Plastic and foam plastic and method for making them

The present invention relates to new plastics and foam plastics and to methods for making the same.
Urea-formaldehyde-resin foam plastics (UF foam plastics), methods for making them and fields of application for the same are known from the literature and patents.
To make UF foam materials, a water-soluble tenside and a UF resin (UF condensation product) are required. The constitution of UF resins has still not been fully investigated.
Suitable tenside mixtures contain, besides the actual tenside in diluted solution, a hardener and a chemical substance to prevent mildewing in the final UF foam plastic, e.g. resorcinol. Compositions have been described in the literature.
As hardeners, preferably inorganic acids, particularly phosphoric acid, are used. As tenside, e.g. diisobutyl naphthalene sulfonic sodium, a water-soluble, anionic tenside, called DIBNS-Na, can be used. 40 ml of a commercial tenside mixture as suited for making foamed plastics consist of, for example, 13.83 g DIBNS-Na, 4.40 g resorcinol and 11.80 g of 85%-phosphoric acid in the form of a yellowish, highly viscous paste with ca. 24 to 30% water content (pH 10 to 12) or in the form of a dry substance as a light, hygroscopic powder (pH 7 to 11).
For making UF foam plastics, the tensides in the foam solution are strongly diluted with water. The ready-for-spraying solutions have a solid content of between 2 and 5%.
Earlier it was assumed that the tenside served only as a carrier for the UF resin (Plastverarbeiter 9 (1958) 453); later, however, it was believed that it might also react ionically with the reactive groups of the UF resin (Plastverarbeiter 27 (1976) 235).
The addition of other chemical substances to the basic solutions in order to improve the physical and chemical properties of the finished UF foam plastic has also long been known (Kunststoffe 47 (1957) 256).
Among many suggestions in the literature, amidosulfonic acid was proposed as a hardener and not as a tenside (Bachmann und Bertz, Aminoplast, VEB-Verlag fur Grundstoff-Industrie, Leipzig 1969).
UF foam plastic, e.g. as thermal insulation material in two-sheet masonry, may frequently give off pungent formaldehyde fumes when drying out. Extensive tests were made for the purpose of finding ways to bind this free formaldehyde in any form whatsoever.
It was surprisingly found that under certain conditions compounds containing sulfonic groups and aldehydes in the presence of a hydroxy compound reacted quantitatively with one another, and that a new plastic material was formed thereby.
The method according to the invention for making this plastic is characterized in that:
(a) one or several compounds containing sulfonic groups in the presence of:
(b) a mono-, di- or polyhydroxy compound or mixtures thereof and
(c) possibly one or several inorganic or organic acids provided, when (a) is present in form of a salt, (c) must be present,
in the form of a concentrated aqueous solution with a water content of about 25 to 30%, as well as
(d) possibly other, customary additives and
(e) possibly other synthetic and natural resins are reacted with
(f) one or several saturated or unsaturated aldehydes or mixtures thereof or a compound which is able to form an aldehyde in acid medium,
under stirring, with or without addition of heat.
This was surprising particularly for the reason that though tenside mixtures that contained sulfonic acid and e.g. resorcinol as hydroxy compound had been used for many years in strongly diluted form in a foaming agent in the preparation of UF foam plastics no substantial reaction between the tenside and excess formaldehyde in the UF plastic had ever been observed.
It was further surprisingly found that according to the invention foam materials could be produced by foaming of only monomers according to the aforementioned components (a), (b), (f) and possibly (c), without requiring the presence of a finished resin product in the starting materials. Only after everything has been foamed is a resin formed from the monomers. The monomeric components (a), (b) and (c) as used for the preparation of the resin according to the invention are introduced into the resin tank in practically undiluted form, i.e. with a water content of 20 to 30%, and preferably 24%, and the same mixture, but in strongly diluted form as tenside together with the aldehyde into the pressure tank for the foaming agent solution, and then everything together foamed up.
The method according to the invention for making foam plastics is characterized in that:
(a) one or several compounds containing sulfonic groups in the presence of:
(b) a mono-, di- or polyhydroxy compound or mixtures thereof and
(c) possibly one or several inorganic or organic acids provided, when (a) is present in the form of a salt, (c) must be present,
in the form of a concentrated aqueous solution with a water content of 20 to 30%, as well as:
(d) possibly other, customary additives and
(e) possibly other synthetic and natural resins are foamed with
(f) one or several saturated or unsaturated aldehydes or mixtures thereof or a compound which is able to form an aldehyde in acid medium,
under addition of a tenside in a dilution as usually used for foam production of component (f) in a conventional foam making installation.
Numerous reactions between formaldehyde, other aldehydes, chemical compounds of an inorganic and organic nature are known; and also the production of synthetic resins. The most widely known are urea-, phenol-, resorcinol-, cresol- and xylol-formaldehyde resins. Further compounds were also prepared:
Huston and Eving prepared xylol-formaldehyde oligomeric aromates with formaldehyde in the presence of acids (Amer. Chem. Soc. (1915) 2394).
Formaldehyde-sulfuric acid is formed by the reaction of sulfur dioxide and formaldehyde (Reinking, Denehl and Labhard (Ber., 38 (1905) 1075).
Kalber obtained methylene-bis-derivatives from beta-naphthyl sulfonic acid and formaldehyde in aqueous solution (U.S. Pat. No. 2,056,924).
Phenol-formaldehyde-novolac (1 mol) can be sulfonated with hydrosulfuric acid (0.45 mol); also ligninsulfonic acids react with phenol-formaldehyde condensates (British Plastics (1949) 641).
Cohn describes a detection of formaldehyde up to 0.00005 mg by placing a layer of the same volume of a 0.1%-resorcinol solution over the solution to be analyzed and then adding slowly 2 ml of conc. sulfuric acid; in the presence of formaldehyde a violet-red zone will result (Chem.Ztg., 45 (1921) 997).
Ellis obtained slightly polyvalent phenolic resin products by reaction with formaldehyde, which are hard to isolate in the intermediate stage ("The Chemistry of Synthetic Resins", 277-395, Reinhold Publishing Corp., 1935, New York).
Fuler prepared methylol derivatives of hydroquinone with formaldehyde (Chem. Centr. (1941) I, 128-9) and CARO prepared methylene-bis-pyrogallol, the latter with formaldehyde in the presence of hydrochloric acid, at room temperature (Ber. 25 (1892) 941).
The new plastics not only yield foam plastics which give off practically no pungent formaldehyde or only for a relatively short period, but also have vis-a-vis UF plastics and UF foam plastics strongly improved stability to acids, alkalis and organic solvents, good temperature and flame resistance, as well as good mechanical and electrical properties. They, furthermore, can be produced at room temperature with simple stirring which results in low costs and energy savings.
The plastics according to the invention can be used in the production of fibers, injection moldings and thermal insulators.
The foam plastics made from these plastics find use as insulating and thermal insulating materials, in plastoponics, as oil absorbents, wound dressings, flower pinning materials, and in powder form as fillers, filter materials and pharmaceutical powders.
As compounds containing sulfonic groups there may be used sulfonic acids, sulfinic acids and sulfamidic acids and their salts either alone or mixed together.
Examples are arylalkyl sulfonates like alkyl benzene sulfonates and alkyl naphthalene sulfonates, which are used as important interface surface-active materials.
Naphtholsulfonic acids, naphthylaminesulfonic acids and aminonaphtholsulfonic acids and their sodium salts are known as readily available basic or intermediate products in dye manufacture. Anthraquinonesulfonic acid and its sodium salts are likewise intermediates in dye synthesis. A list of these compounds is given in "Rompps ChemieLexikon", 7.Ed., P. 2259.
Naphthalenesulfonic acids are known as mono-, di-, tri- and tetrasulfonic acids.
Heterocyclic sulfonic acids can be produced, for example, from acridine and acridone by means of chlorosulfonic acid.
Sulfamic acids are, for example, amidosulfuric acid, amidosulfonic acid or compounds to be denoted as sulfamidic acids.
A number of sulfonic acids that can be used according to the invention are given as follows: phenolsulfonic acids, alkylsulfuric acid and alkylsulfuric salts, alkylsulfonic chlorides, alkylsulfonic esters, alkylsulfonic acid and alkylsulfonic salts, paraaminobenzenesulfonic acids, aminonaphtholsulfonic acids, aminosulfonic acids, anilinsulfonic acids, anthraquinonesulfonic acids, arylsulfonic acids and their amides and chlorides, ethanesulfonic acid, ethylsulfuric acid, benzenedisulfonic acids, benzenesulfamic acid and benzenesulfinic acid, benzcatechinsulfonic acid, bromobenzenesulfonic acid, bromocamphorsulfonic acid, chlorosulfonic ester, diaminoanthraquinonedisulfinic acid, nitrobenzolsulfonic acid, nitronaphthalenesulfonic acid, nitroso-beta-naphthol-6-sulfonic acid, phenoldisulfonic acid, phenolsulfonic acid, phenylhydrazinesulfonic acid, phenylhydrazinesulfonic sodium, pyridinesulfonic acid, thiophenesulfonic acid, vinyl-sulfonic sodium salts, dinitro-oxynaphthalene-sulfonic acid, halogensulfonic acid, hydrazinesulfonic salts, indigosulfonic acid and indigodisulfonic acid, isododecylbenzenesulfonic sodium, perfluorosulfonic acid, bathocuproindisulfonic sodium salt and disodium salt, dimethylbenzenesulfonic acid, morpholino-ethanesulfonic acid, naphthoquinonesulfonic acid and salts and rarer sulfonic acids such as ferrospectral (III (II-pyrinyl)-V, VI-bis (IV-phenylsulfonic acid)-1,2,4-triacine-disodium salt).
Particularly preferred are aryl and alkylaryl sulfonic acids and their salts, and particularly diisobutylnaphthalenesulfonic sodium.
They can be used with success in both aqueous and nonaqueous solutions in relatively concentrated form.
Aldehydes to be used according to the invention are both saturated and unsaturated aliphatic and aromatic aldehydes as well as compounds that are able to form aldehydes in acid medium.
Suitable examples for aldehydes are formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, valeraldehyde, glutardialdehyde, pelargonaldehyde, furfurylaldehyde, crotonaldehyde, tiglicaldehyde, sorbicaldehyde, stearinaldehyde, malonaldehyde, myristicinaldehyde and pyridinaldehyde as well as glyoxal and mixtures thereof. An example of a compound which is able to form an aldehyde in acid medium is hexamethylenetetramine. They can be used in amounts of about 0.5 to 12 mol per mol sulfonic group-containing compound. Usually, the same are used in their commercially obtainable concentrations which may differ from one aldehyde to another. Especially preferred is a 35%-aqueous formaldehyde solution.
Phenols are particularly suited as hydroxy compounds. These phenols can be mono- or polyvalent, substituted or not substituted phenols such as phenol, resorcinol, brenzcatechin, hydroquinone and their tautomeric carbonyl forms; trihydroxybenzenes such as pyrogallol, hydroxyhydroquinone, polyhydroxybenzenes in their three possible forms (1,2,3,4-, 1,2,3,5- and 1,2,4,5-tetrahydroxybenzene); dihydroxytoluene, salicylic acid and gallic acid as well as mixtures thereof. They can be used in amounts of 0.1 to 5 mol per mol of compound containing sulfonic groups. Especially preferred is resorcinol.
When using compounds containing sulfonic groups in the free acid form the use of organic or inorganic acids as hardeners is not absolutely necessary, but has proved to be of a great advantage. When, on the other hand, the compounds containing sulfonic groups are used in the form of their salts then the use of an acid is necessary.
Acids suited according to the invention can be practically all inorganic and organic acids such as hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid, oxalic acid and acetic acid. Especially preferred are phosphoric and sulfuric acids.
Usually, the acids are used in their commercial concentrations; however, the same can also be used in more diluted form.
The amounts to be used can be up to about 10 mol, relative to one mol of the compounds containing sulfonic groups.
The solutions of the starting compounds should be concentrated and contain only enough water or non-aqueous solvent to keep the products dissolved. 20 to 30% water have proved to be of particular advantage.
Other, usually used additions according to the invention are: fillers, dyestuffs, pigments, alcohols, inorganic or organic fibers, buffer substances, indicators, catalysts, regulators, emulsifiers, plasticizers, stabilizers, displacement reagents, deuterated compounds, metalloorganic compounds, metals and metal salts, alcoholates, phenolates, acetyl acetonates, solvents, hydrides, amides, heteroelement compounds, products for regulating the polymerization, polyaddition and polycondensation, radicals and radical initiators, cationic and anionic initiators, enzymes, vitamins, hormones, steroids, biochemicals, additives, flame retardants, cross-linking agents, expanding agents, UV stabilizers, antistatic conductive polymers or substances.
The same can be used alone or in mixture with one another, and in amounts up to about 50 mol per mol of compound containing sulfonic groups.
Also other known synthetic or natural resins or mixtures thereof can further be used before or during the condensation process. The said resins can be soluble or insoluble in water. Suitable resins are for example: resins based on aminoplasts, phenoplasts, desmodur, alpha-omega-urea resins or mixtures thereof, UF, PUR, PF resins, as well as styrene polymers, elastomer-modified copolymers, polyamides, polymethacrylates, polycarbonates, polytetrafluoroethylene and copolymers, basic substances for making polyacetals, aromatic polyethers, polyalkylene terephthalates, unsaturated polyester resins, silicone polymers, melamine resins and epoxide resins. The same can be used in amounts of up to 80 wt.-%.
The formation of the synthetic resins according to the invention takes place in most cases at room temperature without addition of heat, the temperatures rising at times up to 80.degree. C. through exothermic reactions, depending on the kind of starting materials and additions used. With the more diluted solutions, however, external heating may be required or individual components may be preheated to a predetermined temperature so as to affect reaction times. To retard the reaction, individual substances or the entire solution may be cooled to 0.degree. C. or diluted solutions may be used. The latter method is preferred where a particular mixture tends to explosionlike reactions. Usually, the reaction is effected at atmospheric pressure under simple stirring. However, the reaction can likewise be effected in vacuum or under pressure.
By varying the mole ratios of the starting materials within the aforementioned ranges, products with differing physical properties can be obtained such as sediments, precipitates, oligomers, lavalike products, slightly hardened products, viscous solutions, fibers or quantitatively hardened resins. The synthetic resins according to the invention can be hardened by radiation.
The transparent substances are of small crystalline structure, while the non-transparent substances are of an amorphous nature.
For a preliminary condensation, a small portion of the aldehyde to be used can be added to the reaction mixture, and the remainder added at some later time.
As already mentioned, foamed plastics can be produced from the plastics according to the invention, viz. soft (molded and bulk) foam, semirigid, rigid, structural and in situ foamed plastics.
Two processes are known in the manufacture of UF foam plastics. Besides the process described hereinbelow, so-called resin foaming is known. A resin and tenside in powder form are mixed together, dissolved in water before use, and the hardener added after the foaming.
The foams can be produced in situ or stationary, in pressure tanks or with pumps, or parts of the solutions from pressure tanks or conveyed by pumps can be fed to a foam spray gun (foam apparatus). Any desired pressure and any gas or compressed air as suited for foaming can be used.
All apparatuses described in the literature and patent literature can be used for the process according to the invention. It is of no consequence whether the solutions or solid additions are conveyed at an acute angle or at right angles, in parallel flow or in counterflow operation. What is important is that the reaction components are thoroughly mixed so that the necessary chemical reactions are initiated and a foam is produced.
It is also possible to produce foams from small handy spray cans in a one- or multichamber system.
A foam plastic could industrially be produced by using a tenside in place of a UF resin condensate and as foaming agent a similar tenside slightly diluted with water to which formaldehyde had already been added. Tenside concentrates foam very poorly or not at all. To achieve a foaming action, the concentrated tenside must be diluted with water. The degree of foaming can be readily and rationally determined from the foam spray gun in the Baumann-Graf apparatus. (Chemiker Zeitung, Chem. App. 90 (1966) 449).
A concentrated tenside can also be diluted with another sulfonic acid as a dilute or saturated aqueous solution. As a result, the reaction time of resin formation can be shortened.

The examples that follow serve for a further explanation of the invention.
EXAMPLE 1
400 ml of an aqueous mixture of 138.3 g DIBNS-Na, 44 g resorcinol and 118 g of 85% -phosphoric acid with a water content of about 24% were mixed with 40 ml of 35%-formaldehyde and stirred with a glass rod, the temperature rising thereat from 22.degree. C. to 42.degree. C. The dark-brown solution changed its color and first turned light-brown. It then became solid after a few seconds, spontaneously turning red during that time.
A sample of this synthetic resin of 480 g was dried in an oven at 105.degree. C. for one hour. Following that, the sample weighed 431.5 g. After two years of storing at room temperature, the weight dropped to 320 g. After five years, the weight was still the same. The weight loss of 33.33% roughly corresponds to the amount of water of the starting solution. The substance did not change over the entire period.
EXAMPLE 2
10 g of the resin from Example 1 were pulverized, mixed with 100 ml of a 10%-sodium hydroxide solution, and stirred for 15 hours; the mixture was then filtered.
A slightly brownish, needle-shaped substance precipitated from the filtrate which was washed with methanol, acidified with sulfuric acid, and shaken out with ether. After evaporation of the ether, no residue remained.
The precipitate of the resin treated with sodium hydroxide solution gave a yield of 94% after drying at 115.degree. C. This shows that the reactants had combined almost quantitatively.
EXAMPLE 3
10 g DIBNS-Na were acidified with sulfuric acid and shaken out with ether. The diisobutylnaphthalenesulfonic acid went over to the ether and remained after evaporation of the ether. Since, in contrast to the above, no diisobutylnaphthalene sulfonic sodium was found to exist in Example 2 it shows that the sulfonic acid in Example 2 is incorporated in the molecule.
EXAMPLES 4 through 23
In the examples that follow, differing amounts in formaldehyde were tested.
TABLE I______________________________________Differing amounts of formaldehyde added to a 40 ml basic solution(BS) consisting of: 13.83 g diisobutylnaphthalene sulfonic sodium4.40 g resorcin, 11.80 g (85%-) phosphoric acid in aqueous solution(water content ca. 24%) - In all examples,the formaldehyde was added with stirringExam- 35%- Starting Reactionple formalde- tempera- Max. time ColorNo. hyde, ml ture, .degree.C. temp. .degree.C. sec. state______________________________________4 1 28 30 no noticeable reaction5 2 28 45 striation6 3 28 40 striation7 4 24.5 55.5 48 pink, solid8 5 24.5 57 48 pink, solid9 6 24.5 57 48 pink, solid10 7 24.5 59.5 48 pink, solid11 8 24.5 58 48 pink, solid12 9 27.5 59.5 30 pink, solid13 10 27.5 56 48 pink, solid14 11 23.5 52 45 pink, solid15 12 23.5 50.5 45 pink, solid16 13 23.5 51 60 pink, solid17 14 23.5 49 75 pink, solid18 15 23.5 48 75 pink, solid19 16 23.5 49 75 pink, solid20 17 23.5 48 90 pink, solid21 18 24 50 90 pink, solid22 20 24 48 95 pink, solid23 25 24 48 120 pink, solid______________________________________
______________________________________Weight of resins from the reactions using differingamounts of formaldehyde Weight 12 days 30 days 8 monthsExample after reaction after reaction after reaction______________________________________4 40.77 cannot be weighed5 41.85 "6 42.93 "7 44.01 40.10 38.158 45.09 40.30 31.909 46.17 40.40 32.2010 47.25 42.24 33.5511 48.33 41.72 32.5312 49.41 40.00 32.2513 50.49 41.12 32.4814 51.57 41.91 32.4515 52.65 42.25 33.2416 53.75 42.81 33.6517 54.81 42.21 33.0018 55.89 44.26 33.1819 43.88 32.9020 44.20 33.2021 43.86 33.0822 not measured 33.1023 " 33.88______________________________________
In the following examples, various starting materials, molar ratios, temperatures and addition of other compounds as well as the production of foam materials were demonstrated.
EXAMPLE 24
1 mol diisobutylnaphthalene sulfonic sodium +0.6 mol resorcinol +2.4 mols phosphoric acid were mixed in concentrated aqueous solution with 0.7 mol hexamethylene tetramine and heated with stirring. At 50.degree. C., at sticky, light-brown, coherent substance was obtained which, after filtering, did not dissolve in water, sulfuric acid, toluene and hydrochloric acid. It turned yellow in ethanol, red in soda lye. The substance could again be precipitated from the soda lye with hydrochloric acid. In nitric acid the substance turned yellow, and was soluble in n-butanol and dimethylformamide. Also from these solutions, the substance could be recovered with hydrochloric acid. Phosphoric acid hardened the solid substance still further.
EXAMPLE 25
1 mol diisobutylnaphthalene sulfonic sodium +0.6 mol resorcinol, 2.6 mols phosphoric acid and 1.6 mols urea were mixed in concentrated aqueous solution with 2.11 mols formaldehyde.
At 50.degree. C., under stirring, a coherent lavalike resin precipitated, a few milliliters of a greenish solution remained. The solid substance was insoluble in cold soda lye and dimethylformamide. In hot soda lye, it turned bloodred, in dimethylformamide ocher.
The greenish solution did not react with soda lye, hydrochloric acid, n-butanol, cyclohexane and furfural.
EXAMPLE 26
1 mol diisobutylnaphthalene sulfonic sodium was dissolved in water and mixed with 0.6 mol resorcin, 2.4 mols phosphoric acid, 1.6 mols urea and 1.1 mols oxalic acid and heated. At 45.degree. C., 0.7 mol hexamethylene tetramine was added. A lavalike resin as in Example 25 formed; however, the remaining solution was yellow-brown. It was dried in an oven. At 105.degree. C., its volume increased about three-fold.
The filtered resin was boiled in soda lye, and after cooling, precipitated with hydrochloric acid, filtered and washed out. One part of the purified substance was mixed with a solution of soda lye and copper sulfate, a second part was mixed with a solution of ammonium hydroxide and iron-III-chloride. The corresponding salts were obtained in good yield.
EXAMPLE 27
1 mol diisobutylnaphthalene sulfonic sodium was dissolved in 5 mols water and heated to 60.degree. C. This solution was then mixed with 20.5 mol resorcinol and 2 mols formaldehyde. No reaction took place; only after addition of 4 mols phosphoric acid did a red colored substance result.
This example demonstrates that an acid, phosphoric acid in this case, must be added to split off the sodium in the sulfonic acid so that a reaction can take place. The acid is required as an activator as well as a curing catalyst.
EXAMPLE 28
1 mol diisobutylnaphthalene sulfonic sodium was dissolved in 5 mols water and 2 mols formaldehyde and 4 mols phosphoric acid added thereto. The mixture was then heated to 60.degree. C. Here too, no reaction took place. Only upon the addition of 0.5 mols resorcinol did a red resin form.
It can be inferred from this example that a hydroxy compound, resorcinol in this case, is required as the crosslinker of the reaction.
EXAMPLE 29
1 mol diisobutylnaphthalene-disulfonic acid was mixed with 10 mol water, 2.14 mol formaldehyde, 1.23 mols resorcin and 4.58 mols phosphoric acid. On heating, the solution reacted, and a precipitate formed. The latter was filtered off and washed with water until the aqueous solution was neutral. The precipitate was rubberlike and of a dark-brown color. It could not be pressed out on a clay plate. The large volume disintergrated after standing in air for 19 days.
EXAMPLE 30
1 mol diisobutylnaphthalenesulfonic sodium was mixed with 0.6 mol resorcinol and 2.4 mols phosphoric acid in 13 mols water and 0.6 mol formaldehyde added thereto.
The initially brown solution became lighter at 35.degree. C., and thickened at 48.degree. C., but was still stirrable at 80.degree. C. It could not be filtered after cooling, but could be pressed on a clay plate. It did not change when drying at 105.degree. C.
EXAMPLE 31
0.9 mol diisobutylnaphthalene sulfonic sodium, 1.8 mols resorcinol, 0.9 mol hydrochinone, 0.03 mol tin chloride as catalyst, and 8.5 mols phosphoric acid were dissolved in 50 mols water and mixed with 4.8 mols formaldehyde. On heating, a resin precipitated at 50.degree. C.
EXAMPLE 31a
Foam production:
1 l of a commercial tenside consisting of 0.34 g DIBNS-Na, 0.11 g resorcinol and 0.295 g 85%-phosphoric acid in about 24% aqueous solution was introduced into the resin tank of an apparatus used for UF foam plastic production. 1 l of the same tenside which was diluted with 250 cc water and to which 80 cc 35% formaldehyde had been added was introduced into the pressure tank for the foaming agent solution. The whole was then foamed with nozzles used for UF foam plastic production, viz. a 2 mm resin nozzle and 1.5 mm foam nozzle, and with compressed air at 4.5 bars. From the hose connected with the spray gun a slightly yellowish foam emerged which did not collapse. Within 8 minutes, the temperature in the foam rose from 23.5.degree. to 32.5.degree. C. At the start of the reaction, the foam turned reddish. In the course of the reaction, the color turned a deep red. The resultant foam was flexible and resilient, could be dried at 120.degree. C. without any change and under color intensification. Its weight per cubic meter was about 40 kg.
The foam was of open pore structure, individual cells being occasionally covered over with resin films, as they appear in a 30 kg UF foam. The foam was hydrophilic.
______________________________________Solution tests after 24 hours boiled______________________________________1. 95%-sulfuric acid dissolved --(1a) 40%-sulfuric acid no change no change2. 37%-fuming hydro- chloric acid no change no change3. 85%-phosphoric acid no change color intensifi- cation4. 65%-nitric acid dissolved --(4a) 25%-nitric acid dissolved --5. 96%-acetic acid no change no change6. Absolute alcohol no change; substance no change turns yellow7. Acetone no change no change substance turns yellow8. Dimethylformamide no change no change9. Dioxane no change no change substance turns yellow10. Paraffin oil no change no change(10a) Motor oil no destruction --11. 20%-soda lye no change no change12. Water no change no change (the pH value both before and after boiling was 2.5)______________________________________
The melting point of the foam is about 200.degree. C. The foam chars in the flame at about 300.degree. C. without dripping.
TABLE II__________________________________________________________________________In all examples the aldehyde was added under stirring__________________________________________________________________________ Starting Max. Reaction temperature temperature timeNo. BS Aldehyde Hardener .degree.C. .degree.C. sec.__________________________________________________________________________31b BS 4 ml formaldehyde 4 ml H.sub.3 PO.sub.4 30 50 4832 2 ml formaldehyde 2 ml H.sub.3 PO.sub.4 20 6033 BS 6 ml formaldehyde 24 40 4034 6 ml formaldehyde35 BS 5 ml furfurylaldehyde (95%)36 4 ml formaldehyde 23 70 4837 6 ml formaldehyde 23 3038 7 ml formaldehyde 23 2939 7 ml formaldehyde 22.5 3640 BS 7 ml formaldehyde 22.5 7541 BS 7 ml formaldehyde 22.5 7542 BS 9 ml acetaldehyde43 BS 9 ml propionaldehyde44 BS 9 ml butyraldehyde45 BS 7 ml formaldehyde 23 7546 BS 7 ml valeraldehyde47 BS 7 ml formaldehyde 24 42__________________________________________________________________________ Sulfonic acid and/or hydroxy compoundNo. in aqueous solution Other substances Remarks__________________________________________________________________________31b pink, solid32 3.4 anthraquinone-2-sulfonic sodium + 1 g resorcinol red, solid33 2 ml iron-II-chloride solution red, solid34 5 g p-toluenesulfonic acid + 1 g resorcinol pink35 black, solid36 10 g p-toluenesulfonic acid + 4.8 g resorcinol red, solid37 10 g diisobutylnaphthalene-di- 10 ml iron-III-chloride brown, solid sulfonic sodium + 3.5 g resorcinol38 20 g as in 37 + 1.4 g resorcinol 1.4 g tannic acid brown, solid39 15 g benzenesulfonic acid + 1.4 g resorcinol light red, solid40 1.4 g pyrocatechol red, soft41 1.4 g phloroglucinol red, soft42 greasy brown substance, which becomes solid after some time43 brown substance, hardens with prolonged ex- posure44 brown substance, hardens with prolonged ex- posure45 1.4 g hydroquinone brown, soft46 brown substance, hardens with prolonged ex- posure47 20 g diisobutylnaphthalene- brown, solid disulfonic disodium + 4.2 g resorcinol__________________________________________________________________________
TABLE III__________________________________________________________________________ Starting Max. temp. ReactionNo. BS Aldehyde Hardener temp. .degree.C. .degree.C. time sec.__________________________________________________________________________48 7 ml formaldehyde 23.5 5249 7 ml formaldehyde 40 ml 98%- sulfuric acid50 BS 8 ml formaldehyde 18 45 12051 BS 7 ml formaldehyde 20 40 24052 BS 4 ml formaldehyde 20 43 8053 BS 4 ml formaldehyde 18 3854 BS 4 ml formaldehyde 24 12055 BS 24 41 110__________________________________________________________________________ Sulfonic acid and/or hydroxy-No. compound in aqueous solution Other substances Remarks__________________________________________________________________________48 as in example 37 + 5.4 g resorcinol brown, solid49 + 5 g resorcinol red, solid50 + 2.8 g resorcinol red, solid51 3 g sulfanilic acid + 2 g resorcinol brown, soft52 1.4 g ammonium chloro- cuprate II red, solid53 1 g sulfanilic acid red, semirigid54 40 ml water red, solid55 40 ml water red, solid__________________________________________________________________________
TABLE IV__________________________________________________________________________ Starting temp. Max. Reaction timeNo. BS Aldehyde Hardener .degree.C. temp. .degree.C. seconds__________________________________________________________________________56 BS 7 ml formaldehyde 22 30 3057 BS 4 ml formaldehyde 18 27 12758 BS 4 ml formaldehyde 20 38 24059 BS 4 ml formaldehyde 20 41 30060 BS 7 ml pyridinaldehyde 18 40 6061 BS 4 ml pyridinaldehyde 18 40 8062 2 ml formaldehyde 18.7 ml phosphoric 26 35 45 acid63 7 ml formaldehyde 11.8 ml phosphoric 26 38 220 acid64 7 ml glutardialdehyde 6 ml phosphoric 26 40 70 (25%-) acid65 7 ml formaldehyde 11.8 ml phosphoric 28 41 68 acid66 7 ml formaldehyde 11.8 ml phosphoric 28 40 60 acid67 BS 7 ml pelargonaldehyde 21 35 8068 BS 3.5 ml formaldehyde + 3.5 ml pelargonaldehyde 21 40 80__________________________________________________________________________ Sulfonic acid and/or hydroxyNo. compound in aqueous solution Other substances Remarks__________________________________________________________________________56 Mixture of diisobutylnaphthalene 1.4 g tannic acid black, solid di-and-trisulfonic acid + 1.4 g resorcinol57 1 g tannic acid + 4 ml water brown, solid58 3 ml ethanol brown, solid59 1 g 2-amino-diphenyl- yellow substance, amine in 8 ml ethanol solid, after 1 hour recoloration60 soft, hardens after 12 hours61 red, solid62 40 ml of a solution of 282.19 g ben- zenedisulfonic (1,3)-disodium in milky, solid 500 ml water and 3.52 resorcinol pink, solid63 as example 62 pink, solid64 40 ml saturated aqueous solution of turns pink and diisobutylnaphthalenesulfonic-Na + solid at 60.degree. C. 3 g resorcin65 as example 64 and 3 g orcinol yellow substance, solid66 13.8 g dodecylbenzenesulfonic sodium + 3 g resorcinol 18 ml water light pink, solid67 light brown, draws threads68 red, solid__________________________________________________________________________
TABLE V__________________________________________________________________________ Reaction Starting Max. temp. timeNo. BS Aldehyde Hardener temp. .degree.C. .degree.C. seconds__________________________________________________________________________69 BS 7 ml propionaldehyde 22 40 6070 BS 4 ml propionaldehyde 22 40 6571 BS 7 ml butyraldehyde 22 40 6072 BS 4 ml butyraldehyde 22 40 6073 BS 4 ml valeraldehyde 22 40 6074 BS 14 ml formaldehyde 22 44 5075 BS 7 ml formaldehyde + 7 ml butyraldehyde 20 44 55__________________________________________________________________________ Sulfonic acid and/or hydroxyNo. compound in aqueous solution Other substances Remarks__________________________________________________________________________69 darkbrown, soft70 red, solid71 darkbrown, soft72 brown, solid73 brown, solid74 + 4 ml of a saturated raspberry colored, p-toluene sulfonic acid solid75 as Example 74 deep red (jellylike) solid__________________________________________________________________________
TABLE VI__________________________________________________________________________ Starting temp. Max. Reaction timeNo. BS Aldehyde Hardener .degree.C. temp. .degree.C. seconds__________________________________________________________________________76 7 ml formaldehyde 11.8 g phos- 22 40 67 phoric acid77 44 ml 5 ml formaldehyde -- 28 29 65 BS78 5 ml formaldehyde 5 ml sulfuric acid79 1.5 g para- 5 ml sulfuric acid formaldehyde80 7 ml formaldehyde 2.5 ml phosphoric and 0.4 ml sulfuric acid81 1 ml formaldehyde 1 ml phosphoric acid 22 3582 BS 7 ml formaldehyde 18 39 24583 6 ml formaldehyde__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________76 13.8 g commercial dodecyl- Lightred substance. benzenesulfonic acid- quantitatively solid Na and 3 g resorcinol in 18 ml water77 3 ml monostyrene light brown, solid 2 ml ethanol substance78 13 g indigocarmine with 3 g semisoft beige sub- resorcinol in 20 ml water stance79 3 g solid DIBNS powder and oligomers are formed 1 g resorcinol dissolved in 20 ml glacial acetic acid80 40 ml of a saturated solution no immediate reaction, of DIBNS powder and 5 g sali- after hours the sub- cylic acid stance becomes quanti- tatively solid. It is of a green color. At 120.degree. C., it turns into a dirty yellow81 0.5 g o-sulfanilic acid is dissolved Solution turns red in water and mixed with 0.4 g re- and becomes solid sorcinol82 3 g ammonium phosphate A ball of threads is formed under continuous stirring. Color: light- red. Yield 24 g83 40 ml diisobutylnaphthalene- No immediate reaction. disulfonic acid concentrate If after 8 hours a fur- are mixed with 1.4 g resorcinol ther 1.4 g resorcinol are added a fibrous sub- stance is obtained after 15 min. stirring which does not change at 105.degree. C., it is dark brown, turns red in soda__________________________________________________________________________ lye
TABLE VII__________________________________________________________________________ Starting temp. Max. temp. Reaction timeNo. Aldehyde Hardener .degree.C. .degree.C. sec.__________________________________________________________________________84 5 ml formaldehyde 5 ml phosphoric 70.degree. acid85 4 ml formaldehyde86 7 ml formaldehyde 3 ml phosphoric acid87 2 ml formaldehyde 10 ml 95%-sulfuric acid88 7 ml formaldehyde 4 ml phosphoric acid89 1 ml formaldehyde 1 ml phosphoric acid90 7 ml formaldehyde 2 ml sulfuric acid__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________84 10 g anthraquinone-2- Hardener and formaldehyde sulfonic sodium salt are added together at the in 100 ml water + 4 g end, then heated. At about resorcinol 90.degree. C. explosionlike solidifi- cation takes place.85 40 ml diisobutylnaphthalene- upon stirring, a substance disulfonic acid + 14 g resorcinol in form of a ball of threads is formed86 30 g sulfanilic acid + 2.8 g A red resin is formed resorcinol in aqueous solution87 2.8 g resorcinol oligomers are formed under red coloration88 30 g benzenedisulfonic acid- oligomers (1,3) disodium salt + 1.4 g resorcinol89 5 g Na-salt of 4'-(dimethyl- oligomers are formed amino)-azobenzene-4-sulfonic acid dissolved in boiling water + 0.5 g resorcinol90 40 ml diisobutyl-disulfonic disodium salt at 80-85.degree. C. oligomers are + 1 g of phenol formed which harden further after cooling__________________________________________________________________________
TABLE VIII__________________________________________________________________________ Starting temp. Max. temp. ReactionNo. BS Aldehyde Hardener .degree.C. .degree.C. time sec.__________________________________________________________________________91 7 ml formaldehyde 1 ml phos- phoric acid9293 1.5 ml formaldehyde94 10 ml formaldehyde 2 ml phosphoric 20 40 acid95 10 ml formaldehyde 22 48 6096 7 ml formaldehyde 26.5 6297 0.35 ml formaldehyde 3 ml sulfuric acid98 0.7 ml formaldehyde__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________91 40 ml 5%-DIBNS- Reaction takes place upon solution + 2.8 g resorcinol heating, at 90.degree. the solution becomes quantitatively solid92 as 91, but 4.2 g resorcinol same result as example 9193 20 ml of a saturated toluene- The temperature rises from sulfonic acid solution + 17 to 54.degree. C. The solution 9.93 g resorcinol turns wine yellow. With addition of 5 ml phosphoric acid, a resin is formed.94 40 ml of the solution from example 93 A solid raspberry resin is formed. About 20 ml liquid could be decanted which was slightly yellow, but solidi- fied with further addition of formaldehyde95 20 ml of a suspension of congo red in The blue color of the solu- 95%-sulfuric acid are mixed with 6 g tion changes to brown red resorcinol and diluted to 60 ml and becomes solid. Color does not change although pH value is still acid.96 as Example 95, only 5 g resorcinol The solution becomes solid under brownred coloration97 2 g benzenesulfinic sodium With careful heating, a + 0.15 resorcinol pink resin is quantitatively formed98 as Example 97 On heating, the mixture reacts explosionlike. The solid substance is hurled 3 m away from reaction flask__________________________________________________________________________
TABLE IX__________________________________________________________________________ Reaction Starting Max. timeNo. Aldehyde Hardener temp. .degree.C. temp. .degree.C. seconds__________________________________________________________________________ 99 7 ml formaldehyde 10 ml sulfuric acid100 7 ml formaldehyde 10 ml 35%-hydrochloric acid101 7 ml formaldehyde 10 ml phosphoric acid102 BS 5 ml formaldehyde 22.8 43.3 60103 9 ml formaldehyde 3 ml phosphoric acid and 1 ml sulfuric acid104 5 ml formaldehyde 10 ml phosphoric acid 30 40 60105 5 ml formaldehyde 32 48 240__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________ 99 40 ml of a conc. solution solution turns red, a deep- of an alkanesulfonic acid- red precipitate is formed sodium salt with 1.75 g resorcinol100 as Example 99 solution behaves as in Example 99101 as Example 99 the mixture reacts imme- diately and becomes quanti- tatively solid102 40 ml without resorcinol + a solid substance is formed 1.0 g 3,5-dihydroxytoluene103 40 ml of a saturated the solution solidifies DIBNS solution + 5 salicylic acid after several hours stan- ding quantitatively. The resin is of a green color. After drying at 120.degree. C. a yellowish discoloration takes place.104 13.8 g dodecylbenzenesulfonic resin, light pink, solution sodium + 5 g resorcinol in quantitatively solid saturated aqueous solution105 40 ml of a solution from 0.4 freshly prepared solution. mol DIBNS and 0.27 mol re- Solution becomes viscous- sorcinol and 0.83 mol phosphoric acid hard, red and transparent__________________________________________________________________________
TABLE X__________________________________________________________________________ Starting temp. Max. temp. Reaction timeNo. BS Aldehyde Hardener .degree.C. .degree.C. seconds__________________________________________________________________________106 5 ml formaldehyde 25 43 90107 BS 5 ml formaldehyde 27 46 45108 BS 5 ml formaldehyde 26 30 110109 BS 5 ml formaldehyde 26 53 120111 BS 7 ml formaldehyde 23 46 75110 BS 5 ml formaldehyde 24 76 180112 BS 14 ml formaldehyde 23 44 73113 BS 7 ml formaldehyde__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________106 as Example 105 substance solidifies quanti- tatively. Test lasted 18 days. According to mixture from Example 105107 40 ml 20 ml urea-formaldehyde-resin The UF resin was added at the condensate start of the reaction when the solution became cloudy after 45". The resin mixture is amorphous and hard as rock, almost no shrinkage after expo- sure for several weeks.108 40 ml 10 ml phenolic resin (bakelite With the addition of resin, the H 981) solution clears up again. After 2 minutes, a raspberry red resin is formed quantitatively.109 40 ml 10 ml bakelite-resin (AF2580) resin is amorphous, red and hard.111 40 ml 10 ml desmodur 44 V substance is hard and solid.110 40 ml 10 ml furfurylalcohol a green, slightly rubberlike resin is formed112 100 ml 20 ml desmodur 44 V + 3 ml solid, but gritty resin is PU 1109 formed113 25 ml 10 ml desmodur 44 V + a foam is formed. 5-fold 1 ml glycerin foaming. 1 ml desmor 726 B 2 ml frigen__________________________________________________________________________
TABLE XI__________________________________________________________________________ Starting Max. Reaction temp. temp. timeNo. GL Aldehyde Hardener .degree.C. .degree.C. seconds__________________________________________________________________________114 2.33 mols formaldehyde 4 mols phos- 27 46 135 phoric acid115 4 mols formaldehyde 4 mols phos- 27 39 95 phoric acid116 2.33 mols formaldehyde none 25.5 36 300117 4 mols formaldehyde 2 mols phosphoric 26 40 65 acid118 4 mols formaldehyde 2 mols phosphoric 27 39 80 acid119 4 mols formaldehyde none 25 33 540120 5 mols formaldehyde 5 mols phos- 31 52 90 phoric acid121 3 mols formaldehyde 6 mols phos- 31 45.5 80 phoric acid__________________________________________________________________________ Sulfonic acid and/or OtherNo. hydroxy compound substances Remarks__________________________________________________________________________114 1 mol paratoluenesulfonic acid quantitatively solid resin + 1 mol resorcinol in aqueous conc. solution115 as Example 114 quantitatively solid resin116 as Example 114 as examples 114 a. 115117 as Example 114, only 0.45 mol as example 116 resorcinol118 as Example 117 as example 116119 as Example 117 after 14.5 min, solid resin is formed120 1 mol naphthalenetrisulfonic UF resin components do not solidify. trisodium salt + 3 mol resorcinol If UF is added after 3 days (1 part UF resin per 3 parts of solution), the mixture solidifies only after 15 minutes in spite of ph 1 (one) The rapid reaction of UF resin can thus be delayed.121 as Example 120 0.8 mol butanol 2 resin types are precipi- tated. A coherent, fiber- like compound is soluble in NaOH and precipitates again with hydrochloric acid. It is yellow.__________________________________________________________________________
TABLE XII__________________________________________________________________________ Starting Max. Reaction timeNo. BS Aldehyde Hardener temp. .degree.C. temp. .degree.C. seconds__________________________________________________________________________122 2 mol formaldehyde 0.4 mol sulfuric 27 46.5 17 acid123 4 ml formaldehyde 2.5 ml sulfuric 28 41 25 acid124 4 ml formaldehyde 2.5 ml fuming 23 35 55 hydrochloric acid125 4 ml formaldehyde 2.5 ml 65%- 24.5 40 45 nitric acid126 4 ml formaldehyde 2.3 g oxalic acid 22 23 60127 BS 21.2 37.3 185128 BS 21.4 33.6 140__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________122 as Example 120, only 1 mol a red colored resin imme- resorcinol diately precipitates quantitatively123 3.1 g naphthalenetrisulfonic resin is formed immediately trisodium + 0.9 g resorcinol quantitatively124 as Example 123 as example 123125 as 123 as example 123126 as 123 with addition of oxalic acid sodium oxalate precipitates. With addition of 3 ml acetic acid the solution quantitatively solidifies within 15 min.127 20 ml + (15 ml BS + a resin is formed 5 ml water + 5 ml formaldehyde)128 40 ml + (10 ml BS + a resin is formed. (The BS 5 ml formaldehyde) of this example is 3 weeks older than the BS of example 127).__________________________________________________________________________
TABLE XIII__________________________________________________________________________ Starting temp. Max. temp. Reaction timeNo. BS Aldehyde Hardener .degree.C. .degree.C. seconds__________________________________________________________________________129 BS 21.4 37 80130 BS 3 ml formaldehyde 24.4 53.6 300131 BS 4 ml formaldehyde 24.5 37 480132 BS 4 ml crotonaldehyde 3 cc H.sub.2 SO.sub.4 24.5 40 50133 BS 5 ml crotonaldehyde 24.5 41 240 1 ml formaldehyde134 BS 7 ml glyoxalaldehyde 3 cc H.sub.2 SO.sub.4 24.5 40 40135 BS 2 ml glyoxalaldehyde 22.0 5 hours136 BS 4 ml formaldehyde 21.0 42 50__________________________________________________________________________ Sulfonic acid and/orNo. hydroxy compound Other substances Remarks__________________________________________________________________________129 as Example 128 as example 128 (the solution of this example is 4 months old). There is a clearly recognizable color difference between the formed resins of examples 128 and 129.130 40 ml, but without little ethanol the solution becomes viscous at resorcinol + 5.62 g 10 ml furfuryl 48.2. The substance is soluble gallic acid dissolved alcohol in NaOH and precipitates again in hot water with hydrochloric acid. After prolonged standing, the substance hardens further from above. The amorphous substance turns into a clear lightbrown compound. After 14 days, the fully hardened resin is no longer soluble in NaOH. It changes its color lengthwise, it turns red. The amorphous sub- stance still soluble in NaOH no longer precipitates with addition of hydrochloric acid131 40 ml132 40 ml133 40 ml lightbrown, semirigid monomers134 40 ml135 40 ml separation of a green liquid, the formed resin is solid with a brown color136 40 ml polystyrene pellets the pellets are firmly incorpo- (15 g/l) rated in the resin formed__________________________________________________________________________
It will be appreciated that the instant specification and examples are set forth by way of illustration and not limitation, and that various modifications and changes may be made without departing from the spirit and scope of the present invention.

Number	Name	Date
3150108	Villi	Sep 1964
3885010	Bruning et al.	May 1975
4176216	Reid et al.	Nov 1979
4221871	Volodko et al.	Sep 1980

Plastic and foam plastic and method for making them

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