轻质阻燃酚醛泡沫材料的制备与构效关系研究
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摘要
近年来，我国城市建筑火灾频发，不仅威胁人民生命和财产安全，还产生大量有害烟雾，污染环境。引发城市建筑火灾的主要着火源之一就是广泛应用于现代建筑外墙中的有机保温材料。建筑材料的阻燃问题已成为国内外关注的热点。酚醛泡沫作为一种自阻燃型泡沫塑料，在燃烧过程中不会发生熔融，流滴，亦不会产生大量毒性烟雾，具有难燃、低烟、低毒特性和耐热性等优点，将在建筑领域作为理想的隔热结构材料而将得到更为广泛的应用。
传统高固含酚醛树脂的生产过程中，均采用苯酚及含量为37%左右的甲醛溶液作为反应单体，制备的酚醛树脂（固含量约50%）需经过脱水方可达到可发性酚醛树脂对固含量（70～85%）的要求，不可避免地产生大量的工业废水。同时由于酚醛泡沫自身存在的易粉化、生产成本高等缺点，有必要针对可发性酚醛树脂及泡沫存在的问题展开研究，解决树脂生产过程中的废水问题，开发性能优良的酚醛泡沫。
针对可发性酚醛树脂及酚醛泡沫存在的问题，本论文采用先进新型不脱水工艺，直接合成固含量在70～85%的可发性高固含甲阶酚醛树脂。分析了树脂制备过程中甲醛/苯酚（F/P）摩尔比、催化剂对可发性高固含甲阶酚醛树脂性能的影响；讨论了酚醛泡沫制备工艺，重点分析了酸固化剂对酚醛泡沫性能的影响，创建了酚醛泡沫表观密度-力学性能模型；采用不同的木质纤维表面处理方法制备纤维复合酚醛泡沫；采用无卤协同阻燃系统制备复合酚醛泡沫；采用酸化处理无机材料制备复合酚醛泡沫。论文主要的研究内容和结论如下：
1.高固含甲阶酚醛树脂的制备及性能研究
采用NaOH为催化剂，制备不同F/P摩尔比的高固含甲阶酚醛树脂，研究F/P摩尔比对高固含甲阶酚醛树脂性能的影响。研究表明，当F/P=2.0时，树脂的性能较优。粘度为2567mPa·s，固体含量为79.25%，凝胶时间为725s，游离苯酚含量为3.01%，游离甲醛含量为0.86%，羟甲基浓度为36.56%，此时树脂的热稳定性也是最高的。树脂在600℃残炭量随着F/P摩尔比的增加而逐渐降低。固化动力学分析表明，低F/P摩尔比的高固含甲阶酚醛树脂拥有较高的Ea值。并且五种树脂的固化反应级数都为非整数，表明其固化反应都是很复杂的。
2.催化剂对酚醛树脂及泡沫性能的影响
采用氢氧化钡（Ba(OH)_2）、三乙胺（(C_2H5)_3N）和氢氧化钠（NaOH）为催化剂，制备可发性高固含甲阶酚醛树脂，研究催化剂对树脂性能的影响。研究表明，3种催化剂的催化效率依次为：NaOH＞(C_2H_5)_3N＞Ba(OH)_2。以NaOH为催化剂制备的酚醛树脂和泡沫的性能最优。以其为催化剂制备的酚醛树脂的粘度为8625mPa·s，固体含量为79.88%，游离苯酚和甲醛分别为3.36%、0.5%，凝胶时间为397s，900℃时的残炭量为59.31%。以NaOH为催化剂制备的酚醛泡沫的压缩及弯曲强度分别为0.24MPa、0.39MPa，掉渣率为11.1%，极限氧指数为44.5%，初始分解温度为107℃，900℃时的残炭量为60.15%，泡孔较小，泡孔分布较为均匀，泡孔直径维持在100~200μm的范围内。
3.酚醛泡沫的制备工艺及其密度-力学性能模型研究
采用聚山梨酯-80为表面活性剂、石油醚为发泡剂、混合酸为固化剂制备酚醛泡沫，研究表面活性剂、发泡剂和混合酸固化剂的添加量对酚醛泡沫性能的影响。研究表明，适宜的表面活性剂添加量树脂质量的10%，适宜的发泡剂添加量约为树脂量的5%，适宜的固化剂为以盐酸/磷酸/对甲苯磺酸/水复配的6#酸固化剂，且适宜的添加量为树脂质量的15%。建立的酚醛泡沫密度-力学性能模型指数值基本接近于简化的Gibson-Ashby公式中的指数，指数值在1.2352~2.1672范围内，压缩性能指数在1.2521~1.4848范围内，弯曲性能指数在1.2352~2.1672范围内。
4.酚醛泡沫发泡模型分析
采用聚山梨酯-80为表面活性剂、石油醚为发泡剂、混合酸为固化剂制备酚醛泡沫，研究表面活性剂、发泡剂和混合酸固化剂的添加量对酚醛泡沫发泡速度和泡沫平均泡孔直径的影响。通过实验数据拟合得到的不同表面活性剂添加量、发泡剂、固化剂及发泡温度与发泡速度的关系模型，及不同表面活性剂添加量、发泡剂、固化剂及发泡温度与泡沫平均泡孔直径的关系模型，可以为酚醛泡沫的应用研究提供一定的理论基础，对于酚醛泡沫制备工艺条件的优化具有一定的指导意义。
5.无卤阻燃剂协同阻燃酚醛泡沫复合材料性能研究
采用多聚磷酸铵（APP）为阻燃剂，季戊四醇（PER）为成炭剂，氧化锌（ZnO）、三氧化钼（MoO_3）、氯化亚铜（CuCl_2）、氯化亚锡（SnCl_2）为协效剂，分别组成四种协同阻燃系统并制备复合酚醛泡沫，研究协同阻燃系统对复合泡沫的阻燃性能的影响。研究表明，四种协同阻燃系统均能显著提高复合酚醛泡沫的氧指数，复合酚醛泡沫的极限氧指数基本都维持在73%左右，而阻燃系统对复合泡沫的热稳定性影响不是很显著。四种协同阻燃体系复合酚醛泡沫的热释放速率、平均热释放、总热释放、有效燃烧热、耗氧量、总氧消耗、一氧化碳产量和一氧化碳产率显著降低，但是比消光面积和总烟产率却显著提高。阻燃系统在泡沫中的阻燃机理是属于气相阻燃机理。在所有阻燃系统中，APP/PER/ZnO是一种比较适合作为酚醛泡沫阻燃改性的阻燃系统。
6.纤维表面改性及其复合酚醛泡沫性能研究
采用碱、偶联剂和碱与偶联剂复合处理的方法对木质纤维进行表面改性，制备纤维复合酚醛泡沫，研究纤维改性对酚醛泡沫性能的影响。研究表明，处理后的纤维复合泡沫的强度都较未处理纤维复合泡沫有不同程度的提高，尤其以氢氧化钠与硅烷偶联剂A-171复合处理方法和硅烷偶联剂KH-792处理方法处理后的纤维复合泡沫的各项性能较优。这说明纤维处理后，纤维表面与树脂基体之间的界面相容性明显得到改善。处理后的纤维复合泡沫的极限氧指数较未处理纤维复合泡沫都有不同程度的降低，这说明纤维处理，对阻燃效果是没有积极意义的。
7.无机复合酚醛泡沫制备及性能研究初探
采用15%磷酸对粉煤灰和膨润土进行酸化处理，制备无机复合酚醛泡沫，研究无机材料酸化处理及其添加量对复合酚醛泡沫性能的影响。研究表明，酸化处理后的无机材料复合泡沫的强度都较未酸化处理的无机材料复合泡沫有不同程度的提高，经过酸化处理的无机复合泡沫的泡孔较小，泡孔分布较为均匀，尤其酸化处理的粉煤灰复合泡沫的各项性能较优。这说明经酸化后的粉煤灰较适合作为复合酚醛泡沫的填料。但无机复合泡沫的极限氧指数较酚醛泡沫都有不同程度的降低。
In recent years, the fires of urban high-rise buildings frequently occur in China, which notonly imperil people's lives and properties, but also produce a large number of harmful smokeand pollute the environment. One of the main ignition sources of city building fires is organicthermal insulation materials, which are widely used in the exterior wall of modern building.Thereby, flame retardant construction materials have been receiving increasing attention. As akind of flame retardant foam featured with non-moltening, difficuity in producing flow drops,less toxic smoke generation during the combustion process, flame retardation, low toxicity andheat resistance, phenolic foam would be used as an ideal thermal insulation material and getmore extensive applications in the construction field.
Traditional high solid resol phenolic resins (HSRPRs)(70～85%), which are prepared bydehydration of phenolic resins (about50%) that are synthesized by reaction between phenoland formaldehyde solution (37wt%), would usually generate a large amount of industrialwastewater. Meanwhile, phenolic foams (PFs) have some disadantages, such as fragility, highproduction cost, etc. Hence, it is necessary to study and develop an efficent way to solve theexisting problems in phenolic resins and foams, as well as to prevent the contamination ofwaste water during the process of resins production. To this end, we aim to develop highperformance PFs.
In this thesis, an advanced and undehydrated technology was used to synthesize HSRPRswith the solid content of70～85%. The effects of formaldehyde/phenol (F/P) molar ratio andcatalysts on the properties of HSRPRs were inverstigated in the process of HSRPRspreparation. The process of PFs was also studied. Particularly, we analyzed the effects of acidcuring agent on the properties of PFs in detail, and created the mathematical model of apparentdensity-mechanical properties of PFs. The wood fibers modified by different surface treatmentmethods were used to enhance PFs. Halogen-free synergistic flame retardant systems wereused to prepare the flame retardant composite PFs. The acid pretreatment method was applied to modify inorganic materials and to prepare inorganic material composite PFs. The mainresults and discoveries are described as follows:
1. preparation and characteration of HSRPRs
A series of HSRPRs were synthesized with different molar ratios of formaldehyde tophenol (1.6,1.8,2.0,2.2and2.4) using sodium hydroxide as catalyst. HSRPRs with bestproperties were obtained when the F/P molar ratio was2.0. These HSRPRs have the viscosityof2567mPa·s, solid content of79.25%, gel time of725s, free formaldehyde content of0.86%,free phenol content of3.01%and hydroxymethyl concentration of36.56%. And the thermalstability was also the best. The residue (600℃) of HSRPRs decreased when the F/P molarratios increased. The low F/P molar ratios of HSRPRs had higher Ea values than that of highmolar ratios, indicating that less heat was needed to cure HSRPRs at high molar ratios thanthose at low molar ratios. The reaction orders of five different F/P molar ratios werenon-integer, and the result indicated that the curing reaction was quite complicated. The resulthad a guiding significance on choosing the right F/P molar ratios during the manufacturing ofHSRPRs.
2. The effects of catalysts on the properties of HSRPRs and PFs
Barium hydroxide (Ba(OH)_2), triethylamine ((C_2H_5)_3N) and sodium hydroxide (NaOH)were chose as catalysts in the synthesis of HSRPRs and the preparartion of PFs at70℃. Theeffects of different catalysts on the properties of HSRPRs and PFs were investigated. Theresults showed that the catalytic efficiency of three kinds of catalysts was listed as follows:NaOH＞(C2H5)3N＞Ba(OH)2. The optimal properties of phenolic resins and foams wereachieved when the phenolic resins were prepared with NaOH as catalyst. And the viscosity,solid content, free phenol, free formaldehyde, gel time and the amount of residual carbon of theresin (NaOH as catalyst) were8625mPa·s,79.88%,3.36%,0.5%,397s and59.31%(900℃)respectively. The compression strength, bending strength, mass loss rate, limited oxygen index(LOI), initial decomposition temperature and the amount of residual carbon of PFs (NaOH ascatalyst) were0.24MPa,0.39MPa,11.1%,44.5%,107℃and60.15%(900℃) respectively. And PFs was characterized to have smaller cells with a diameter of100~200μm, and relativelyuniform cell distribution.
3. Research on the preparation process and model of density-mechanical properties of PFs
Surfactant (polysorbate-80), blowing agent (petroleum ether), and curing agent (mixedacid) were selected to prepare PFs at70℃. The influences of amount of surfactant, blowingagent and curing agent on the properties of PFs were investigated. The results showed that thesuitable amount of surfactant and blowing agent were10%and5%respectively, and theproperties of foams was the best using hydrochloric acid/phosphoric acid/p-toluene sulfonicacid/water as curing agent, and the suitable amount of curing agent was15%. Themathematical model of density-mechanical properties was established by the foam model ofGibson-Ashby's mechanical properties and density. The results showed that there was a goodexponential relationship between mechanical properties and density. The exponential valueswere in the range of1.2352~2.1672. The exponential values of compression properties were inthe range of1.2521~1.4848, and the exponential values of bending properties were in the rangeof1.2352~2.1672.
4. Study on foaming model of phenolic foam
Polyoxyethylene-80(surfactant), petroleum ether (blowing agent) and mixed acids (curingagent) were selected to prepare PFs at different foaming temperatures. The effects of foamingtemperature, amount of surfactant, foaming agent, curing agent on the foaming speed andaverage cell diameter of PFs were investigated. Foaming speeds and average cell diameter ofPFs were obtained by experiments tests. The mathematical models of foaming speed andaverage cell diameter were obtained by nonlinear fitting of these experiment data. The modelof foaming speed, which reflected a relationship between foaming temperature, amount ofsurfactant, foaming agent, curing agent and the growth speed of foam volume, was set up. Andthe model of average cell diameter, which reflected a relationship between foamingtemperature, amount of surfactant, foaming agent, curing agent and average cell diameter offoam, was established. These models could provide basic theories for the guidance to the research on the application of PFs. In the meantime, It is meaningful for this basic theory toguide the preparation of PFs and optimize preparation technology.
5. Preparation and characteration of PFs with Eco-friendly Halogen-free Flame Retarant
The retardant additives, including eco-friendly halogen-free flame retardants (APP), charforming agent (PER), and synergist (ZnO, MoO_3, CuCl_2, and SnCl_2), were added in HSRPRsto fabricate the flame retardant composite phenolic foams (FRCPFs). The effects of theseretardant additives on the performance and properties of FRCPFs were investigated. It wasfound that LOIs of FRCPFs significantly increased and reached to around73%. HRR, AHRE,THR, EHC, O_2C, TOC, and emission of toxic gases (COP and COY) remarkably decreased,while for SEA and TSR, they significantly increased. The flame-retardant system agreed withthe gasphase flame-retarding mechanism. The results showed that FRCPFs had excellentfire-retarding performance, although it has a minor negative effect in respect of reduction in thesmoke release. APP/PER/ZnO was concluded as a better flame-retardant system for PFs.
6. Modification of the wood fiber surface and the research on the preparation andcharacteration of wood fiber composite PFs
The wood fibers pretreated by alkali, coupling coupling agents and alkali-couplingcoupling agents were used to prepare fiber composite PFs. The effects of wood fibers onproperties of PFs were studied. The results showed that the mechnical properties of treatedfiber composite PFs increased to different levels, compared with untreated fiber composite PFs.Especially the properties of treated fiber composite PFs were better while using silane couplingagent (A-171)-sodium hydroxide composite treatment and silane coupling agent (KH-792)treatment method. The results indicated after pretreatment, the interfacial compatibilitybetween fiber surface and resins significantly improved. But limiting oxygen indexs of treatedfiber composite PFs decreased to different levels, compared with untreated fiber composite PFs.This indicated that there was no positive effect of fiber modification on the flame retardant ofwood fiber composited PFs.
7. Preparation and initial investigation of inorganic materials composite PFs
Pulverized fuel ash and bentonite were modified to phosphate by15wt%phosphoric acidand used to prepare inorganic material composite PFs. The effects of acidification method ofinorganic materials and amount of inorganic materials on the properties of PFs wereinvestigated. The results showed that the mechnical properties of acidification-treated inorganicmaterials composite PFs increased to different levels, compared with untreated inorganicmaterial composite PFs. The cells of PFs were smaller and cell distribution was relativelyuniform. Particularly, the properties of acidification-treated pulverized fuel ash composite PFswere better. The results showed that the suitable inorganic material for composite PFs waspulverized fuel ash treated by acidification method. But limited oxygen indexs of inorganicmaterial composite PFs decreased to different levels, compared with phenolic foam.
传统高固含酚醛树脂的生产过程中，均采用苯酚及含量为37%左右的甲醛溶液作为反应单体，制备的酚醛树脂（固含量约50%）需经过脱水方可达到可发性酚醛树脂对固含量（70～85%）的要求，不可避免地产生大量的工业废水。同时由于酚醛泡沫自身存在的易粉化、生产成本高等缺点，有必要针对可发性酚醛树脂及泡沫存在的问题展开研究，解决树脂生产过程中的废水问题，开发性能优良的酚醛泡沫。
针对可发性酚醛树脂及酚醛泡沫存在的问题，本论文采用先进新型不脱水工艺，直接合成固含量在70～85%的可发性高固含甲阶酚醛树脂。分析了树脂制备过程中甲醛/苯酚（F/P）摩尔比、催化剂对可发性高固含甲阶酚醛树脂性能的影响；讨论了酚醛泡沫制备工艺，重点分析了酸固化剂对酚醛泡沫性能的影响，创建了酚醛泡沫表观密度-力学性能模型；采用不同的木质纤维表面处理方法制备纤维复合酚醛泡沫；采用无卤协同阻燃系统制备复合酚醛泡沫；采用酸化处理无机材料制备复合酚醛泡沫。论文主要的研究内容和结论如下：
1.高固含甲阶酚醛树脂的制备及性能研究
采用NaOH为催化剂，制备不同F/P摩尔比的高固含甲阶酚醛树脂，研究F/P摩尔比对高固含甲阶酚醛树脂性能的影响。研究表明，当F/P=2.0时，树脂的性能较优。粘度为2567mPa·s，固体含量为79.25%，凝胶时间为725s，游离苯酚含量为3.01%，游离甲醛含量为0.86%，羟甲基浓度为36.56%，此时树脂的热稳定性也是最高的。树脂在600℃残炭量随着F/P摩尔比的增加而逐渐降低。固化动力学分析表明，低F/P摩尔比的高固含甲阶酚醛树脂拥有较高的Ea值。并且五种树脂的固化反应级数都为非整数，表明其固化反应都是很复杂的。
2.催化剂对酚醛树脂及泡沫性能的影响
采用氢氧化钡（Ba(OH)_2）、三乙胺（(C_2H5)_3N）和氢氧化钠（NaOH）为催化剂，制备可发性高固含甲阶酚醛树脂，研究催化剂对树脂性能的影响。研究表明，3种催化剂的催化效率依次为：NaOH＞(C_2H_5)_3N＞Ba(OH)_2。以NaOH为催化剂制备的酚醛树脂和泡沫的性能最优。以其为催化剂制备的酚醛树脂的粘度为8625mPa·s，固体含量为79.88%，游离苯酚和甲醛分别为3.36%、0.5%，凝胶时间为397s，900℃时的残炭量为59.31%。以NaOH为催化剂制备的酚醛泡沫的压缩及弯曲强度分别为0.24MPa、0.39MPa，掉渣率为11.1%，极限氧指数为44.5%，初始分解温度为107℃，900℃时的残炭量为60.15%，泡孔较小，泡孔分布较为均匀，泡孔直径维持在100~200μm的范围内。
3.酚醛泡沫的制备工艺及其密度-力学性能模型研究
采用聚山梨酯-80为表面活性剂、石油醚为发泡剂、混合酸为固化剂制备酚醛泡沫，研究表面活性剂、发泡剂和混合酸固化剂的添加量对酚醛泡沫性能的影响。研究表明，适宜的表面活性剂添加量树脂质量的10%，适宜的发泡剂添加量约为树脂量的5%，适宜的固化剂为以盐酸/磷酸/对甲苯磺酸/水复配的6#酸固化剂，且适宜的添加量为树脂质量的15%。建立的酚醛泡沫密度-力学性能模型指数值基本接近于简化的Gibson-Ashby公式中的指数，指数值在1.2352~2.1672范围内，压缩性能指数在1.2521~1.4848范围内，弯曲性能指数在1.2352~2.1672范围内。
4.酚醛泡沫发泡模型分析
采用聚山梨酯-80为表面活性剂、石油醚为发泡剂、混合酸为固化剂制备酚醛泡沫，研究表面活性剂、发泡剂和混合酸固化剂的添加量对酚醛泡沫发泡速度和泡沫平均泡孔直径的影响。通过实验数据拟合得到的不同表面活性剂添加量、发泡剂、固化剂及发泡温度与发泡速度的关系模型，及不同表面活性剂添加量、发泡剂、固化剂及发泡温度与泡沫平均泡孔直径的关系模型，可以为酚醛泡沫的应用研究提供一定的理论基础，对于酚醛泡沫制备工艺条件的优化具有一定的指导意义。
5.无卤阻燃剂协同阻燃酚醛泡沫复合材料性能研究
采用多聚磷酸铵（APP）为阻燃剂，季戊四醇（PER）为成炭剂，氧化锌（ZnO）、三氧化钼（MoO_3）、氯化亚铜（CuCl_2）、氯化亚锡（SnCl_2）为协效剂，分别组成四种协同阻燃系统并制备复合酚醛泡沫，研究协同阻燃系统对复合泡沫的阻燃性能的影响。研究表明，四种协同阻燃系统均能显著提高复合酚醛泡沫的氧指数，复合酚醛泡沫的极限氧指数基本都维持在73%左右，而阻燃系统对复合泡沫的热稳定性影响不是很显著。四种协同阻燃体系复合酚醛泡沫的热释放速率、平均热释放、总热释放、有效燃烧热、耗氧量、总氧消耗、一氧化碳产量和一氧化碳产率显著降低，但是比消光面积和总烟产率却显著提高。阻燃系统在泡沫中的阻燃机理是属于气相阻燃机理。在所有阻燃系统中，APP/PER/ZnO是一种比较适合作为酚醛泡沫阻燃改性的阻燃系统。
6.纤维表面改性及其复合酚醛泡沫性能研究
采用碱、偶联剂和碱与偶联剂复合处理的方法对木质纤维进行表面改性，制备纤维复合酚醛泡沫，研究纤维改性对酚醛泡沫性能的影响。研究表明，处理后的纤维复合泡沫的强度都较未处理纤维复合泡沫有不同程度的提高，尤其以氢氧化钠与硅烷偶联剂A-171复合处理方法和硅烷偶联剂KH-792处理方法处理后的纤维复合泡沫的各项性能较优。这说明纤维处理后，纤维表面与树脂基体之间的界面相容性明显得到改善。处理后的纤维复合泡沫的极限氧指数较未处理纤维复合泡沫都有不同程度的降低，这说明纤维处理，对阻燃效果是没有积极意义的。
7.无机复合酚醛泡沫制备及性能研究初探
采用15%磷酸对粉煤灰和膨润土进行酸化处理，制备无机复合酚醛泡沫，研究无机材料酸化处理及其添加量对复合酚醛泡沫性能的影响。研究表明，酸化处理后的无机材料复合泡沫的强度都较未酸化处理的无机材料复合泡沫有不同程度的提高，经过酸化处理的无机复合泡沫的泡孔较小，泡孔分布较为均匀，尤其酸化处理的粉煤灰复合泡沫的各项性能较优。这说明经酸化后的粉煤灰较适合作为复合酚醛泡沫的填料。但无机复合泡沫的极限氧指数较酚醛泡沫都有不同程度的降低。
In recent years, the fires of urban high-rise buildings frequently occur in China, which notonly imperil people's lives and properties, but also produce a large number of harmful smokeand pollute the environment. One of the main ignition sources of city building fires is organicthermal insulation materials, which are widely used in the exterior wall of modern building.Thereby, flame retardant construction materials have been receiving increasing attention. As akind of flame retardant foam featured with non-moltening, difficuity in producing flow drops,less toxic smoke generation during the combustion process, flame retardation, low toxicity andheat resistance, phenolic foam would be used as an ideal thermal insulation material and getmore extensive applications in the construction field.
Traditional high solid resol phenolic resins (HSRPRs)(70～85%), which are prepared bydehydration of phenolic resins (about50%) that are synthesized by reaction between phenoland formaldehyde solution (37wt%), would usually generate a large amount of industrialwastewater. Meanwhile, phenolic foams (PFs) have some disadantages, such as fragility, highproduction cost, etc. Hence, it is necessary to study and develop an efficent way to solve theexisting problems in phenolic resins and foams, as well as to prevent the contamination ofwaste water during the process of resins production. To this end, we aim to develop highperformance PFs.
In this thesis, an advanced and undehydrated technology was used to synthesize HSRPRswith the solid content of70～85%. The effects of formaldehyde/phenol (F/P) molar ratio andcatalysts on the properties of HSRPRs were inverstigated in the process of HSRPRspreparation. The process of PFs was also studied. Particularly, we analyzed the effects of acidcuring agent on the properties of PFs in detail, and created the mathematical model of apparentdensity-mechanical properties of PFs. The wood fibers modified by different surface treatmentmethods were used to enhance PFs. Halogen-free synergistic flame retardant systems wereused to prepare the flame retardant composite PFs. The acid pretreatment method was applied to modify inorganic materials and to prepare inorganic material composite PFs. The mainresults and discoveries are described as follows:
1. preparation and characteration of HSRPRs
A series of HSRPRs were synthesized with different molar ratios of formaldehyde tophenol (1.6,1.8,2.0,2.2and2.4) using sodium hydroxide as catalyst. HSRPRs with bestproperties were obtained when the F/P molar ratio was2.0. These HSRPRs have the viscosityof2567mPa·s, solid content of79.25%, gel time of725s, free formaldehyde content of0.86%,free phenol content of3.01%and hydroxymethyl concentration of36.56%. And the thermalstability was also the best. The residue (600℃) of HSRPRs decreased when the F/P molarratios increased. The low F/P molar ratios of HSRPRs had higher Ea values than that of highmolar ratios, indicating that less heat was needed to cure HSRPRs at high molar ratios thanthose at low molar ratios. The reaction orders of five different F/P molar ratios werenon-integer, and the result indicated that the curing reaction was quite complicated. The resulthad a guiding significance on choosing the right F/P molar ratios during the manufacturing ofHSRPRs.
2. The effects of catalysts on the properties of HSRPRs and PFs
Barium hydroxide (Ba(OH)_2), triethylamine ((C_2H_5)_3N) and sodium hydroxide (NaOH)were chose as catalysts in the synthesis of HSRPRs and the preparartion of PFs at70℃. Theeffects of different catalysts on the properties of HSRPRs and PFs were investigated. Theresults showed that the catalytic efficiency of three kinds of catalysts was listed as follows:NaOH＞(C2H5)3N＞Ba(OH)2. The optimal properties of phenolic resins and foams wereachieved when the phenolic resins were prepared with NaOH as catalyst. And the viscosity,solid content, free phenol, free formaldehyde, gel time and the amount of residual carbon of theresin (NaOH as catalyst) were8625mPa·s,79.88%,3.36%,0.5%,397s and59.31%(900℃)respectively. The compression strength, bending strength, mass loss rate, limited oxygen index(LOI), initial decomposition temperature and the amount of residual carbon of PFs (NaOH ascatalyst) were0.24MPa,0.39MPa,11.1%,44.5%,107℃and60.15%(900℃) respectively. And PFs was characterized to have smaller cells with a diameter of100~200μm, and relativelyuniform cell distribution.
3. Research on the preparation process and model of density-mechanical properties of PFs
Surfactant (polysorbate-80), blowing agent (petroleum ether), and curing agent (mixedacid) were selected to prepare PFs at70℃. The influences of amount of surfactant, blowingagent and curing agent on the properties of PFs were investigated. The results showed that thesuitable amount of surfactant and blowing agent were10%and5%respectively, and theproperties of foams was the best using hydrochloric acid/phosphoric acid/p-toluene sulfonicacid/water as curing agent, and the suitable amount of curing agent was15%. Themathematical model of density-mechanical properties was established by the foam model ofGibson-Ashby's mechanical properties and density. The results showed that there was a goodexponential relationship between mechanical properties and density. The exponential valueswere in the range of1.2352~2.1672. The exponential values of compression properties were inthe range of1.2521~1.4848, and the exponential values of bending properties were in the rangeof1.2352~2.1672.
4. Study on foaming model of phenolic foam
Polyoxyethylene-80(surfactant), petroleum ether (blowing agent) and mixed acids (curingagent) were selected to prepare PFs at different foaming temperatures. The effects of foamingtemperature, amount of surfactant, foaming agent, curing agent on the foaming speed andaverage cell diameter of PFs were investigated. Foaming speeds and average cell diameter ofPFs were obtained by experiments tests. The mathematical models of foaming speed andaverage cell diameter were obtained by nonlinear fitting of these experiment data. The modelof foaming speed, which reflected a relationship between foaming temperature, amount ofsurfactant, foaming agent, curing agent and the growth speed of foam volume, was set up. Andthe model of average cell diameter, which reflected a relationship between foamingtemperature, amount of surfactant, foaming agent, curing agent and average cell diameter offoam, was established. These models could provide basic theories for the guidance to the research on the application of PFs. In the meantime, It is meaningful for this basic theory toguide the preparation of PFs and optimize preparation technology.
5. Preparation and characteration of PFs with Eco-friendly Halogen-free Flame Retarant
The retardant additives, including eco-friendly halogen-free flame retardants (APP), charforming agent (PER), and synergist (ZnO, MoO_3, CuCl_2, and SnCl_2), were added in HSRPRsto fabricate the flame retardant composite phenolic foams (FRCPFs). The effects of theseretardant additives on the performance and properties of FRCPFs were investigated. It wasfound that LOIs of FRCPFs significantly increased and reached to around73%. HRR, AHRE,THR, EHC, O_2C, TOC, and emission of toxic gases (COP and COY) remarkably decreased,while for SEA and TSR, they significantly increased. The flame-retardant system agreed withthe gasphase flame-retarding mechanism. The results showed that FRCPFs had excellentfire-retarding performance, although it has a minor negative effect in respect of reduction in thesmoke release. APP/PER/ZnO was concluded as a better flame-retardant system for PFs.
6. Modification of the wood fiber surface and the research on the preparation andcharacteration of wood fiber composite PFs
The wood fibers pretreated by alkali, coupling coupling agents and alkali-couplingcoupling agents were used to prepare fiber composite PFs. The effects of wood fibers onproperties of PFs were studied. The results showed that the mechnical properties of treatedfiber composite PFs increased to different levels, compared with untreated fiber composite PFs.Especially the properties of treated fiber composite PFs were better while using silane couplingagent (A-171)-sodium hydroxide composite treatment and silane coupling agent (KH-792)treatment method. The results indicated after pretreatment, the interfacial compatibilitybetween fiber surface and resins significantly improved. But limiting oxygen indexs of treatedfiber composite PFs decreased to different levels, compared with untreated fiber composite PFs.This indicated that there was no positive effect of fiber modification on the flame retardant ofwood fiber composited PFs.
7. Preparation and initial investigation of inorganic materials composite PFs
Pulverized fuel ash and bentonite were modified to phosphate by15wt%phosphoric acidand used to prepare inorganic material composite PFs. The effects of acidification method ofinorganic materials and amount of inorganic materials on the properties of PFs wereinvestigated. The results showed that the mechnical properties of acidification-treated inorganicmaterials composite PFs increased to different levels, compared with untreated inorganicmaterial composite PFs. The cells of PFs were smaller and cell distribution was relativelyuniform. Particularly, the properties of acidification-treated pulverized fuel ash composite PFswere better. The results showed that the suitable inorganic material for composite PFs waspulverized fuel ash treated by acidification method. But limited oxygen indexs of inorganicmaterial composite PFs decreased to different levels, compared with phenolic foam.
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