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Gels Horizons: From Science to Smart Materials Sandhya P. K. Sreekala M. S. Sabu Thomas Editors Phenolic Based Foams Preparation, Characterization, and Applications Gels Horizons: From Science to Smart Materials SeriesEditor VijayKumarThakur,SchoolofAerospace,TransportandManufacturing, CranfieldUniversity,Cranfield,Bedfordshire,UK This series aims at providing a comprehensive collection of works on the recent advances and developments in the domain of Gels, particularly as applied to the various research fields of sciences and engineering disciplines. It covers a broad range of topics related to Gels ranging from Polymer Gels, Protein Gels, Self- HealingGels,ColloidalGels,Composites/NanocompositesGels,Organogels,Aero- gels,Metallogels&HydrogelstoMicro/Nanogels.Theseriesprovidestimelyand detailed information on advanced synthesis methods, characterization and their application in a broad range of interrelated fields such as chemistry, physics, polymer science & engineering, biomedical & biochemical engineering, chemical engineering, molecular biology, mechanical engineering and materials science & engineering. ThisSeriesacceptsbotheditedandauthoredworks,includingtextbooks,mono- graphs,referenceworks,andprofessionalbooks.Thebooksinthisserieswillprovide adeepinsightintothestate-of-artofGelsandserveresearchersandprofessionals, practitioners,andstudentsalike. Moreinformationaboutthisseriesathttps://link.springer.com/bookseries/15205 · · Sandhya P. K. Sreekala M. S. Sabu Thomas Editors Phenolic Based Foams Preparation, Characterization, and Applications Editors SandhyaP.K. SreekalaM.S. SchoolofChemicalSciences SreeSankaraCollege MahatmaGandhiUniversity Kalady,India Kottayam,India SabuThomas MahatmaGandhiUniversity Kottayam,India ISSN2367-0061 ISSN2367-007X (electronic) GelsHorizons:FromSciencetoSmartMaterials ISBN978-981-16-5236-3 ISBN978-981-16-5237-0 (eBook) https://doi.org/10.1007/978-981-16-5237-0 ©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature SingaporePteLtd.2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSingaporePteLtd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore Preface Phenolic foams are considered as the most efficient insulation material that are commonly available and are inexpensive. Compared with other types of foams phenolic foams possess good fire resistance, less smoke during burning, low heat conduction coefficient, and good balance between cost and mechanical properties. Phenolic foams are considered as a leading candidate in various fields such as construction industry, petrochemicals, aerospace, and fire protection. However, theextremefriabilityandbrittlenessofphenolicfoamslimitstheirapplications.So itisveryimportanttoimprovethetoughnessofthephenolicfoamsbyreinforcing withothermaterials. Numerous efforts have been made to improve the toughness of phenolic foams over the past decades. Thus, it is essential to acquire knowledge about the preparation, properties, and applications of phenolic foams by research scholars and students.Mostoftheresearchworksweredonetoimprovethepropertiesofphenolic foamsaccordingtoitstargetedapplications.Thetoughnessofphenolicfoamscanbe enhancedbyaddingvarioustougheningagentslikeflexiblepolymers,naturalfillers, andnanofillers.Alltheeffortsweretoimprovethephysicalpropertiesofphenolic foamsbymaintainingtheirinherentthermal,insulation,andevolutionoflesstoxic substancesduringburning.Theeffortofresearcherstopreparebio-basedphenolic foamsisalsoappreciablesinceitiseasilyavailable,cost-effective,andreducesthe environmentalpollution. Thisbookisdividedinto25units.Thefirstunitfocusesonthegeneralintroduction aboutphenolicfoams.Thesucceedingtwounitsdealwiththeintroductionoffoam manufactureandthechemistrybehindit.Nextthreeunitsdiscusstheeffectofhybrid fillers and toughening agents on the properties of phenolic foams. The following chapterdescribesthepropertiesofphenolicsyntacticfoams.Thenexttwounitsare about the morphology and shape memory effects of PF foams. The following few chaptersdiscussthemechanical,thermal,electrical,andflameretardantproperties of PF foams. This book also covers PF foams with nanofillers such as clay, CNT, graphene,andnanosilicaasreinforcements.Thelasteightchaptersincludediscussion ofbio-basedPFfoamsandapplicationsofPFfoams. v vi Preface Wehopeallthescientificcommunityandstudentswillbebenefittedbythisbook andwelookforwardtohavesuggestionsandfeedbacktoimproveuponit. Kottayam,India SandhyaP.K. Kalady,India SreekalaM.S. Kottayam,India SabuThomas Contents 1 Phenolic-BasedFoams:StateoftheArt,NewChallenges, andOpportunities ............................................. 1 P.K.Sandhya,M.S.Sreekala,andSabuThomas 2 IntroductiononFoamManufacture ............................. 15 ShahramMehdipour-AtaeiandMaryamMohammadi 3 MaterialsandChemistryofPhenolicFoams ..................... 35 FelipeM.deSouza,AnilM.Palve,andRamK.Gupta 4 Hybrid Composite Foam: Effect of Hybrid Fillers ontheMechanicalPropertiesofPhenolicFoams ................. 65 ZunaidaZakariaandNorAzuraAbdulRahim 5 ToughenedPhenolicFoams .................................... 81 TiejunGe,KaihongTang,andAilingZhang 6 ShapeMemoryPhenolicFoams ................................ 103 UmeshR.MahajanandS.T.Mhaske 7 MechanicalPropertiesofPhenolicFoams ....................... 121 AshutoshPandey,RuchiDubey,ShashankKumarSrivastava, RahulSaxena, GauravKumarGupta, D.P.Mondal, andRajeevKumar 8 ThermalStabilityofPhenolicFoams ............................ 137 LakshmipriyaRavindran, M.S.Sreekala, S.Anilkumar, andSabuThomas 9 ThermalConductivityofPhenolicFoams ........................ 155 ZhongleiMa 10 ElectromagneticInterferenceShieldinginPhenolicFoam ......... 175 RajeevKumar, AnushiSharma, VeerendraKumarPatle, AshutoshPandey,NeerajDwivedi,andD.P.Mondal vii viii Contents 11 FlameRetardantModificationofPhenolicFoam ................. 195 FeiSongandPuyouJia 12 Modification in Phenolic Foams and Properties of Clay ReinforcedPF ................................................ 209 GraceMoniandSimoneA.Silva 13 GrapheneReinforcedPhenolicFoams ........................... 221 MichałStrankowski 14 NanoSilicaReinforcedPhenolicFoams ......................... 235 SeyyedehFatemehHosseini, MasoumehKiyanfar, HodaDaneshvar,andMirSaeedSeyedDorraji 15 SynthesisofBio-/lignin-BasedPhenolicFoamsforInsulation andFloralApplications ........................................ 253 HongweiLi, BingLi, ZhongshunYuan, YongshengZhang, andChunbaoCharlesXu 16 FoamsinWoodComposites .................................... 275 AliShalbafan 17 WoodFlour-ReinforcedPhenolicFoams(WFPF) ................. 301 AdamOlszewski,PaulinaKosmela,andŁukaszPiszczyk 18 LigninNanoparticle-ReinforcedPhenolicFoams ................. 317 MasoumehKiyanfar, HodaDaneshvar, SeyyedehFatemehHosseini,andMirSaeedSeyedDorraji 19 The Role of Polyurethane Chemistry on the Properties ofPhenolicFoamsAppliedintheThermalInsulationIndustry .... 331 ChiacchiarelliLeonelMatías 20 PhenolicFoams:TheInsulatingMaterialstoReducetheFrost Penetration,Skidding,andFloodingRiskofRoadandAirfield Pavements .................................................... 359 ShohelAminandMohamedHeweidak Editors and Contributors AbouttheEditors Sandhya P. K. is currently Research Assistant at School of Chemical Sciences, MahatmaGandhiUniversity,Kerala,India.ShehasreceivedherM.Phil.inChem- istry in 2009 and Ph.D. in Chemistry in 2019 from Mahatma Gandhi University, Kerala. Her doctoral research is focused on graphene-based phenol formaldehyde nanocomposites,andherresearchinterestsincludethepreparationofphenolicfoams reinforcedwithgraphene.Shehaspublishedsevenresearchpapersininternational journalsandauthoredfourbookchapters.Shehasparticipatedinseveralconferences andseminarsofnationalandinternationalrepute. SreekalaM.S.isAssistantProfessorofChemistryatPostgraduateResearchDepart- mentofChemistry,SreeSankaraCollege,India.ShereceivedherMaster’sofPhilos- ophyinChemistryin1995andPh.D.degreeinChemistryin2001fromMahatma GandhiUniversity,India.Shehaspublishedover50papersinpeer-reviewedjour- nalsandhasheldanumberofscientificpositionsandresearchfellowships.Shehas editedsixbooks.ShebaggedtheprestigiousAlexandervonHumboldt(AvH)post- doctoralfellowshipfromtheHumboldtFoundation,Germany,andawardedtheJSPS post-doctoralfellowshipfromJapanSocietyforPromotionofScience.In2020,she was included in the top 2% scientists in the world (Rising stars List) by Stanford University,USA.Shehasanh-index30andi10-index43with6488citations. Prof. Sabu Thomas is currently Vice Chancellor of Mahatma Gandhi University, Kerala, India. He is an outstanding leader with sustained international acclaim for hisworkinnanoscience,polymerscienceandengineeringandgreenmaterials.He hasreceivedmorethan30nationalandinternationalawards.Hehaspublishedover 1200peer-reviewedresearchpapers,reviews,andbookchapters.Hehasco-edited 150 books and is an inventor of 15 patents. The H index of him is 114 and has morethan62,000citations.Hehasdeliveredover350plenary/inauguralandinvited lecturesinnational/internationalmeetingsover40countries.Hehassupervised115 ix