Cellular expanded thermoset resins

Claim 1

THE METHOD OF PREPARING A CELLULAR EXPANDED THERMOSET RESINOUS BODY COMPRISING ADMIXING (A) BETWEEN 70% AND 97% BY WEIGHT OF A THERMOSETTING PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOLE OF AT LEAST ONE MONOHYDRIC PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND BETWEEN 1 AND 3 MOLES OF AT LEAST ONE ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENETETRAMINE, AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% TO 5%, BASED ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AT A TEMPERATURE OF BETWEEN 50*C. AND 115*C. FOR A TIME OF BETWEEN 1/2 HOUR AND 20 HOURS, AND DEHYDRATING THE REACTION PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5% AND 0.1% BY WEIGHT OF A SURFACE ACTIVE, ORGANIC FOAM-INCREASING AGENT SELECTED FROM THE GROUP CONSISTING OF ALKYL ALKALINE SULFOSUCCINATES IN WHICH THERE IS AN ALKYL GROUP HAVING BETWEEN FOUR AND TWENTY-FOUR CARBON ATOMS, ALKYL ARYL SULFATES AND SULFONATES IN WHICH THE ALKYL GROUPS HAVE FROM FOUR TO THIRTY CARBON ATOMS DISPOSED IN A LONG CHAIN, ALKYL ARYL POLYETHER ALCOHOLS AND ALKYL ARYL POLYETHER SULFONATES IN WHICH THE ALKYL GROUP HAS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, ALKALI SOAPS OF FATTY ACIDS HAVING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, POLYOXYALKYLENE SORBITAN ESTES OF ACIDS CONTAINING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, SORBITAN ESTES OF ACIDS HAVING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, ALKYL AND ALKARYL QUATERNARY AMMONIUM HALIDE COMPOUNDS WHEREIN AT LEAST ONE ALKYL GROUP OF THE FORMER HAS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, AND AT LEAST ONE ALKARYL GROUP OF THE LATTER TOTALS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, ALKYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM EIGHT TO THIRTY-FOUR CARBON ATOMS, AND SULFATED AND SULFONATED ALKYL AMINES AND AMIDES WHEREIN THERE IS ONE ALKYL GROUP HAVING FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, AND (C) BETWEEN 25% AND 1% BY WEIGHT OF AT LEAST ONE PEROXIDE FROM THE GROUP CONSISTING OF AT LEAST PEROXIDES OF CALCIUM, SODIUM, POTASSIUM, LEAD, BARIUM, MAGNESIUM, ZINC AND UREA, AND HEATING THE MIXTURE TO A TEMPERATURE OF BETWEEN 110* C. AND 350* C. WHEREBY A CELLULAR EXPANDED THERMOSET RESIN BODY IS PRODUCED.

Claim 2

THE METHOD OF PREPARING A CELLULAR EXPANDED THERMOSET RESINOUS BODY COMPRISING ADMIXING (A) BETWEEN 70% AND 97% BY WEIGHT OF A THERMOSETTING PARTIALLY REACTED AQUEOUS REACTION PRODUCT OF ONE MOLE OF AT LEAST ONE MONOHYDRIC PHENOL SELECTED FROM THE GROUP CONSISTING OF PHENOL, CRESOL, XYLENOL AND CRESYLIC ACID AND BETWEEN 1 AND 3 MOLES OF AT LEAST ONE ALDEHYDE SELECTED FROM THE GROUP CONSISTING OF FORMALDEHYDE, POLYMERS OF FORMALDEHYDE, ACETALDEHYDE, HEXAMETHYLENETETRAMINE, AND FURFURALDEHYDE, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF FROM 0.05% TO 5%, BASED ON THE WEIGHT OF THE PHENOL, OF AN ALKALINE CATALYST FOR THE REACTION, THE REACTION BEING CARRIED OUT IN THE PRESENCE OF SUBSTANTIAL AMOUNTS OF WATER AT A TEMPERATURE OF BETWEEN 50*C. AND 115*C. FOR A TIME OF BETWEEN 1/2 HOUR AND 20 HOURS, AND DEHYDRATING THE REACTION PRODUCT WHILE MAINTAINING IT AT A PH OF BETWEEN 3 AND ABOUT 11 TO PROVIDE A RESINOUS PRODUCT CONTAINING BETWEEN 3% AND 25% WATER AND HAVING A VISCOSITY OF BETWEEN 1 AND 250 POISES, (B) BETWEEN 5% AND 0.1% BY WEIGHT OF A SURFACE ACTIVE, ORGANIC FOAM-INCREASING AGENT SELECTED FROM THE GROUP CONSISTING OF ALKYL ALKALINE SULFOSUCCINATES IN WHICH THERE IS AN ALKYL GROUP HAVING BETWEEN FOUR AND TWENTY-FOUR CARBON ATOMS, ALKYL ARYL SULFATES AND SULFONATES IN WHICH THE ALKYL GROUPS HAVE FROM FOUR TO THIRTY CARBON ATOMS DISPOSED IN A LONG CHAIN, ALKYL ARYL POLYETHER ALCOHOLS AND ALKYL ARYL POLYETHER SULFONATES IN WHICH THE ALKYL GROUP HAS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, ALKALI SOAPS OF FATTY ACIDS HAVING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, POLYOXYALKYLENE SORBITAN ESTES OF ACIDS CONTAINING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, SORBITAN ESTES OF ACIDS HAVING FROM TWELVE TO TWENTY-FOUR CARBON ATOMS, ALKYL AND ALKARYL QUATERNARY AMMONIUM HALIDE COMPOUNDS WHEREIN AT LEAST ONE ALKYL GROUP OF THE FORMER HAS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, AND AT LEAST ONE ALKARYL GROUP OF THE LATTER TOTALS FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, ALKYL SULFATES AND SULFONATES WHEREIN THE ALKYL GROUPS HAVE FROM EIGHT TO THIRTY-FOUR CARBON ATOMS, AND SULFATED AND SULFONATED ALKYL AMINES AND AMIDES WHEREIN THERE IS ONE ALKYL GROUP HAVING FROM EIGHT TO TWENTY-FOUR CARBON ATOMS, AND (C) BETWEEN 25% AND 1% BY WEIGHT OF AT LEAST ONE PEROXIDE FROM THE GROUP CONSISTING OF AT LEAST PEROXIDES OF CALCIUM, SODIUM, POTASSIUM, LEAD, BARIUM, MAGNESIUM, ZINC AND UREA, AND HEATING THE MIXTURE TO A TEMPERATURE OF BETWEEN 110* C. AND 350* C. WHEREBY A CELLULAR EXPANDED THERMOSET RESIN BODY IS PRODUCED.