then, this paper improved the synthetic process of thermosetting phenolic resin using the optimization of polyether polyols 330N as raw material through the acetal reaction and preparation of glutaraldehyde hemiacetal compounds, instead of part of paraformaldehyde synthesis of modified phenolic resin. We also studied the effect the change of process conditions on properties of modified phenolic resin. The toughness of the material is improved while Polyether polyols 330N flexible chain segment was introduced into the phenolic resin molecules. This paper determined the optimum synthetic technology conditions of modified phenol resin:firstly, hemiacetal was synthetized at the reaction temperature 80℃ for 3h, P-toluene sulfonic acid as catalyst, while 5% of the mass of the dosage of the p-toluene sulfonic acid as reactants. And then, we added NaOH as catalyst, phenolic 1-1.5 synthesis of modified phenolic resin in the system. The content of free phenol modified phenolic resin is 6.15%; The free aldehyde content is 0.35%; Moisture content is 10%; Solid content is 81%; Viscosity of 5200 cps, which superior to the performance of the technology products.This paper carried out the experiment of foamed phenolic material preparation in the self-design phenolic insulation profile pilot plant using modified phenolic resin as the raw materials, and the technology of organic and inorganic composite materials preparation. We determined the preparation conditions of high performance phenolic insulation profile pilot optimum process:modified phenolic resin:glass fiber:surface active agent:foaming agent= 1:0.02:0.05:0.10; the raw material conveying flow is 2 kg/min; obdurate perlite adding quantity is 0.4 kg/min; curing agent flow is 0.21 kg/min, the foaming time is for 20 min under the temperature of 70℃, bubble reached 0.21 MPa compressive strength, bending strength is 0.12 MPa, pulverization rate was 2.4%, the springback rate is 41.0%, oxygen index is 44.5, which is a flame retardant grade. Its various performance indicators are better than similar phenolic foam products at home and abroad.