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Pultrusion techniques and evaluations of sandwich beam using phenolic foam composite

Phenolic resin has the excellent properties of fire resistance, low smoke production during burning, and a good balance between its cost and mechanical properties compared with other types of resin used in fire-resistant polymers (FRPs). If phenolic resin can be employed as a matrix of FRP, such FRP can have a higher fire safety factor which will be a desirable property in the structures of vessels and railway carriages. However, for the case of the resole type of phenolic resin, water formed from the condensation reaction remains in the matrix, and this water evaporates resulting in the formation of voids during the curing process. In order to develop a new type of phenolic composite that can overcome this weakness, we used a foam type of phenolic resin and glass fibers as the matrix and the reinforcement, respectively. We, then, developed a new pultrusion technique for the new phenolic foam composite and examined its mechanical properties and thermal conductivity.In this paper, we report a new technique to mold not only a phenolic foam composite but also a sandwich beam in which the phenolic foam composite as a core and a thin phenolic FRP layer as a faceplate are used. We also investigated the compressive strength and elastic modulus under high temperatures and compared the result with that at room temperature. Finally, we show that the compressive properties of the phenolic foam composite and the sandwich beam are stable at higher temperatures.