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A sonochemical technique was developed to infuse Cloisite clay nanoparticles into phenolic foam materials. Phenolic resin solution (Part A) was mixed with clay particles, and irradiated using a high intensity ultrasonic liquid processor. In the next step, the modified phenolic resin solution containing clay particles was mixed with Part B (containing phenol sulfonic acid, catalyst) through a high‐speed mechanical stirrer. The reaction mixture was then cast into rectangular molds to make nanophased foam panels. Test coupons were cut precisely from the panels to carry out thermal, morphological, and mechanical characterizations. The as‐prepared foam samples were characterized by scanning electron microscopy (SEM), X‐ray diffraction, thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). The SEM studies have shown that the particles are well dispersed over the entire volume of the …