Phenolic Based Foams: Preparation, Characterization, and Applications

Description

This book covers the latest developments in phenolic foams and their applications. Compared with polystyrene and polyurethane foams, phenolic foams are known as third-generation polymeric foams. Phenolic foams exhibit excellent fire-retardant properties, including low flammability, low peak heat release rate, no dripping during combustion, and low toxicity. This book discusses various aspects of phenolic foams including properties, synthesis, fabrication methodologies, and applications. The contents also cover the methods for toughening of phenolic foams to make them more widely applicable. This book is of interest to both academics and industry alike. It is also a useful reference for fire safety regulators and policy-makers looking for new materials and methods for sustainable fire protection. 493292_1_En_OFC 493292_1_En_BookFrontmatter_OnlinePDF Preface Contents Editors and Contributors Abbreviations 493292_1_En_1_Chapter_OnlinePDF 1 Phenolic-Based Foams: State of the Art, New Challenges, and Opportunities 1 Introduction 2 Toughening Agents in Phenolic Foams 2.1 Nanofillers 2.2 Natural Fillers 2.3 Polymers 3 PF Foam Production Methods 4 Current Problems and Solutions 5 Applications of PF Foam 6 Conclusion References 493292_1_En_2_Chapter_OnlinePDF 2 Introduction on Foam Manufacture 1 Introduction 1.1 Mechanism of Foaming 1.2 Role of Mixing in Foaming 2 Foaming of Polymers 2.1 Nucleation, Growth, Stabilization, and Solidification 3 Classification of Polymer Foam Processing Techniques 3.1 Physical Foaming 3.2 Chemical Foaming 3.3 Mechanical Foaming 4 Polymer Foam Processing Techniques 4.1 Slab-Stock/Slab-Stock by Pouring 4.2 Molding 4.3 Batch Foaming 4.4 Extrusion 4.5 Extrusion Molding 4.6 Injection Molding 4.7 Heat/Microwave Sintering 4.8 Bead Foaming 4.9 Spraying 4.10 Pour Foaming 4.11 Rotation Foaming 4.12 Hollow Blowing 4.13 Thermal Degradation/Treatment 4.14 Frothing 4.15 Casting 4.16 Phase Separation 4.17 Leaching 4.18 Etching 4.19 Stretching 4.20 Sintering 4.21 Foam Preparation Methods Based on Foam Structure 5 Conclusion References 493292_1_En_3_Chapter_OnlinePDF 3 Materials and Chemistry of Phenolic Foams 1 Introduction 2 Materials and Chemistry of Phenolic Foams 3 Chemistry-Based Applications of Phenolic Foams 4 Conclusion and Future Lookout References 493292_1_En_4_Chapter_OnlinePDF 4 Hybrid Composite Foam: Effect of Hybrid Fillers on the Mechanical Properties of Phenolic Foams 1 Introduction 2 Fillers in Hybrid Composite Foam 2.1 Hybrid Fiber 2.2 Hybrid Particulates 3 Mechanical Properties of Hybrid Composite Phenolic Foam 4 Conclusion References 493292_1_En_5_Chapter_OnlinePDF 5 Toughened Phenolic Foams 1 Introduction 2 Foam Molding 3 Toughness of Phenolic Foam 4 Cell Nucleus and Phenolic Foam Toughness 4.1 Nucleating Agent 4.2 Nucleation Density 5 Cell Wall and Phenolic Foam Toughness 5.1 Expansion Resistance of Foamable Matrix 5.2 Control the Rate of Cell Growth 6 Testing and Characterization of Phenolic Foam Toughness 7 Conclusion References 493292_1_En_6_Chapter_OnlinePDF 6 Shape Memory Phenolic Foams 1 Introduction 2 Need and Purpose of Shape Memory Phenolic Foam 3 Properties of Shape Memory Phenolic Foam (SMPF) and Approaches to Enhance Shape Memory Effect 3.1 Mechanical Properties 3.2 Influence of Cell Size 3.3 Compressive Strength 3.4 Flexural Strength 4 Fire-Resistant (FR) Properties 5 Shape Memory Properties 6 New Trends in Shape Memory Phenolic Foam 7 Conclusion References 493292_1_En_7_Chapter_OnlinePDF 7 Mechanical Properties of Phenolic Foams 1 Introduction 2 Synthesis of PF 3 Why is the Need for Improving the Mechanical Properties of PF? 4 How Mechanical Properties of PF Can Be Enhanced? 5 Effect of Cell Size on the Mechanical Properties of PF 5.1 Effect of Fibers and Particles on Cell Morphology of PF 5.2 Effect of Chemical Modification on Cell Morphology 6 Effect of Fiber Reinforcement on Mechanical Properties of PF 6.1 Compressive Strength 6.2 Flexural Strength 7 Effect of Particle Reinforcement on the Mechanical Properties of PF 7.1 Compressive Strength 7.2 Flexural Strength 8 Conclusion References 493292_1_En_8_Chapter_OnlinePDF 8 Thermal Stability of Phenolic Foams 1 Introduction 2 Phenolic Foams 3 Thermal Stability of Phenolic Foam Composites 4 Thermal Stability of Toughened Phenolic Foams 5 Conclusions References 493292_1_En_9_Chapter_OnlinePDF 9 Thermal Conductivity of Phenolic Foams 1 Introduction 2 Theories of Thermal Conduction Mechanisms 2.1 Thermal Conductivity in Polymeric Foams 3 Types of Thermally Insulating Phenolic Foams 3.1 Phenolic Foams with Tailored Morphologies and Modified Matrix 3.2 Phenolic Foams Containing Micro- or Nanofillers 3.3 Phenolic Syntactic Foams Containing Hollow Microspheres 3.4 Phenolic-Based Carbon Foams 4 Conclusion References 493292_1_En_10_Chapter_OnlinePDF 10 Electromagnetic Interference Shielding in Phenolic Foam 1 Introduction 2 A Brief Review of Electromagnetic Interference Shielding 3 Electromagnetic Interference Shielding in Phenolic-Based Carbon Foams 4 Conclusions and Future Outlook References 493292_1_En_11_Chapter_OnlinePDF 11 Flame Retardant Modification of Phenolic Foam 1 Introduction 2 Boron-Containing Flame Retardant Modified Phenolic Foam 3 Nitrogen-Containing Flame Retardant Modified Phenolic Foam 4 Phosphorus-Containing Flame Retardant Modified Phenolic Foam 5 Silicon-Containing Flame Retardant Modified Phenolic Foam 6 Compound Flame Retardant Modified Phenolic Foam 7 Nano-Materials Modified Phenolic Foam 8 Conclusion References 493292_1_En_12_Chapter_OnlinePDF 12 Modification in Phenolic Foams and Properties of Clay Reinforced PF 1 Introduction 2 Properties of Phenolic Foams 3 Modifications of Phenolic Foams 3.1 Chemical Modification 3.2 Addition of Fillers 3.3 Density 4 Phenolic Foams with Clay Reinforcement 4.1 Montmorillonite Reinforced Phenolic Foams 4.2 Nanoclay, Mineral Clay, and Kaolin Reinforced Phenolic Foams 5 Conclusion References 493292_1_En_13_Chapter_OnlinePDF 13 Graphene Reinforced Phenolic Foams 1 Introduction 2 Graphene Derivatives in Phenolic Foam Modification 3 Conclusion References 493292_1_En_14_Chapter_OnlinePDF 14 Nano Silica Reinforced Phenolic Foams 1 Introduction 2 Preparation of Silica Nanoparticle Reinforced Phenolic Foams 3 Microstructure of Reinforced PFs 4 Physical Properties 4.1 Mechanical Properties 4.2 Thermal Stability and Degradation 4.3 Flame Retardant Properties 4.4 Pulverization Ratio 4.5 Electromagnetic Interference (EMI) Shielding 5 Conclusion References 493292_1_En_15_Chapter_OnlinePDF 15 Synthesis of Bio-/lignin-Based Phenolic Foams for Insulation and Floral Applications 1 Introduction 1.1 Foamable Phenol Formaldehyde Resins 1.2 Blowing Agent 1.3 Surfactants 1.4 Curing Agent 1.5 Wetting Agent 1.6 Fillers 2 Bio-Based Phenolic Foams 2.1 Production of Bio-Phenols 2.2 Preparation of BPF Foams 3 Market Evaluation of Phenolic Insulation and Floral Foams 4 Challenges and Future Work of Preparing BPF Foams 5 Conclusion References 493292_1_En_16_Chapter_OnlinePDF 16 Foams in Wood Composites 1 Introduction 2 Sandwich Composites 3 Foam Core Panels 3.1 Discontinuous (Batch) Processes 3.2 Continuous Processes 3.3 Simultaneous (Integrated) Processes 4 Polymeric Foams 4.1 Expandable Bead Foams 4.2 Thermosetting Foams 5 Strategies Toward Bio-Based Foams 5.1 Bio-Based Expandable Bead Foams 5.2 Bio-Based Polyurethane Foam 5.3 Bio-Based Phenolic Foam 6 Conclusions and Outlook References 493292_1_En_17_Chapter_OnlinePDF 17 Wood Flour-Reinforced Phenolic Foams (WFPF) 1 Introduction 2 Wood and Wooden Fillers 2.1 Production of Wood Flour 2.2 Impact of Wood Flour on Material Properties 3 Methods of Wood Flour Management 4 Wood Plastic Composites 4.1 Properties of WPC 5 Reinforced Phenolic Foams 6 Wood Flour Reinforced Phenolic Foams 7 Conclusions References 493292_1_En_18_Chapter_OnlinePDF 18 Lignin Nanoparticle-Reinforced Phenolic Foams 1 Introduction 2 Preparation of Lignin Nanoparticle-Reinforced PFs 3 Microstructure of Lignin Nanoparticle-Reinforced PFs 4 Physical Properties 4.1 Mechanical Properties and Friability 4.2 Thermal Stability and Degradation 5 Conclusion References 493292_1_En_19_Chapter_OnlinePDF 19 The Role of Polyurethane Chemistry on the Properties of Phenolic Foams Applied in the Thermal Insulation Industry 1 Introduction 2 A Brief Introduction to the Polyurethane Chemistry 3 Correlating Cellular Structures Based on Polyurethane and Phenolic Chemistry 3.1 Systems Based on PF and PUF Precursors 3.2 Blowing Agents 3.3 Cure Kinetics 3.4 Friability 3.5 Environmental Impact and Renewable Content 3.6 Flammability or Fire Resistance 4 Synergistic Reactive Routes to Improve the Properties of PF Using the Polyurethane Chemistry 4.1 Principles Associated with the Development of Synergistic Routes 4.2 Study Cases 5 Conclusions References 493292_1_En_20_Chapter_OnlinePDF 20 Phenolic Foams: The Insulating Materials to Reduce the Frost Penetration, Skidding, and Flooding Risk of Road and Airfield Pavements 1 Introduction 2 Physical Properties of Phenolic Foams 3 Airfield Soft Ground Arrestor, Skid Resistance, and Safety 4 Frost Penetration Below Highways and Airfield Pavements 5 Permeability and Sustainable Drainage System 6 Conclusions References