Handbook ofPolymeric Foams

and Foam Technologyedited by

Daniel Klempner and Kurt C. Frisch

with 179 Figures and 79 Tables

Hanser Publishers, Munich Vienna New York Barcelona

Distributed in the United States of America and in Canada byOxford University Press New York

Contents

Chapter 1: Introduction 1

by Dr. K. C. Frisch and Dr. D. Klempner

Chapter 2: Fundamentals of Foam Formation 5

by J. H. Saunders

1 Introduction 62 Fundamental Principles of Foam Formation 53 Supporting Evidence from Specific Foam Systems 114 Summary 135 References 14

Chapter 3: Cellular Structure and Properties of Foamed Polymers 17

by Dr. Fyodor A. Shutov

1 Introduction ,,/ 182 Porous and Cellular Systems ''. 183 Open- and Closed-Cell Foamed Polymers 224 Density of Foamed Polymers 255 Cell Shape of Foamed Polymers 276 Cell Size of Foamed Polymers 327 Models of Cellular Structure and Calculation of Mechanical Properties

of Foamed Polymers 378 Cellular Structure and Thermal Conductivity of Foamed Polymers 399 References 45

Chapter 4: Flexible Polyurethane Foams 47

by F. E. Bailey, Jr.

1 Introduction 472 General Description of Foam Intermediates 493 Foam Chemistry 534 Laboratory Preparation of Polyurethane Foam 605 Foam Properties and Their Relationship to Foam Structure 626 Commercial Production and Processing 667 Applications 688 References 71

Chapter 5: Rigid Polyurethane Foams 73

by Dr. John K. Backus

1 Introduction 742 Structure 743 Chemistry 75

X Contents

4 Reactants 765 Formulations 826 Foam Preparation 827 Foam Physics 848 Properties 859 Applications 90

10 Health and Safety 9111 Future Trends 9312 References 93

Chapter 6: Polyisocyanurate Foams 95

by Dr. Kaneyoshi Ashida

1 Introduction 962 Isocyanurate Chemistry 983 Preparation of Modified Polyisocyanurate Foams 1124 Applications 1285 References 131

Chapter 7: Rim and Prim Foams y/ 135

Dr. Rick Tabor and Robert B. Turner

1 Introduction and General Description 1352 Chemistry and Preparation 1373 Properties and Relation to Structure 1444 Commercial Production and Processing 1465 Applications 1466 References 149

Chapter 8: Polystyrene and Structural Foam 151

by Dr. K. W. Suh

1 Introduction and General Description 1522 Chemistry and Preparation 1543 Properties and Their Relation to Structure 1564 Commercial Production and Processing 1685 Applications 1736 References 183

Chapter 9: Polyolefin Foam 187

by Dr. Chung Poo Park

1 Introduction 1882 Chemistry and Preparation 1903 Properties and Their Relation to Structure 2114 Commercial Production and Processing 2235 Applications 2356 References 238

Contents XI

Chapter 10: PVC Foams 243

by Dipl.-Ing. Reinhold Brathun and Ing. P. Zingsheim

1 Introduction 2442 Extrusion of Foam Profiles, Sheet, and Tubing from Rigid PVC 2453 Injection-Molded Foam Process 2544 Foamed Plastisols 2555 References 271

Chapter 11: Epoxy Foams 273

by Dr. H.-P. Homer

1 Introduction 2732 Chemistry and Formation 2743 Properties and Their Relationship to Structure and Raw Materials . . . . 2794 Commercial Production and Processing 2835 Applications 2856 References 288

Chapter 12: Urea-Formaldehyde Foams 289

by Professor Heinz H. Baumann /^

1 State of the Art in UF Foam Plastics 2902 Development of UF Foam Plastics 2903 Raw Materials and Auxiliary Agents for Foam Generation 2924 Reactions of Foam-Stabilizing Agents and Formaldehyde 2945 Effects of Other Chemical anpounds on UF Foam 2956 Chemistry of the Resins 2967 Chemistry of the Foam-Stabilizing Agents 2978 Manufacturing Processes for Plastic Foams 2979 Standardization and Quality Safeguards 298

10 Properties of Foams 29911 Industrial Applications of UF Foam Plastics 30212 Summary 30913 References 310

Chapter 13: Latex Foam and Sponge 315

by Robert F. Mausser

1 Introduction 3152 Dunlop Process 3163 Freeze Process 3214 Sponge 3225 References 325

Chapter 14: Silicone Foams 327

by Jack R. Harper and Therese M. Bauman

1 Background and Development 3282 Chemistry and Preparation 330

XII Contents

3 Properties and Their Relation to Structure 3334 Commercial Production and Processing 3345 Applications 3376 References 338

Chapter 15: Fluoropolymer Foams 339

by Dr. Chakra V. Gupta

1 History and Introduction 3392 Chemistry and Physics of Foam Preparation 3413 Properties and Their Relation to Cell Structure 3454 Commercial Production and Processing 3495 Applications 3526 References 353

Chapter 16: Syntactic Polymer Foams 355

by Dr. Fyodor A. Shutov

1 Introduction 3562 Hollow Sphere Fillers 3563 Syntactic Foam Processing , . ' . 3594 Syntactic Foam Production .,.": 3645 Physical Properties of Syntactic Foams 3686 Main Applications 3727 References 374

Chapter 17: Blowing Agents for Polymer Foams 375

by Dr. Fyodor A. Shutov

1 Introduction 2762 Classification 3763 Chemical Blowong Agents 3784 Physical Blowing Agents 4025 Gases 4076 Nucleazites 4077 References 408

APPENDIX I 409

APPENDIX II 411

INDEX 413