Industrial Technology Research Institute

Peter T Wu

Shen-Nan Tong

Jui-Hsiang Chen

Shih-Jung Tsai

Jui-Chi Hung

Shih-June Tsai

Interpenetrating polymer network composition, of shaped solid polyester material, e.g. new or reused polyester containing particles, sheeting, fiber or fiber fabric, in a matrix of curable prepolymer resin, e.g. a thermosetting phenol-aldehyde resin of basic pH for providing a flame retardant composition, an interfacial dissolving agent for the polyester material, e.g. an aromatic alcohol and/or a halohydrocarbon, optionally an accelerator for the resin, e.g. a weak acid, and optionally a filler, e.g. in a weight ratio of matrix to polyester material of about 0.25-15:1, wherein the polyester material is distributed, e.g. dissolved, in the manner of a filler in random directional spatial orientation in the matrix and/or preferably is polyester containing linear fiber or fiber fabric arranged as structually reinforcing material in definite directional spatial orientation in the matrix, the composition being consolidated and heat cured to form a prepreg product, and then hot compression molded to form a finally cured, especially flame retardant, structural product.

Preparation of interpenetrating polymer network composition

Production of a lightweight, flame retardant, sound absorption composition in the form of a phenol-aldehyde/polyurethane hybrid polymer foam of open cell structure and interconnected continuous porous architecture, by reacting 100 parts by weight phenolic resin, such as a resole resin of an aldehyde and a phenol, e.g. formaldehyde and phenol, having an aldehyde to phenol mole ratio greater than about 1:1; about 50-300 parts by weight aromatic or aliphatic polyisocyanate; about 0-100 parts by weight aliphatic group containing polyol, e.g. a polyether, polyester, polycaprolactone or polybutadiene polyol; and about 0-100 parts by weight filler; in the presence of a catalyst, e.g. a basic and/or metal salt catalyst in an amount of about 0.01-2 parts by weight, and a blowing agent, especially with all reactants but the polyisocyanate being premixed and then combined with the polyisocyanate for reaction in an open mold, e.g. with the resole resin having a pH of about 4.5-9.5, a solid content of about 50-98%, and a viscosity of not greater than about 100,000 cps at 25.degree. C., and optionally with a surfactant being included in the premixed reactants.

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Taipei, Taiwan

Peter T Wu