A 'B' STAGE POLYMER MATERIAL BASED ON A PHENOLIC RESIN, A METHOD OF PRODUCING IT AND A LAMINATE COMPRISING A LAYER OF THIS MATERIAL

Abstract: This invention concerns a stable 'B' stage plastics polymer material, a method of producing said material, and a laminate comprising at least one layer of said material and at least one layer of a metal foil. The plastics polymer material comprises the reaction product of the following components: (a) a phenolic based resin: (b) at least one inorganic and/or further organic material; and (c) an acid catalytic curing sys­ tem; the components being selected such that the reaction between them ends at the 'B' stage. The plastics polymer materials according to this inven­ tion are flexible and have improved stability and flame retar­ dant properties over the known 'B' stage phenolic based mat­ erials.

Description: DESCRIPTION "IMPROVEMENTS IN OR RELATING TO PHENOLIC MATEPIAIS". The present invention relates to a stable 'B' stage plastics polymer material, to a method of producing said material, and to a laminate comprising at least one layer of said material. Thenolic resin based plastics materials evolve in three stages which are connected with the degree nf condensation. Firstly, there is the Resol or 'A' age wherein the material is a soluble fluid which retains a large quantity of water which is generated during condensation, the material being only slightly che@ically crosslinked. Secondly, there is the Resitol or 'B' stage wherein the material becomes a flexible ho@@geneous mass being partly chemically cross-linked, and finally there is the Resite or 'C' stage wherein the material is a fully chemically crcss-linked thermoset. It is well known that phenolic resin based plastics materials have good fire retardent properties and are generally heat resistant. Such known compositions, however, are normally rigid (that is in the 'C' stage) and are extremely brittle thus limiting their scope and useful application. Those known flexible phenolic materials (that is those in the 'B' stage and occasionally in the 'C' stage) exhibit poor stability and much lover resistance to fire when compared with the rigid ls and are, therefore, seldom used. By practice of the present invention there may be provided a material, and a method of manufacturing s-e, which has all the advantages of the known rigid phenolic based materials but which is still flexible and yct capable of being rigidified by the application or ffi if so desired. According to the present invention there is provided a stable 'B' stage plastics polymer materials characterized in that it comprises the reaction product of the following components: (a) a phenolic based resin; (b) at least one inorganic and/or further organic material; and (c) an acid catalytic curing system; the components being selected such that the reaction between them ends at the 'B' stage. According to the present invention there is also provided a method of producing a stable 'B' stage plastics polymer material in accordance with the present invention, characterized in that a mixture of a phenolic based resin and at least one inorganic and/or further organic material is formed and an acid catalytic curing system is subsequently added to the mixture of phenolic based resin and at least one inorganic and/or further organic material, and the resulting mixture is allowed to react to form a stable 'B' stage material. Typically, the phenolic based resin is a licuid phenolic resin, preferably of the resol type. The further organic material may, for example, comprise at least one polymeric material other than the phenolic resin. ¯¯Suitably, the at least one other polymeric material is any material capable of effecting a copolymerisation with the phenolic based resin, for example it can be an epoxy resin. epoxy resins which may be used include materials (resins) produced by reacting epichlorohydrin with Bisphenol-A and these materials are preferably used in a ratio of 1 part by weight of Bisphenol-A to 1 part by weight of epichlorohydrin. The at least one other polymeric material is preferably utilized in the plastics polymer material of the present invention in an amount of up to 35 parts by weight based on 100 parts of the phenolic based resin. Preferably, the at least one inorganic and/or further organic material comprises at least one material selected the phenolic sheet which contacted the release paper is found to have an adhesive nature. An example of a suitable silicone treated polyethylene release paper is that manufactured by Stirling Coated Materials Stud. In a still further embodiment of the present invention, the non-drooping properties of sheets of the stable 'B' stage plastics polymer material may be improved by incorporating a layer of glass fibre-tissue or scrim (for example, having an approximate weight of 7 grams/square metre) into the surface of the sheet. The effect is shown most dramatically by sheeting bonded to a vertical or non-horizontal surface. A non-glass scrim treated sample of a sheet of the polymer material in accordance with the present invention will tend to slowly creep or flow under its own weight, whereas a sheet of the polymer material in accordance with the present invention and containing the glass scrim in its surface remains stable for considerable periods of time, depending on the thickness of the phenolic sheet, ambient temperatures, etc. If silicon carbide fibres, e.g. less than lmm in length, are included in the plastics polymer sheet in accordance with the present invention in place of the glass fibre (scrim), a considerable resistance to flow in sheets formed therefrom may be achieved. The silicon carbide may, for example be present, in the sheet, in an amount of from 2 to 15 percent by weight. Other short fibres such as short ceramic fibres may, for example, result in an anti-flow effect or resistance to droop when included in the plastics polymer materials in accordance with the present invention. - The stable IBt stage plastics polymer materials in accordance with the present invention will generally exhibit one or more of the following properties: (i) They will be non-combustible, for example up to a temperature of 2, 0000C in air, and under a force from cement powder, plaster of Paris, hollow fly-ash spheres, carbon black, mica, silica, glass fibre and other fibrous material. The at least one inorganic and/or further organic material is preferably used in an amount of up to 300 parts by weight, based on 100 parts by weight of the phenolic based resin. The formulations used to produce the stable 'B' stage plastics polymer material in accordance with the present invention may be varied both in the constituents and the quantity of each constituent to give a wide variety of physical properties. For example, in one embodiment of the present invention, the stable 'B' stage plastics polymer material can be produced in the form of a flexible grout. When producing such flexible grouts, glass fibre, for example, chopped glass fibre, or any other fibrous material should not be present since such materials will deleteriously affect the flexibility of the grout. The flexibility grouts have a putty-like texture and can be used to fill gaps, for example in bulkhead cable penetration structures and the like. It may, for example, be applied by simple trowelling techniques and offers excellent resistance to thermal, i.e. flame, ptnetration. In a further embodiment of the present invention, the stable 'B' stage plastics polymer material can be produced in the form of a self-adhesive phenolic sheet. This embodiment obviates the need to apply glues or any bonding agents when attaching the sheet to a substrate. One method of producing such self-adhesive phenolic sheets involves casting the sheet upon a non-porous, i.e. nonpermeating, release paper or other film. For example, a suitable release paper is a polyethylene paper which has a suitable silicone treatment on the side which contacts the phenolic sheet being cast. When the phenolic sheet has been cast and the release paper removed, the face of flame will generate effectively little or no visible smoke. (ii) They will produce no toxic gases except minute quantities of carbon monoxide. (iii) They have a resistance to flame penetration. For example, using a butane torch with a flame temperature of approximately 1300 to 16000 C the ablation rate will be of the order of 2= per hour. (iv) The specific gravity will be of the order of 1.4. (v) They will have sound/noise attenuation properties such that a 6mm thick flexible sheet will show a retardation in sound of the order of 26 decibels over a large frequency range. (vi) They act as excellent high temperature insulants due to their ability to carbonise and ablate under intense heat yet still retain their original shape together with a certain amount of structural integrity. In addition to the above properties, the plastics polymer materials according to the present invention will typically have the following resistance to well known corrodents and solvents: Effect after 48 hours Corrodent#Solvent total immersion Rydrochloric acid No effect Sodium hydroxide Slight decomposition Toluene No effect tylene No effect Petroleum No effect Engine oil No effect Diethyl ether No effect Carbon tetrachloride No effect Methylene chloride No effect Acetone Slightly soluble Methanol Dissolves slightly to give an orange solution. It will be understood that the basic formulation of the stable 'B' stage plastics polymer materials can be suitably modified to cater for other such corrodents and solvents. The electrical properties typical of the plastics polymer material according to the present invention are as follows for a 6mm thick sheet. (a) Surface Resistivity = 3 x 106 Ohms (b) Volume Resistivity = 4 x 106 Ohm cms The electrical properties of the material can similarly be modified by the incorporation of, for example, a conducting carbon black if a conducting material is required, or alternatively particulate mica or silica can be introduced to improve electrical insulat n. The plastics polymer material according to the present invention has unexpectedly high fire rest ardent and heat and could insulating properties. Therefore, 'it has many potential applications. For example, it can be used in thermal insulation where high temperature steam pipes need insulating. At present, such pipes are clad with either asbestos or mineral wool covered by a protective sheath. Problems are often encountered when using such materials in confined spaces or where complex shapes have to be covered. The material according to the present invention, however, may solve there problems in that a flexible sheet can be easily formed around a pipe or gland allowing the heat from the pipe to fully cross-link the sheet thereby alleviating the need to cover the finished insulation with a protective sheath. A further potential application of the plastics polymer material in accordance with the present invention is as a liner for vessels into which molten metal is poured. In this application it has the advantages that it retains the heat in the molten metal for a longer period and protects the surface of the vessel from the high thermal shock that would occur if the molten metal contacted the naked vessel. A further potential application of the plastics polymer material according to the present invention is in the m facture of low temperature cryogenic cabinets since the plastics polymer material may be easily bonded to such materials as sheet steel using conventional adhesives, for example, epoxies. The stable 'B' stage plastics polymer material of the present invention may be further polymerized by additional cross-linking, for example under the influence of heat, high frequency radiation or microwave radiation, to produce a rigid 'C' stage thermoset. One particular method, in accordance with the method of the present invention, for manufacturing a stable 'B' stage plastics polymer material comprising phenolic based resin, epoxy resin, Plaster of Paris cement, hollow fly-ash spheres, glass fibres and catalyst system is as follows: The Plaster of Paris, cement, hollow fly-ash and glass fibres are placed in the mixing chamber of a suitable mixer and preblended until they appear as a homogeneous mass. At this stage the phenolic resin and epoxy resin, which have been previously mixed together, are then added to the mixer whilst the initial ingredients are being further mixed. The mixture is then pumped from the mixing chamber to a dispensing unit which has the ability to add and disperse into the mix the catalyst system. The fully mixed formulation is then dispensed into a lined mould or on to a suitably prepared platen which is located in a press. The press is then closed and held in that position at a nominal pressure for a period of from 5 to 30 minutes at ambient temperature. The press is then opened and the product, which may be in sheet form, is then removed. The product so produced i8 always in the 'B' stage. If a thermoset (i.e. 'C' stage) product be required then the platens of the press are heated to a temperature of from 120 to 1500 C. Should a 'B' stage product require converting to a thermoset at a later date then it can be placed back in the press and heated or, alternatively, placed in an oven under similar temperature conditions. It is obvious that there are other methods of producing the plastics polymer material according to the present invention, for example, by continuous calendering, extrusion, vacuum forming, injection moulding and other processes commonly used in the rubber and plastics industry. Similarly, there are alternative p methods of mixing with the ingredients. The plastics polymer material according to the present invention may be in the form of a syntactic foam if materials such as hollow fly-ash spheres are incorporated therein. The term "syntactic foam" will be clearly understood by one skilled in the art and is different from a plastics foam material foxed by the incorporation therein of a foaming agent which evolves a gas thereby causing the plastics material itself to foam. --laminates, comprising at least one layer of a stable 'B' stage plastics polymer material in accordance with the present invention and at least one layer of a metal foil, may be produced. An example of a suitable metal foil is aluminium foil. Preferably, the or each layer of the mental foil has a thickness of from 0.0125mm to O.5mm and, preferably, the or each layer of the plastics polymer material has a thickness of about 9mums. The laminates, particularly in the form of alternate layers of the plastics polymer material and metal foil, greatly improve the thermal resistance of the plastics polymer sheet using the same total thickness of @@ @or cladding) material. The presence of the @@tal foil assists in the conductance of thermal energy away from the structure being protected by the laminate and also presumably eliminates "hot spots". For example, in an experiment carried out on a 200mm thick plastics polymer sheet in accordance with the present invention, and being used as a cladding for a pipe, an impinging flame at 1200 to 1300 C is found to result in a temperature of 147 C being reached after 50 minutes at the pipeXcladding interface. In a further similar experiment carried out on a "laminate" of only 18mm thickness and comprising a 9mm layer of a plastics polymer material in accordance with the present invention, a temperature of only 11200 was reached after 50 minutes under identical ignition conditions. After 60 minutes, the temperature at the pipe/laminate interface had reached only 129 C. The present invention will now be further illustrated by way of the following examples which list the compositions of a number of plastics polymeric materials according to the present invention. EXAMPLE 1. The following is a basic formula of a typical polymeric plastics material: Parts by weight Phenolic resin (as typified by Lankro LM36) 100 Catalyst (as typified by Phencat 38) 10 - 25 Epoxy resin (as typified by CIBA CX 219 up to 20 Plaster of Paris (2 Ca SO4.H2O) 25 - 100 Hollow Fly-Ash spheres (HCM) 10 - 25 Cement (Portland) 5 - 60 Glass fibre (6mm length or similar) 5 - 30 EXAMPLE 2 If it is desired to produce a material which has the properties of being semi-rigid i.e. towards the end of the 'B' stage condition, and which is capable of being softened under the application of heat at approximately 600C and fully cross-linked with the application of heat at elevated temperature of l300C- 150 C, then the basic fornrtila given in Example 1 could b modified as follows: : Parts by weight Phenolic resin (e.g.Schenectady SMD3083 or Lankro LM36) 100 Catalyst (Phencat 38) 25 Epoxy resin 8 Plester of Paris 60 Portland Cement 15 Glass fibre (6mm or 12mm length) 10 HCM 30 EXAMPLE 3 If it is desired to produce a material which has the properties of being initially very flexible before being fully cross-linked by the application of heat at a temperature of 130 C then the basic formula given in Example 1 could be modified as follows: : Parts by weight Phenolic resin (as above) 100 Catalyst (as above) 25 Plaster of Paris 60 HCM 30 Cement 15 Glass fibre (6mm or 12mm length) 10 Epoxy resin 1 EXAMPLE 4 If -it is desired to produce a composite sheet material wherein a plastics polymer material according to the present invention is moulded over a single layer of continuous glass-fibre mat of typical weight 350 gms per square netre, to form a glass reinforced flexible material having good tear strength, then the basic formula of Example 1 could be modified as follows to provide a material for use as the plastics polymer material: Parts by weight Thenolic resin (as above) 100 Catalyst (as-above) 25 Epoxy resin (as above) 8 Plaster of Paris 60 HCM 30 Cement 45 Glass fibre 10

Claims: CLAIMS 1. A stable 'ss' stage plastics polymer materal, characterized in that it comprises the reaction product of the following components: (a) a phenolic based resin; (b) at least one inorganic and/or further organic material; and (c) an acid catalytic curing system; the components being selected such that the reaction between them ends at the 3' stage. 2. A plastics polymer material as claimed in claim 1, characterized in that the phenolic based resin is a resol type phenolic based resin. 3. A plastics polymer material as claimed in claim 1 or claim 2, characterized in that the at least one inorganic and/or further organic material comprises at least one material selected from cement powder, plaster of Paris, hollow fly-ash spheres, carbon black, mica, silica1 glass fibre and other fibrous material. 4. A plastics polymer material as claimed in any of claims 1 to 3, characterized in that the at least one inorganic and/or further organic material is used in an amount of up to 300 parts by weight, based on 100 parts 'Dy weight of the phenolic based resin. 5. A plastics polymer material as claimed in any of claims 1 to 4, characterized in that the further organo material comprises at least one polymeric material other than the phenolic resin. 6. A plastics polymer material as claimed in claim 5, characterized in that the at least one other polymeric material comprises an epoxy resin. 7. A plastics polymer material as claimed in claim 5 or claim 6, characterized in that the at least one other polymeric material is used in an amount of up to 35 parts by weight, based on 100 parts by weight of the phenolic based resin. b. A method of producing a stable 'B' stage plastics polymer material as claimed in any of clams 1 to 7, characterized in that a mixture of a phenolic based resin and at least one inorganic and/or further organic material is forned and an acid catalytic curing system is @ sequently added to the mixture of phenolic based resin, and at least one inorganic and/or further organic material, and the resulting mixture is allowed to react to form a stable 'B' stage material. 9. A nethod as claimed in claim 8, in which the mixture of the phenolic based resin,the at least one inorganicandZororganic material and the acid catalytic curing system is held in a nould or a press for a period of from 5 o 30 minutes at ambient temperature to produce the stable 'B' stage material. 10. A laminate, characterized in that it comprises at least one layer ot a stable 'B' stage plastics polymeric material as claimed in any of claims 1 to y and at least one layer of a metal foil. II. A laminate as claimed in claim 1O, charact- erized in that the metal foil is aluminium foil. 12. A stable 'B' stage plastics polymer material, characterized In that it comprises the reaction product of the following components: (a) a phenolic based resin; (b) at least one polymeric material other than the phenolic resin; (c) at least one inorganic and/or further organic material; and (d) an acid catalytic curing system; the components being selected such that the reaction between then ends at the 'B' stage. 13. A plastics polymer material as claimed in claim 12, characterized in that the at least one other polymeric material comprises an epoxy resin.

Inventors: GIDDINS, ARTHUR JOHN, OSWITCH, STANLEY, PICKIN, KEVIN, ROBERTS, RICHARD TIMOTHY
Applicants: DESAI POLYMER DEVELOPMENTS LIMITED
Application year: 1979
Main classification: C08L61
IPC codes: C08L61, C08G59, C08L63, C08J5, B32B15, B32B27, C08J9