Mixed tannin-phenolic foams

Patent metadata

Field	Value
Publication number	US-9260579-B2
Application number	US-201214118940-A
Country	US
Kind code	B2
Filing date	May 25, 2012
Priority date	May 25, 2011
Publication date	Feb 16, 2016
Grant date	Feb 16, 2016

Abstract

Disclosed are foam compositions and processes to form mixed tannin-phenolic foams. The foams comprises a continuous polymeric phase defining a plurality of cells, wherein the continuous polymeric phase comprises a mixed-resin derived from a phenol, a tannin, and a first monomer, and wherein the plurality of cells comprises a plurality of open-cells and a plurality of closed-cells with an open-cell content measured according to ASTM D6226-5, of less than 50%. The foam composition also comprises a discontinuous phase disposed in at least a portion of the plurality of closed-cells, the discontinuous phase comprising one or more blowing agents.

First claim

What is claimed is:

1. A foam comprising:
(a) a continuous polymeric phase defining a plurality of cells, wherein:
the continuous polymeric phase comprises a mixed-resin derived from a tannin, furfuryl alcohol, and a phenolic resole, wherein the phenolic resole is derived from a phenol and one or more of formaldehyde, paraformaldehyde, furfural, glyoxal, acetaldehyde, 5-hydroxymethylfurfural, 5-furandicarboxylic aldehyde, and difurfural (DFF) as a first monomer, and
the plurality of cells comprises a plurality of open-cells and a plurality of closed-cells with an open-cell content measured according to ASTM D2856, of less than 50%; and

b) one or more blowing agents disposed in at least a portion of the plurality of closed-cells.

2. The foam of claim 1 , wherein the phenol, the tannin, and the first monomer are present in a weight ratio of 1:0.05:0.3 to 1:3:3.

3. The foam of claim 1 , wherein the mixed-resin further comprises a second monomer comprising one or more of acrolein, levulinate esters, sugars, 2,5-furandicarboxylic acid, urea, glycerol, sorbitol, and lignin.

4. The foam of claim 3 , wherein the phenol, urea, and the first monomer are present in a weight ratio of 1:0.05:0.3 to 1:0.008:3.

5. The foam of claim 1 , wherein the open-cell content measured according to ASTM D6226-5, is less than 40%.

6. The foam of claim 1 , wherein the foam has a density in the range of 10-500 kg/m 3 .

7. The foam of claim 1 , wherein at least one of the one or more blowing agents has a gas phase thermal conductivity of less than or equal to 0.016 W/m·K at 25° C.

8. The foam of claim 1 , wherein at least one of the one or more blowing agents comprises 1,1,1,4,4,4-hexafluoro-2-butene.

9. The foam of claim 1 , wherein the foam has a thermal conductivity in the range of 0.015-0.050 W/m·K.

10. The foam of claim 1 , wherein the tannin is derived from mimosa, acacia, quebracho, pine, spruce, fir, tanoak, oak, birch, maple, eucalyptus, tara, catechu, or mixtures thereof.

11. The foam of claim 1 , wherein the foam has a limiting oxygen index of at least 23, measured according to ASTM-D2863.

12. The foam of claim 1 , wherein at least one the phenolic resole, the tannin or the mixed-resin comprises an additive.

13. The foam of claim 12 , wherein the additive comprises cellulose fiber, bacterial cellulose, sisal fiber, clays, Kaolin-type clay, mica, vermiculite, sepiolite, hydrotalcite and other inorganic platelet materials, glass fibers, polymeric fibers, alumina fibers, aluminosilicate fibers, carbon fibers, carbon nanofibers, poly-1,3-glucan, lyocel fibers, chitosan, boehmite (AlO.OH), zirconium oxide, a polyester polyol, or mixtures thereof.

14. An article comprising the foam of claim 1 .

15. The article of claim 14 comprising a sandwich panel structure, wherein the sandwich panel structure comprises the foam disposed between two similar or dissimilar non-foam materials.

Assignees

• Cobb Michael W
• Harmer Mark Andrew
• Kapur Vivek
• Liauw Ann Y
• Williams Sharlene Renee
• Du Pont

Inventors

• Cobb Michael W
• Harmer Mark Andrew
• Kapur Vivek
• Liauw Ann Y
• Williams Sharlene Renee

Classifications

• C08J9/0061 Primary

  characterized by the use of several polymeric components · CPC title

• C08J2203/162

  Halogenated unsaturated hydrocarbons, e.g. H2C=CF2 · CPC title

• Y10T428/249976

  Voids specified as closed · CPC title

• C08J9/146 Primary

  only fluorine as halogen atoms · CPC title

• C08J2361/06

  of aldehydes with phenols · CPC title