Cellular resins

Claim 1

THE METHOD OF PREPARING A CELLULAR EXEXPANDED THERMOSET RESINOUS BODY COMPRISING ADMIXING (A) BETWEEN 70 AND 95 PARTS BY WEIGHT OF A THERMOSETTABLE PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOL OF AT LEAST ONE MONOHYDRIC PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND FROM 1 TO 3 MOLS OF AN ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENE TETRAMINE AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% TO 5%, BASES ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, AND IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AT A TEMPERATURE OF BETWEEN 50* C. AND AND 115* C. FOR A PERIOD OF TIME OF BETWEEN 1/2 AND 20 HOURS, AND THEN VACUUM DEHYDRATING THE REACTION OF PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% BY WEIGHT OF WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5 AND 0.1 PART BY WEIGHT OF AT LEAST ONE SURFACE ACTIVE, ORGANIC FOAM-INCREASING AGENT SELECTED FROM THE GROUP CONSISTING OF ALKYL ALKALINE SULFOSUCCINATES, IN WHICH THERE IS AN ALKYL GROUP HAVING FROM 4 TO 24 CARBON ATOMS, ALKYL ARYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM 4 TO 30 CARBON ATOMS, ALKYL ARYL POLYETHER ALCOHOLS AND ALKYL ARYL POLYETHER SULFONATES IN WHICH THE ALKYL GROUP HAS FROM 8 TO 24 CARBON ATOMS, ALKALI SOAPS OF FATTY ACIDS HAVING FROM 12 TO 24 CARBON ATOMS, POLYOXYALKYLENE SORBITAN ESTERS OF ACIDS CONTAINING FROM 12 TO 24 CARBON ATOMS, SORBITAN ESTERS OF ACIDS HAVING FORM 12 TO 24 CARBON ATOMS, ALKYL AND ALKARYL QUATERNARY AMMONIUM HALIDE COMPOUNDS WHEREIN AT LEAST ONE ALKYL GROUP OF THE FORMER HAS FROM 8 TO 24 CARBON ATOMS AND AT LEAST ONE ALKARYL GROUP IN THE LATTER TOTALS FROM 8 TO 24 CARBON ATOMS, ALKYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM 8 TO 30 CARBON ATOMS, AND SULFATED AND SULFONATED ALKYL AMINES AND AMIDES WHEREIN THERE IS AT LEAST ONE ALKYL GROUP HAVING FROM 8 TO 24 CARBON ATOMS, (C) BETWEEN 0.5 AND 15 PARTS BY WEIGHT OF AT LEAST ONE GAS-EVOLVING NITROGENOUS COMPOUND SELECTED FORM THE GROUP CONSISTING OF ORGANIC NITRATES AND AZO COMPOUNDS, AND (D) FROM 1 TO 30 PARTS BY WEIGHT OF AN ORGANIC HYDROCARBON DIISOCYANATE, AND HEATING THE MIXTURE TO A TEMPERATURE OF BETWEEN 130* C. TO 250* C. WHEREBY IT EXPANDS INTO A CELLULAR STRUCTURE AND THERMOSETS IN SUCH EXPANDED STATE.

Claim 2

THE METHOD OF PREPARING A CELLULAR EXEXPANDED THERMOSET RESINOUS BODY COMPRISING ADMIXING (A) BETWEEN 70 AND 95 PARTS BY WEIGHT OF A THERMOSETTABLE PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOL OF AT LEAST ONE MONOHYDRIC PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND FROM 1 TO 3 MOLS OF AN ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENE TETRAMINE AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% TO 5%, BASES ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, AND IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AT A TEMPERATURE OF BETWEEN 50* C. AND AND 115* C. FOR A PERIOD OF TIME OF BETWEEN 1/2 AND 20 HOURS, AND THEN VACUUM DEHYDRATING THE REACTION OF PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% BY WEIGHT OF WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5 AND 0.1 PART BY WEIGHT OF AT LEAST ONE SURFACE ACTIVE, ORGANIC FOAM-INCREASING AGENT SELECTED FROM THE GROUP CONSISTING OF ALKYL ALKALINE SULFOSUCCINATES, IN WHICH THERE IS AN ALKYL GROUP HAVING FROM 4 TO 24 CARBON ATOMS, ALKYL ARYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM 4 TO 30 CARBON ATOMS, ALKYL ARYL POLYETHER ALCOHOLS AND ALKYL ARYL POLYETHER SULFONATES IN WHICH THE ALKYL GROUP HAS FROM 8 TO 24 CARBON ATOMS, ALKALI SOAPS OF FATTY ACIDS HAVING FROM 12 TO 24 CARBON ATOMS, POLYOXYALKYLENE SORBITAN ESTERS OF ACIDS CONTAINING FROM 12 TO 24 CARBON ATOMS, SORBITAN ESTERS OF ACIDS HAVING FORM 12 TO 24 CARBON ATOMS, ALKYL AND ALKARYL QUATERNARY AMMONIUM HALIDE COMPOUNDS WHEREIN AT LEAST ONE ALKYL GROUP OF THE FORMER HAS FROM 8 TO 24 CARBON ATOMS AND AT LEAST ONE ALKARYL GROUP IN THE LATTER TOTALS FROM 8 TO 24 CARBON ATOMS, ALKYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM 8 TO 30 CARBON ATOMS, AND SULFATED AND SULFONATED ALKYL AMINES AND AMIDES WHEREIN THERE IS AT LEAST ONE ALKYL GROUP HAVING FROM 8 TO 24 CARBON ATOMS, (C) BETWEEN 0.5 AND 15 PARTS BY WEIGHT OF AT LEAST ONE GAS-EVOLVING NITROGENOUS COMPOUND SELECTED FORM THE GROUP CONSISTING OF ORGANIC NITRATES AND AZO COMPOUNDS, AND (D) FROM 1 TO 30 PARTS BY WEIGHT OF AN ORGANIC HYDROCARBON DIISOCYANATE, AND HEATING THE MIXTURE TO A TEMPERATURE OF BETWEEN 130* C. TO 250* C. WHEREBY IT EXPANDS INTO A CELLULAR STRUCTURE AND THERMOSETS IN SUCH EXPANDED STATE.