Method of producing cellular resinous compositions

Claim 1

THE METHOD OF PRODUCING A CELLULAR COMPOSITION COMPRISING FORMING A WATER-CONTAINING MIXTURE OF A PERMANENTLY FUSIBLE DIHYDRIC PHENOLFORMALDEHYDE-CONTAINING RESIN, THE RATIO OF THE ALDEHYDE TO THE TOTAL PHENOLIC BODY BEING LESS THAN 1:1, THE DIHYDRIC PHENOL BEING SELECTED FROM THE GROUP CONSISTING OF RESORCINOL, CATECHOL AND HYDROQUINONE; AND A SOLUTION OF A FORMALDEHYDE SETTING AGENT, SAID SOLUTION HAVING A VISCOSITY BETWEEN 3 AND 130 CENTIPOISES AT 20* C., DELAYING THE GEL-FORMING REACTION IN THE RESINOUS MASS BY HAVING PRESENT THEREIN AN ORGANIC RETARDER SELECTED FROM THE GROUP CONSISTING OF UNSUBSTITUTED POLYHYDRIC AND MONOHYDRIC ALCOHOLS AND PARTIAL ALKYL ETHERS OF UNSUBSTITUTED POLYHYDRIC ALCOHOLS WHICH SIMULTANEOUSLY PREVENTS GAS BUBBLES SUBSEQUENTLY GENERATED IN THE RESINOUS MASS FROM ESCAPING DURING THE TIME THE MIXTURE IS IN A LIQUID STATE AND PRIOR TO THE TIME THE RESINOUS MASS HAS ATTAINED A SUBSTANTIAL GELLED STRUCTURE, GENERATING GAS BUBBLES IN THE RESINOUS MASS, SHORTENING THE GEL TIME OF THE RESINOUS MASS WITH RESPECT TO THE TIME OF THE GAS FORMING REACTION BY MAINTAINING THE PH OF THE RESINOUS MASS OUTSIDE OF THE RANGE OF 2.5 TO 6, AND SETTING THE RESINOUS MASS AT A TEMPERATURE VARYING BETWEEN 60* AND 120* F. PRIOR TO THE ESCAPE OF THE GAS BUBBLES.

Claim 2

THE METHOD OF PRODUCING A CELLULAR COMPOSITION COMPRISING FORMING A WATER-CONTAINING MIXTURE OF A PERMANENTLY FUSIBLE DIHYDRIC PHENOLFORMALDEHYDE-CONTAINING RESIN, THE RATIO OF THE ALDEHYDE TO THE TOTAL PHENOLIC BODY BEING LESS THAN 1:1, THE DIHYDRIC PHENOL BEING SELECTED FROM THE GROUP CONSISTING OF RESORCINOL, CATECHOL AND HYDROQUINONE; AND A SOLUTION OF A FORMALDEHYDE SETTING AGENT, SAID SOLUTION HAVING A VISCOSITY BETWEEN 3 AND 130 CENTIPOISES AT 20* C., DELAYING THE GEL-FORMING REACTION IN THE RESINOUS MASS BY HAVING PRESENT THEREIN AN ORGANIC RETARDER SELECTED FROM THE GROUP CONSISTING OF UNSUBSTITUTED POLYHYDRIC AND MONOHYDRIC ALCOHOLS AND PARTIAL ALKYL ETHERS OF UNSUBSTITUTED POLYHYDRIC ALCOHOLS WHICH SIMULTANEOUSLY PREVENTS GAS BUBBLES SUBSEQUENTLY GENERATED IN THE RESINOUS MASS FROM ESCAPING DURING THE TIME THE MIXTURE IS IN A LIQUID STATE AND PRIOR TO THE TIME THE RESINOUS MASS HAS ATTAINED A SUBSTANTIAL GELLED STRUCTURE, GENERATING GAS BUBBLES IN THE RESINOUS MASS, SHORTENING THE GEL TIME OF THE RESINOUS MASS WITH RESPECT TO THE TIME OF THE GAS FORMING REACTION BY MAINTAINING THE PH OF THE RESINOUS MASS OUTSIDE OF THE RANGE OF 2.5 TO 6, AND SETTING THE RESINOUS MASS AT A TEMPERATURE VARYING BETWEEN 60* AND 120* F. PRIOR TO THE ESCAPE OF THE GAS BUBBLES.