阅读说明：本技术 含hcfo的异氰酸酯反应性组合物、相关的泡沫形成组合物和pur-pir泡沫 (Isocyanate-reactive HCFO-containing compositions, related foam-forming compositions and PUR-PIR foams ) 是由 B·W·帕克斯 于 2020-03-03 设计创作，主要内容包括：本文公开了含HCFO的异氰酸酯反应性组合物、包含所述异氰酸酯反应性组合物的泡沫形成组合物、使用所述泡沫形成组合物制备的硬质PUR-PIR泡沫,以及生产此类泡沫的方法,包括使用所述泡沫作为绝热材料在不连续泡沫板应用中的用途。异氰酸酯反应性组合物可具有长的保存期、可为储存稳定的,并且生产具有良好的物理性能的泡沫。(Disclosed herein are HCFO-containing isocyanate-reactive compositions, foam-forming compositions comprising the isocyanate-reactive compositions, rigid PUR-PIR foams made using the foam-forming compositions, and methods of producing such foams, including the use of the foams as thermal insulation materials in discontinuous foam board applications. The isocyanate reactive composition may have a long shelf life, may be storage stable, and produce a foam with good physical properties.)

1. An isocyanate-reactive composition comprising:

(a) a polyol blend comprising:

(1) a sugar-initiated polyether polyol having an OH number of 200 to 600mg KOH/g and a functionality of 4 to 6;

(2) an aromatic polyester polyol having an OH number of 150 to 410mg KOH/g and a functionality of 1.5 to 3; and

(3) an alkanolamine-initiated polyether polyol having an OH value of at least 500mg KOH/g and a functionality of from 2.5 to 4;

(b) a blowing agent composition comprising:

(1) hydrochlorofluoroolefins; and

(2) a carbon dioxide generating chemical blowing agent; and

(c) a tertiary amine catalyst.

2. The isocyanate reactive composition of claim 1 wherein the sugar-initiated polyether polyol is the reaction product of at least one alkylene oxide with one or more starter compounds in the presence of a suitable catalyst, wherein the starter compounds comprise sucrose.

3. The isocyanate reactive composition of claim 2 wherein the alkylene oxide comprises propylene oxide.

4. The isocyanate-reactive composition according to any one of claims 1 or 3, wherein the average molecular weight of the saccharide-initiated polyether polyol is from 300 to 1600Da, such as from 440 to 1000 Da.

5. The isocyanate reactive composition according to any one of claims 1 to 4 wherein the saccharide initiated polyether polyol has an OH value of 300 to 550mg KOH/g, 400 to 500mg KOH/g or 450 to 500mg KOH/g.

6. The isocyanate reactive composition according to any one of claims 1 to 5 wherein the saccharide initiated polyether polyol has a functionality of from 5 to 6, from 5.2 to 5.8 or from 5.4 to 5.6.

7. The isocyanate reactive composition according to any one of claims 1 to 6 wherein the saccharide initiated polyether polyol is present in an amount of 10 to 45 wt.%, 10 to 30 wt.%, or 15 to 25 wt.%, based on the total weight of the polyol blend.

8. The isocyanate reactive composition of any one of claims 1 to 7 wherein the aromatic polyester polyol is the reaction product of a diol and/or triol comprising ethylene glycol, propylene glycol, butylene glycol, 1, 3-butylene glycol, neopentyl glycol, diethylene glycol, dipropylene glycol, triethylene glycol, tripropylene glycol, glycerol, trimethylolethane, trimethylolpropane, pentanediol, hexanediol, heptanediol, 1, 3-and 1, 4-dimethylolcyclohexane, or a mixture of any two or more thereof, and an aromatic diacid or anhydride comprising phthalic acid, isophthalic acid, terephthalic acid or phthalic anhydride, or a mixture of any two or more thereof.

9. The isocyanate reactive composition of any one of claims 1 to 8 wherein the aromatic polyester polyol has an OH number of 150 to 360mg KOH/g, 200 to 335mg KOH/g, or 200 to 250mg KOH/g.

10. The isocyanate reactive composition of any one of claims 1 to 9 wherein the aromatic polyester polyol has a functionality of 1.9 to 2.5.

11. The isocyanate reactive composition of any one of claims 1 to 10 wherein the aromatic polyester polyol is present in an amount of 50 to 85 weight percent or 60 to 80 weight percent based on the total weight of the polyol blend.

12. The isocyanate reactive composition according to any one of claims 1 to 11, wherein the aromatic polyester polyol and the sugar initiated polyether polyol are present in a polyol blend in a weight ratio of at least 2:1, 2:1 to 8:1, 2:1 to 6:1, or 3:1 to 4: 1.

13. The isocyanate reactive composition of any one of claims 1 to 12 wherein the alkanolamine used in the preparation of the alkanolamine-initiated polyether polyol comprises monoethanolamine, 1-amino-2-propanol, 2-amino-1-propanol, 3-amino-1-propanol, 1- (2-aminoethoxy) ethanol, 1-amino-2-butanol, 2-amino-3-butanol, 2-amino-2-methylpropanol, 5-aminopentanol, 3-amino-2, 2-dimethylpropanol, 4-aminocyclohexanol, or a mixture of any two or more thereof, wherein alkanolamine is reacted with an alkylene oxide comprising ethylene oxide, propylene oxide, a mixture of ethylene oxide, propylene oxide, and mixtures of any two or more thereof, Butylene oxide, styrene oxide, epichlorohydrin, or a mixture of any two or more thereof.

14. The isocyanate reactive composition according to any one of claims 1 to 13 wherein the alkanolamine initiated polyether polyol has an OH value of from 500 to 900mg KOH/g, from 600 to 800mg KOH/g or from 680 to 720mg KOH/g.

15. The isocyanate reactive composition according to any one of claims 1 to 14 wherein the alkanolamine initiated polyether polyol has a functionality of from 2.5 to 3.5.

16. The isocyanate reactive composition according to any one of claims 1 to 15 wherein the alkanolamine initiated polyether polyol is present in an amount of from 5 to 40 weight percent, from 5 to 20 weight percent or from 5 to 15 weight percent based on the total weight of polyol blend.

17. The isocyanate reactive composition according to any one of claims 1 to 16 wherein the aromatic polyester polyol and the alkanolamine initiated polyether polyol are present in the polyol blend in a weight ratio of at least 2:1, 2:1 to 8:1, 3:1 to 6:1 or 4:1 to 5: 1.

18. The isocyanate reactive composition of any one of claims 1 to 17, wherein the sugar initiated polyether polyol and the alkanolamine initiated polyether polyol are present in the polyol blend in a weight ratio of at least 0.5:1, 0.5:1 to 4:1, 1:1 to 2:1, or 1:1 to 1.5: 1.

19. The isocyanate reactive composition of any one of claims 1 to 18 wherein the polyol blend has a weighted average functionality of 2 to 4, 2 to 3, or 2.5 to 3.0.

20. The isocyanate reactive composition according to any one of claims 1 to 19 wherein the polyol blend has a weighted average hydroxyl number of from 300 to 500mg KOH/g or from 300 to 400mg KOH/g.

21. The isocyanate reactive composition of any one of claims 1 to 20 wherein the polyol blend comprises less than 20 weight percent, less than 10 weight percent, less than 5 weight percent, or less than 1 weight percent ethylene oxide based on the total weight of the sugar-initiated polyether polyol and the alkanolamine-initiated polyether polyol in the polyol blend.

22. The isocyanate reactive composition according to any one of claims 1 to 21, wherein the HCFO comprises 1-chloro-3, 3, 3-trifluoropropene (HCFO-1233zd, E and/or Z isomers), 2-chloro-3, 3, 3-trifluoropropene (HCFO-1233xf), HCFO1223, 1, 2-dichloro-1, 2-difluoroethylene (E and/or Z isomers), 3, 3-dichloro-3-fluoropropene, 2-chloro-1, 1,1,4,4, 4-hexafluorobutene-2 (E and/or Z isomers), 2-chloro-1, 1,1,3,4,4, 4-heptafluorobutene-2 (E and/or Z isomers), or a mixture of any two or more thereof.

23. The isocyanate reactive composition according to any one of claims 1 to 22 wherein HCFO is present in an amount of at least 10 wt%, 10 to 30 wt%, or 10 to 20 wt%, based on the total weight of the isocyanate reactive composition.

24. The isocyanate reactive composition according to any one of claims 1 to 23 wherein the isocyanate reactive composition comprises one or more CFCs, HCFCs and/or HFCs, and/or one or more hydrocarbon blowing agents comprising butane, n-pentane, cyclopentane, hexane and/or isopentane.

25. The isocyanate reactive composition according to any one of claims 1 to 24 wherein the isocyanate reactive composition is substantially free or completely free of CFCs, HCFCs and/or HFCs and/or butanes, n-pentanes, cyclopentane, hexanes and/or isopentanes.

26. The isocyanate reactive composition of any one of claims 1 to 25 wherein the carbon dioxide generating chemical blowing agent comprises water present in an amount of from 0.5 to 5.0 wt.%, from 1 to 4 wt.%, from 1.0 to 3.0 wt.%, or from 2.0 to 3.0 wt.%, based on the total weight of the isocyanate reactive composition.

27. The isocyanate reactive composition of any one of claims 1 to 26 wherein HCFO and the carbon dioxide generating chemical blowing agent are present in an amount of at least 90 wt.%, at least 95 wt.%, or at least 99 wt.%, based on the total weight of blowing agent composition.

28. The isocyanate reactive composition of any one of claims 1 to 27 wherein HCFO and carbon dioxide generating chemical blowing agent are present in the blowing agent composition in a weight ratio of at least 2:1, at least 4:1, 4:1 to 10:1, or 4:1 to 6: 1.

29. The isocyanate reactive composition according to any one of claims 1 to 28 wherein the isocyanate reactive composition further comprises a surfactant comprising an organosilicon compound, such as a polysiloxane-polyolefin block copolymer (e.g. polyether modified polysiloxane), a polyethylene glycol ether of a long chain alcohol, a tertiary amine or alkanolamine salt of a long chain alkyl acid sulfate, alkyl sulfonate or alkyl aryl sulfonic acid.

30. The isocyanate reactive composition according to any one of claims 1 to 29 wherein the tertiary amine catalyst comprises morpholine and/or imidazole, for example wherein the morpholine catalyst comprises dimorpholinodiethyl ether, dimorpholinodimethyl ether, N-ethyl morpholine, N-methyl morpholine or a mixture of any two or more thereof, and/or the imidazole catalyst comprises imidazole, N-methylimidazole, 1, 2-dimethylimidazole or a mixture of any two or more thereof.

31. The isocyanate reactive composition according to any one of claims 1 to 30 wherein the tertiary amine catalyst is present in an amount of less than 2 wt%, 0.1 to 1.9 wt%, or 0.5 to 1.5 wt%, based on the total weight of the isocyanate reactive composition.

32. The isocyanate reactive composition according to any one of claims 1 to 31, wherein the isocyanate reactive composition is substantially free or, in some cases, completely free of gel catalysts, such as organometallic catalysts (e.g., dibutyltin dilaurate, dibutyltin diacetate, stannous octoate, potassium acetate, and potassium lactate).

33. The isocyanate reactive composition according to any one of claims 1 to 32, wherein the isocyanate reactive composition further comprises a trimerisation catalyst, such as a quaternary ammonium salt, for example a quaternary ammonium carboxylate salt, such as ammonium (2-hydroxypropyl) trimethyl 2-ethylhexanoate and ammonium (2-hydroxypropyl) trimethylammonium formate.

34. The isocyanate reactive composition according to claim 33 wherein the trimerisation catalyst is present in the isocyanate reactive composition in an amount of from 0.25 to 3.0 wt% or from 0.25 to 1 wt% based on the total weight of the isocyanate reactive composition.

35. A process for producing a rigid PUR-PIR foam comprising mixing an organic isocyanate with the isocyanate-reactive composition of any one of claims 1 to 34 at an isocyanate index of from 90 to 150 or from 120 to 150 to form a reaction mixture.

36. The process of claim 35, wherein the organic isocyanate comprises a methylene bridged polyphenyl polyisocyanate and/or a prepolymer of a methylene bridged polyphenyl polyisocyanate having an average functionality of 1.8 to 3.5 or 2.0 to 3.1 isocyanate groups per molecule and an NCO content of 25 to 32 weight percent.

37. The method of claim 35 or 36, wherein the reaction mixture is poured into a mold cavity of a desired part, wherein the cavity is lined with a veneer.

38. A PUR-PIR foam produced by the process of any of claims 35 to 37.

39. A composite article comprising the PUR-PIR foam of claim 38 sandwiched between one or more facing substrates.

40. The composite article of claim 39, in which the facing substrate comprises metal board, particle board, gypsum board, fiber cement, or plastic.

41. The composite article of claim 39 or 40, wherein the composite article is in particular a door, such as a garage door.

Technical Field

The present specification relates generally to isocyanate-reactive compositions comprising hydrochlorofluoroolefins ("HCFO"), foam-forming compositions containing said isocyanate-reactive compositions, rigid foams made using said foam-forming compositions, and processes for producing said foams, including the use of said foams as insulation sheeting.

Background

Flame retardant rigid polyurethane foams are used in many industries. They are prepared by the following method: suitable polyisocyanates and isocyanate-reactive compounds (usually polyols) are reacted in the presence of blowing agents and catalysts to give polyisocyanurate-and polyurethane-containing foams. One use of such foams is as a thermal insulation medium in the construction of panel assemblies, such as doors, including garage doors. The thermal insulation properties of closed cell rigid foams depend on many factors, including the average cell size and the thermal conductivity of the cell contents.

Chlorofluorocarbons (CFCs) and hydrogen-containing chlorofluorocarbons (HCFCs) have been used as blowing agents to prepare these foams because of their very low vapor thermal conductivity. However, their ozone depletion potential is a disadvantage of using them. Alternative blowing agents, such as Hydrofluorocarbons (HFCs), have also been used, but they are greenhouse gases. Hydrocarbon compounds, such as pentane isomers, are also used, but they are flammable and less energy efficient. Halogenated hydrogen olefin compounds (e.g., HCFO) are candidates for current potential replacements for HFCs because their chemical instability in the lower atmosphere provides a lower global warming potential and zero or near zero ozone depletion performance.

Formulations for producing insulating rigid polyurethane foams, particularly rigid polyurethane foams for use in panel assembly construction, use catalysts to control the relative rates of water-polyisocyanate (gas forming or blowing), polyol-polyisocyanate (gel) reaction to form polyurethane ("PUR"), and isocyanate-isocyanate trimerization reaction to form polyisocyanurate ("PIR"). In the gel reaction, an isocyanate reacts with a polyol to form a polyurethane foam matrix. In the trimerization reaction, isocyanates react with each other to form macromolecules having an isocyanurate structure (polyisocyanurate). In the foaming reaction, the isocyanate in the formulation reacts with water to form polyurea and carbon dioxide. Although these reactions proceed at different rates, they must be properly balanced to produce high quality foams. For example, if the foaming reaction occurs faster than the gelling reaction, the gas generated by the reaction may expand and foam collapse may occur before the polyurethane matrix is strong enough to hold the gas. In contrast, if the gelling reaction occurs faster than the foaming reaction, the cells will remain closed, causing the foam to shrink as it cools. Furthermore, if the gelling reaction occurs while the reaction mixture is still flowing, cell stretching may occur, resulting in elongation of the cell structure. Foams having such elongated cell structures typically have poor physical properties such as poor compressive strength, poor dimensional stability (more foam shrinkage), poor thermal insulation properties, and poor foam quality (due to surface voids and other imperfections).

Thus, to achieve the proper balance, the formulation typically uses a combination of a blowing catalyst, a gelling catalyst, and/or a trimerization catalyst. For example, amine catalysts are known to have a greater effect on the water-polyisocyanate foaming reaction, while organotin catalysts are known to have a greater effect on the polyol-polyisocyanate gelling reaction.

A disadvantage of at least some HCFO as a blowing agent in producing a satisfactory isocyanate-based foam is the short shelf life (shelf-life). The blowing agent is typically combined with the polyol and other components (e.g., surfactants and catalysts) to form a so-called "part B (B-side)" premix that can be stored for up to several months prior to combination with the "part a (a-side)" isocyanate component to form a foam.

However, for part B compositions containing certain HCFO, the quality of the foam may be lower if aged prior to combining with the polyisocyanate, and may even collapse during foam formation. It is believed that the poor foam structure is due to the partial decomposition of the blowing agent resulting from the reaction of certain catalysts, particularly amine catalysts, with these HCFO, which leads to unwanted modification of the silicone surfactant, resulting in poor foam structure and quality.

To address this problem, certain amine catalysts have been identified that can have significantly improved stability to HCFO. These amine catalysts include morpholine and imidazole. However, these catalysts are not without disadvantages. In addition to being relatively expensive, these catalysts tend to be weak catalysts and therefore need to be used at relatively high loadings, which both magnifies the cost impact and limits the ability of the foam formulator to optimize foam flow properties and quality. Thus, there is a need to identify methods of reducing the amount of such amine catalysts needed in a formulation.

Foam-forming compositions for producing panel assemblies, especially those produced in discontinuous open and closed casting processes, must exhibit a strict combination of properties. For example, in addition to good thermal insulation properties, they must have a target cream time (gel time) and gel time that are advantageous to the manufacturing equipment and process used, and they must have a long shelf life, which means that the gel time cannot vary greatly after long-term (several months or more) storage of the foam-forming composition components, even when chemical blowing agents (e.g., water) are also used. The isocyanate-reactive composition used must also be phase stable in that it does not exhibit any significant phase separation over time. Even when the free-foaming foam has less than 2.0 pounds per cubic foot (lb/ft) ³) The foam must also exhibit good dimensional stability (low foam shrinkage) at relatively low densities.

Therefore, there is a great need for compositions that can meet most, if not all, of these requirements while using HCFO blowing agents.

Disclosure of Invention

In certain aspects, the present disclosure relates to isocyanate-reactive compositions. These compositions comprise: (a) a polyol blend, (b) a blowing agent composition, and (c) a tertiary amine catalyst. The polyol blend comprises: (1) a sugar-initiated polyether polyol having an OH number of 200 to 600mg KOH/g and a functionality of 4 to 6; (2) an aromatic polyester polyol having an OH number of 150 to 410mg KOH/g and a functionality of 1.5 to 3; and (3) an alkanolamine initiated polyether polyol having an OH value of at least 500mg KOH/g and a functionality of from 2.5 to 4. The blowing agent composition comprises a physical blowing agent comprising a hydrochlorofluoroolefin and a carbon dioxide-generating chemical blowing agent.

The present specification also relates to a foam-forming composition comprising the isocyanate-reactive composition, a rigid PUR-PIR foam produced from the foam-forming composition, a process for making such a rigid foam and a composite article comprising the rigid foam, and a thermal insulation panel comprising the rigid foam.

Detailed Description

Various embodiments are described and illustrated herein to provide a thorough understanding of the structure, function, performance, and use of the disclosed invention. It should be understood that the embodiments described and illustrated in this specification are non-limiting and non-exhaustive. Accordingly, the invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed in this specification. The features and characteristics described in connection with each embodiment may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. Thus, the claims may be amended to recite any features or characteristics explicitly or inherently recited in, or explicitly or inherently supported by, the present specification. Further, the applicant reserves the right to amend the claims to expressly disclaim features or characteristics that may be present in the prior art. Accordingly, any such modifications comply with the requirements of 35u.s.c. § 112 and 35u.s.c. § 132 (a). The embodiments disclosed and recited in this specification may include, consist of, or consist essentially of the features and characteristics described herein in the various ways.

Unless otherwise indicated, any patent, publication, or other disclosure material, identified herein, is incorporated by reference in its entirety into this specification, but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this specification. Accordingly, and to the extent necessary, the explicit disclosure set forth in this specification supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicants reserve the right to modify this specification to explicitly set forth any subject matter or portion thereof that is incorporated by reference herein.

In the present specification, unless otherwise indicated, all numerical parameters which have the inherent variability characteristic of the underlying measurement technique used to determine the numerical value of the parameter are to be understood as being referred to and modified in all instances by the term "about". At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter recited in the specification should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Additionally, any numerical range recited in this specification is intended to include all sub-ranges subsumed within that range with the same numerical precision. For example, a range of "1.0 to 10.0" is intended to include all sub-ranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0, i.e., all sub-ranges having a minimum value equal to or greater than 1.0 and a maximum value of equal to or less than 10.0, e.g., 2.4 to 7.6. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, applicants reserve the right to modify the specification, including the claims, to expressly recite any sub-ranges subsumed within the ranges expressly recited herein. All such ranges are intended to be inherently described in this specification such that modifications to explicitly set forth any such sub-ranges are in compliance with the requirements of 35 u.s.c. § 112 and 35 u.s.c. § 132 (a).

The grammatical articles "a", "an" and "the" as used in this specification are intended to include "at least one" or "one or more" unless otherwise indicated. Thus, the articles are used in this specification to refer to one or to more than one (i.e., "at least one") of the grammatical objects of the articles. For example, "a component" means one or more components, thus, more than one component is contemplated and may be employed or used in the practice of the described embodiments. Furthermore, unless the context requires otherwise, the use of a singular noun includes the plural, and the use of a plural noun includes the singular.

As used herein, the term "functionality" refers to the average number of reactive hydroxyl groups-OH present per molecule of the-OH functional species being described. In the production of polyurethane foams, hydroxyl groups react with isocyanate groups — NCO attached to isocyanate compounds. The term "hydroxyl number" refers to the number of reactive hydroxyl groups available for reaction and is expressed as milligrams of potassium hydroxide equivalent to the hydroxyl content of one gram of polyol (ASTM D4274-16). The term "equivalent weight" refers to the weight of a compound divided by its valence. For polyols, the equivalent weight is the weight of the polyol to be combined with the isocyanate groups, and can be calculated by dividing the molecular weight of the polyol by its functionality. The equivalent weight of the polyol can also be calculated by dividing 56,100 by the hydroxyl number of the polyol — equivalent weight (g/eq) — (56.1x1000)/OH number.

As described, certain embodiments of the present specification relate to isocyanate-reactive compositions that can be used to produce rigid foams. Rigid foams are characterized by a ratio of compressive strength to tensile strength of at least 0.5:1, elongation of less than 10%, and low recovery from deformation, low elastic limit, as described in "Polyurethanes: Chemistry and Technology, Part II Technology," j.h.saunders & k.c. friech, Interscience Publishers,1964, page 239.

The rigid foam of the present description is the reaction product of a polyurethane foam-forming composition comprising: (a) a diisocyanate and/or polyisocyanate; and (b) an isocyanate-reactive composition.

Any known organic isocyanate, modified isocyanate or isocyanate-terminated prepolymer prepared from any known organic isocyanate may be used. Suitable organic isocyanates include aromatic, aliphatic, and cycloaliphatic polyisocyanates and combinations thereof. Useful isocyanates include: diisocyanates such as m-phenylene diisocyanate, p-phenylene diisocyanate, 2, 4-tolylene diisocyanate, 2, 6-tolylene diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 4-hexamethylene diisocyanate, 1, 3-cyclohexane diisocyanate, 1, 4-cyclohexane diisocyanate, isomers of hexahydrotolylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, 1, 5-naphthalene diisocyanate, 4 '-diphenylmethane diisocyanate, 2,4' -diphenylmethane diisocyanate, 4 '-biphenyl diisocyanate, 3' -dimethoxy-4, 4 '-biphenyl diisocyanate and 3,3' -dimethyldiphenylpropane-4, 4' -diisocyanate; triisocyanates such as 2,4, 6-toluene triisocyanate; and polyisocyanates such as 4,4' -dimethyldiphenylmethane-2, 2',5,5' -tetraisocyanate and polymethylene polyphenyl polyisocyanates.

Undistilled polyisocyanates or crude polyisocyanates may also be used. Crude toluene diisocyanate obtained by phosgenating a mixture of toluene diamines and crude diphenylmethane diisocyanate obtained by phosgenating crude diphenylmethane diamine (polymeric MDI) are examples of suitable crude polyisocyanates. Suitable undistilled polyisocyanates or crude polyisocyanates are disclosed in U.S. patent No. 3,215,652.

Modified isocyanates are obtained by chemical reaction of diisocyanates and/or polyisocyanates. Useful modified isocyanates include, but are not limited to, those containing ester groups, urea groups, biuret groups, allophanate groups, carbodiimide groups, isocyanurate groups, uretdione groups and/or urethane groups. Examples of modified isocyanates include prepolymers containing NCO groups and having an NCO content of from 25 to 35% by weight, for example from 29 to 34% by weight, such as those based on polyether polyols or polyester polyols and diphenylmethane diisocyanate.

In certain embodiments, the polyisocyanate comprises a methylene bridged polyphenyl polyisocyanate and/or a prepolymer of a methylene bridged polyphenyl polyisocyanate having an average functionality of 1.8 to 3.5, e.g., 2.0 to 3.1, isocyanate groups per molecule and an NCO content of 25 to 32 weight percent because of their ability to crosslink the polyurethane.

The isocyanate reactive composition described in this specification comprises a polyol blend. The polyol blend comprises a sugar-initiated polyether polyol. As used herein, "saccharide-initiated polyether polyol" refers to a polyether polyol prepared by reacting at least one alkylene oxide with one or more suitable starter compounds in the presence of a suitable catalyst, wherein the starter compounds comprise one or more saccharide initiators. Examples of suitable alkylene oxides include ethylene oxide, propylene oxide, butylene oxide, styrene oxide, epichlorohydrin, or mixtures of any two or more thereof. Some examples of suitable sugar initiators are sucrose, sorbitol, maltitol, and the like, as well as other monosaccharides, disaccharides, trisaccharides, and polysaccharides. Other initiator compounds are typically used in combination with the saccharide initiators to prepare saccharide-initiated polyether polyols. The sugar may be co-initiated with, for example, the following compounds: water, propylene glycol, glycerol, ethylene glycol, ethanolamine, diethylene glycol, or a mixture of any two or more thereof. It is to be understood that a plurality of individual initiator compounds can be used in combination with one another, wherein the individual initiator compounds do not have a functionality that falls within the functionality described herein, provided that the average functionality of the initiator compound mixture meets the overall functionality ranges disclosed herein.

Some examples of suitable catalysts that may be used include basic catalysts (e.g., sodium hydroxide, or potassium hydroxide, or tertiary amines, such as methylimidazole) and Double Metal Cyanide (DMC) catalysts.

In some embodiments, a sugar (e.g., sucrose) is first reacted with ethylene oxide and then with propylene oxide. In some cases, ethylene oxide is used in an amount of 10 to 50 weight percent, e.g., 20 to 40 weight percent, and propylene oxide is used in an amount of 50 to 90 weight percent, e.g., 60 to 80 weight percent, of the total alkylene oxide used. In some embodiments, the total amount of alkylene oxide used is selected such that the average molecular weight of the product is from 300 to 1600 daltons (Da), for example from 440 to 1000 Da.

In some embodiments, the saccharide-initiated polyether polyol has an OH value of 200 to 600mg KOH/g, such as 300 to 550mg KOH/g, for example 400 to 500mg KOH/g, or in some cases 450 to 500mg KOH/g, and a functionality of 4 to 6, such as 5 to 6, 5.2 to 5.8, or 5.4 to 5.6.

In some embodiments, the sugar-initiated polyether polyol is used in an amount of 10 to 45 weight percent, such as 10 to 30 weight percent, or in some cases 15 to 25 weight percent, based on the total weight of the polyol blend.

The polyol blend also includes an aromatic polyester polyol. Suitable aromatic polyester polyols include, for example, the reaction products of aromatic diacids or anhydrides and suitable diols or triols. For example, the polyester polyol can be the reaction product of a diol and/or triol, such as ethylene glycol, propylene glycol, butylene glycol, 1, 3-butylene glycol, neopentyl glycol, diethylene glycol, dipropylene glycol, triethylene glycol, tripropylene glycol, glycerol, trimethylolethane, trimethylolpropane, pentanediol, hexanediol, heptanediol, 1, 3-and 1, 4-dimethylolcyclohexane, or a mixture of any two or more thereof, and an aromatic diacid or an aromatic anhydride, such as phthalic acid, isophthalic acid, terephthalic acid, phthalic anhydride, or a mixture of any two or more thereof. Some examples of suitable aromatic polyester polyols include those available under the Stepanpol trade name from Stepan Chemical (e.g., Stepanpol @)PS 3024 and stepnopol PS 2502A), or from InvistaTerate trade name (e.g. Terate)HT-5100 and HT-5500), or from Coim under the Isoester trade name (e.g., from Coimt) TB-265).

In certain embodiments, the aromatic polyester polyol has an OH number of 150 to 410mg KOH/g, such as 150 to 360mg KOH/g, such as 200 to 335mg KOH/g, or in some cases 200 to 250mg KOH/g, and a functionality of 1.5 to 3, such as 1.9 to 2.5.

In some embodiments, the aromatic polyester polyol is used in an amount of 50 to 85 weight percent, such as 60 to 80 weight percent, based on the total weight of the polyol blend.

In certain embodiments, the aromatic polyester polyol and the sugar-initiated polyether polyol are present in the polyol blend in a weight ratio of at least 2:1, such as from 2:1 to 8:1, or in some cases from 2:1 to 6:1 or from 3:1 to 4: 1.

The polyol blend also comprises an alkanolamine initiated polyether polyol. As used herein, "alkanolamine-initiated polyether polyol" refers to polyether polyols prepared by reacting at least one alkylene oxide with one or more suitable starter compounds in the presence of a suitable catalyst, wherein the starter compounds comprise one or more alkanolamines. Suitable catalysts include basic catalysts (e.g., sodium hydroxide, or potassium hydroxide, or tertiary amines, such as methylimidazole) and DMC catalysts.

As used herein, the term "alkanolamine" refers to a compound represented by the formula:

NH₂—Z—OH

wherein Z represents a divalent group which is a linear or branched alkylene group having 2 to 6 carbon atoms, a cycloalkylene group having 4 to 6 carbon atoms or a dialkylene ether group having 4 to 6 carbon atoms. The dialkylene ether group can be represented by the formula:

—R—O—R—

wherein each R represents a hydrocarbon group having 2 to 3 carbon atoms.

Specific examples of suitable alkanolamines that may be used in the preparation of the alkanolamine-initiated polyether polyol include monoethanolamine, 1-amino-2-propanol, 2-amino-1-propanol, 3-amino-1-propanol, 1- (2-aminoethoxy) ethanol, 1-amino-2-butanol, 2-amino-3-butanol, 2-amino-2-methylpropanol, 5-aminopentanol, 3-amino-2, 2-dimethylpropanol, 4-aminocyclohexanol, and mixtures of any two or more thereof.

To prepare the alkanolamine-initiated polyether polyol, an alkanolamine is reacted with an alkylene oxide. Suitable alkylene oxides include ethylene oxide, propylene oxide, butylene oxide, styrene oxide, and epichlorohydrin, and mixtures of any two or more thereof.

In some embodiments, the alkanolamine-initiated polyether polyol has an OH value of at least 500mg KOH/g, such as from 500 to 900mg KOH/g, such as from 600 to 800mg KOH/g, or in some cases from 680 to 720mg KOH/g, and a functionality of from 2.5 to 4, such as from 2.5 to 3.5.

In some embodiments, the alkanolamine-initiated polyether polyol is used in an amount of from 5 to 40 weight percent, such as from 5 to 20 weight percent or from 5 to 15 weight percent, based on the total weight of the polyol blend.

In certain embodiments, the aromatic polyester polyol and alkanolamine initiated polyether polyol are present in the polyol blend in a weight ratio of at least 2:1, such as from 2:1 to 8:1, or in some cases from 3:1 to 6:1 or from 4:1 to 5: 1. In certain embodiments, the sugar-initiated polyether polyol and alkanolamine-initiated polyether polyol are present in the polyol blend in a weight ratio of at least 0.5:1, such as from 0.5:1 to 4:1, or in some cases from 1:1 to 2:1 or from 1:1 to 1.5: 1.

It has surprisingly been found that the inclusion of alkanolamine initiated polyether polyols in the polyol blends described in this specification enables the production of rigid PUR-PIR foams having a combination of good physical properties, even while limiting the amount of HCFO and tertiary amine blowing catalyst used, and thus their negative cost impact, while providing an isocyanate-reactive composition with a long shelf life for producing said foams.

If desired, the polyol blend may include other compounds containing isocyanate reactive groups, such as chain extenders and/or crosslinkers, as well as higher molecular weight polyether polyols and polyester polyols not described above. Chain extenders and/or crosslinkers include, for example, ethylene glycol, propylene glycol, butylene glycol, glycerol, diethylene glycol, dipropylene glycol, dibutylene glycol, trimethylolpropane, pentaerythritol, ethylenediamine, diethyltoluenediamine, and the like. The polyester polyols can be prepared, for example, from: organic dicarboxylic acids having 2 to 12 carbon atoms (e.g., aliphatic dicarboxylic acids having 4 to 6 carbon atoms) and polyhydric alcohols (e.g., diols or triols having 2 to 12 carbon atoms). Examples of dicarboxylic acids are succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid and terephthalic acid. Instead of the free dicarboxylic acids, the corresponding dicarboxylic acid derivatives can be used, for example dicarboxylic acid monoesters or diesters prepared by esterification with alcohols having 1 to 4 carbon atoms, or dicarboxylic acid anhydrides.

In certain embodiments, the polyol blend has a weighted average functionality of 2 to 4, such as 2 to 3 or 2.5 to 3.0, and/or a weighted average hydroxyl number of 300 to 500mg KOH/g, such as 300 to 400mg KOH/g.

In certain embodiments, the polyol blend comprises less than 20 weight percent, less than 10 weight percent, less than 5 weight percent, or in some cases less than 1 weight percent ethylene oxide, based on the total weight of the sugar-initiated polyether polyol and the alkanolamine-initiated polyether polyol in the polyol blend.

As described, the isocyanate-reactive composition of the present specification further comprises a blowing agent composition. The blowing agent composition comprises: (1) a physical blowing agent comprising HCFO; (2) a chemical blowing agent that generates carbon dioxide.

Suitable HCFOs include 1-chloro-3, 3, 3-trifluoropropene (HCFO-1233zd, E and/or Z isomers), 2-chloro-3, 3, 3-trifluoropropene (HCFO-1233xf), HCFO1223, 1, 2-dichloro-1, 2-difluoroethylene (E and/or Z isomers), 3, 3-dichloro-3-fluoropropene, 2-chloro-1, 1,1,4,4, 4-hexafluorobutene-2 (E and/or Z isomers), 2-chloro-1, 1,1,3,4,4, 4-heptafluorobutene-2 (E and/or Z isomers). In some embodiments, the boiling point of the HCFO at atmospheric pressure is at least-25 ℃, at least-20 ℃, or in some cases at least-19 ℃, and 40 ℃ or less, such as 35 ℃ or less, or in some cases 33 ℃ or less. The boiling point of HCFO at atmospheric pressure may be, for example, -25 ℃ to 40 ℃, or-20 ℃ to 35 ℃, or-19 ℃ to 33 ℃.

In some embodiments, the HCFO is used in an amount of at least 10 wt%, such as 10 to 30 wt% or 10 to 20 wt%, based on the total weight of the isocyanate-reactive composition.

In certain embodiments, the isocyanate-reactive composition comprises one or more other physical blowing agents, such as other halogenated blowing agents, e.g., CFCs, HCFCs, and/or HFCs; and/or hydrocarbon blowing agents such as butane, n-pentane, cyclopentane, hexane, and/or isopentane (i.e., 2-methylbutane), and the like. In other embodiments, the isocyanate-reactive composition is substantially free, or in some cases completely free, of other physical blowing agents, such as other halogenated blowing agents, e.g., CFCs, HCFCs, and/or HFCs; and/or hydrocarbon blowing agents such as butane, n-pentane, cyclopentane, hexane, and/or isopentane (i.e., 2-methylbutane), and the like. As used herein, the term "substantially free" when used in reference to these blowing agents means that the blowing agent (if present) is present in an amount less than 10 percent by weight, such as less than 1 percent by weight, based on the total weight of the blowing agent composition.

As noted above, the isocyanate-reactive composition includes a carbon dioxide-generating chemical blowing agent, such as water and/or a formate-terminated amine. In some of these embodiments, the carbon dioxide-generating chemical blowing agent (e.g., water) is used in an amount of 0.5 to 5.0 wt.%, such as 1 to 4 wt.%, or 1.0 to 3.0 wt.%, or 2.0 to 3.0 wt.%, based on the total weight of the isocyanate-reactive composition.

In certain embodiments, the blowing agent composition comprises HCFO and a carbon dioxide-generating chemical blowing agent (e.g., water), wherein the HCFO and the carbon dioxide-generating chemical blowing agent are present in an amount of at least 90 wt.%, such as at least 95 wt.%, or in some cases at least 99 wt.%, based on the total weight of the blowing agent composition. In certain embodiments, the HCFO and the carbon dioxide-generating chemical blowing agent are present in the blowing agent composition in a weight ratio of at least 2:1, such as at least 4:1, for example, from 4:1 to 10:1 or from 4:1 to 6: 1.

If desired, the blowing agent composition may include other physical blowing agents, such as (a) other Hydrofluoroolefins (HFOs), such as pentafluoropropane, tetrafluoropropene, 2,3,3, 3-tetrafluoropropene, 1,2,3, 3-tetrafluoropropene, trifluoropropene, tetrafluorobutene, pentafluorobutene, hexafluorobutene, heptafluorobutene, heptafluoropentene, octafluoropentene, and nonafluoropentene; (b) hydrofluorocarbons, (c) hydrocarbons, such as any pentane isomer and butane isomer; (d) hydrofluoroethers (HFEs); (e) c₁To C₅Alcohol, C₁To C₄Aldehyde, C₁To C₄Ketones, C₁To C₄Ethers and diethers and carbon dioxide. Specific examples of such blowing agents are described in U.S. patent application publication No. US 2014/0371338A 1 [0051 ] ]Paragraph and [0053 ]]In this paragraph, the referenced portion is incorporated by reference herein.

In some embodiments, the isocyanate-reactive composition further comprises a surfactant. Any suitable surfactant may be used, including organosilicon compounds, such as polysiloxane-polyolefin block copolymers, e.g., polyether-modified polysiloxanes. Other useful surfactants include polyethylene glycol ethers of long chain alcohols, tertiary amine or alkanolamine salts of long chain alkyl acid sulfate, alkyl sulfonate or alkyl aryl sulfonic acids. The surfactant is used in an amount sufficient to stabilize the foaming reaction mixture, prevent collapse and form large and uneven cells. In some embodiments, the surfactant is used in an amount of 0.2 to 5.0 wt.%, such as 1 to 3 wt.%, based on the total weight of the isocyanate-reactive composition.

As previously mentioned, the isocyanate reactive composition further comprises a tertiary amine catalyst. It is understood that tertiary amine catalysts are referred to as "blowing catalysts" because they have a greater impact on the water-polyisocyanate blowing reaction. In some embodiments, the tertiary amine catalyst comprises morpholine and/or imidazole. Suitable morpholine catalysts include, for example, dimorpholinodiethyl ether, N-ethyl morpholine and N-methyl morpholine. Suitable imidazole catalysts include, for example, imidazole, n-methylimidazole, and 1, 2-dimethylimidazole.

However, in some embodiments of the isocyanate-reactive compositions of the present description, the tertiary amine catalyst may be used in relatively low amounts while still achieving the desired level of reactivity for the water-polyisocyanate foaming reaction. For example, in some embodiments, the tertiary amine catalyst (e.g., morpholine and/or imidazole) is present in an amount of less than 2 wt.%, such as from 0.1 to 1.9 wt.%, or from 0.5 to 1.5 wt.%, based on the total weight of the isocyanate-reactive composition.

Further, in some embodiments, the isocyanate-reactive composition may be substantially free, or in some cases completely free, of gel catalysts that catalyze the reaction between the polyol and the polyisocyanate, such as organometallic catalysts (e.g., dibutyltin dilaurate, dibutyltin diacetate, stannous octoate, potassium acetate, and potassium lactate). As used herein, the term "substantially free" when used in reference to the absence of a catalyst means that the catalyst is present in an amount of no more than 0.1% by weight, based on the total weight of the isocyanate-reactive composition.

In certain embodiments, the isocyanate-reactive composition further comprises a trimerization catalyst, which is not an amine catalyst. It is to be understood that a trimerisation catalyst is a substance which catalyses the formation of isocyanurate groups from a polyisocyanate. This means that isocyanates can react with one another to form macromolecules with isocyanurate structure (polyisocyanurates). The reaction of isocyanate with polyol to form urethane and the reaction of isocyanate with isocyanate (homopolymerization) to form isocyanurate may occur simultaneously or sequentially to form macromolecules with urethane and isocyanurate.

Various trimerization catalysts may be suitable. However, in some embodiments, the trimerization catalyst comprises a quaternary ammonium salt, such as a quaternary ammonium carboxylate. Useful quaternary ammonium carboxylates include, for example, (2-Hydroxypropyl) ammonium trimethyl 2-ethylhexanoate (available from Evonik Industries)TMR) and (2-hydroxypropyl) ammonium trimethyl formate (from Evonik Industries)TMR-2). In some embodiments, the trimerization catalyst is present in the isocyanate reactive composition in an amount of from 0.25 to 3.0 weight percent, for example from 0.25 to 1 weight percent, based on the total weight of the isocyanate reactive composition.

Other materials that may optionally be included in the foam-forming compositions of the present invention include: pigments, colorants, fillers, antioxidants, flame retardants, and stabilizers. Exemplary flame retardants that can be used in the foam-forming compositions of the present invention include, but are not limited to, bromine-based reactive compounds known for polyurethane chemistry, and chlorinated phosphate esters, including, but not limited to, tris (2-chloroethyl) phosphate (TECP), tris (1, 3-dichloro-2-propyl) phosphate, tris (1-chloro-2-propyl) phosphate (TCPP), and dimethylpropyl phosphate (DMPP).

The specification also relates to a process for producing rigid polyurethane-polyisocyanurate ("PUR-PIR") foams. In the process, a diisocyanate and/or polyisocyanate (collectively referred to as "polyisocyanate") is reacted with an isocyanate-reactive composition of the type described above. In some embodiments, the isocyanate functional component and the isocyanate reactive composition are mixed at an isocyanate index of 90 to 150, for example 120 to 150.

In certain embodiments, the polyol blend of the isocyanate-reactive composition is reacted with the polyisocyanate in the presence of the blowing agent composition, the catalyst composition, the surfactant, and any other optional ingredients. Rigid foams can be prepared by blending all the components of the isocyanate-reactive composition together in a phase-stable mixture, which is then mixed with the polyisocyanate in the appropriate proportions. Alternatively, one or more components (e.g., surfactants) may be mixed with the polyisocyanate, which is then mixed with the isocyanate-reactive component. Other possible embodiments include adding one or more components as separate streams with the isocyanate-reactive component and the polyisocyanate. As used herein, the term phase stable means that the isocyanate reactive composition does not separate when stored at about 70 ° f (or 21 ℃) for 7 days.

Many foaming machines are designed to condition and mix only two components in the proper ratio. For the use of these machines, it may be advantageous to use a premix of all the components except the polyisocyanate. According to the two-component process (component a: polyisocyanate; and component B: isocyanate-reactive composition, which typically comprises a polyol blend, a blowing agent, water, a catalyst and a surfactant), these components can be mixed in suitable proportions at a temperature of 5 to 50 ℃, e.g. 15 to 35 ℃, injected or cast into a mould controlled at a temperature in the range of 20 to 70 ℃, e.g. 35 to 60 ℃. The mixture is then expanded to fill the cavity with rigid polyurethane foam. This simplifies the metering and mixing of the reactive components forming the foam-forming mixture, but requires that the isocyanate-reactive composition be phase-stable.

Alternatively, rigid polyurethane foams can also be prepared by the so-called "quasi prepolymer" process. In this process, a portion of the polyol component is reacted with the polyisocyanate component in proportion to provide 10% to 35% free isocyanate groups in the prepolymer-based reaction product in the absence of a urethane-forming catalyst. To prepare the foam, the remaining portion of the polyol is added and the components are reacted together in the presence of a blowing agent and other suitable additives (e.g., catalysts and surfactants). Other additives may be added to the isocyanate prepolymer or the remaining polyol or both prior to mixing the components to provide a rigid foam at the end of the reaction.

In addition, rigid foams can be prepared in a batch or continuous process by the one-shot or quasi-prepolymer process using any known foaming equipment. Rigid foams can be made in the form of slabs (slab stock), moldings, cavity fillers, spray foams, foam foams or laminates with other materials such as cardboard, gypsum board, plastics, paper or metal as a facing substrate.

For closed cell insulating foams, the objective is to retain the blowing agent in the cells to maintain low thermal conductivity of the insulating material (i.e., rigid foam). Therefore, a high closed cell content in the foam is desirable. Foams produced according to embodiments of the present description have a closed cell content of greater than 80%, typically greater than 85%, or greater than 88%, measured according to ASTM D6226-15. Further, the thermal conductivity of the foam produced according to various embodiments of the present description indicates that the foam has acceptable thermal insulation properties, i.e., the foam has a thermal conductivity of less than 0.132BTU-in/h-ft for foam from the core of a 2 inch plank measured at 35 ° F (2 ℃) ²- ° F and a thermal conductivity of less than 0.149BTU-in/h-ft measured at 75 ° F (24 ℃)²- ° F, measured according to ASTM C518-15.

The present description also relates to the use of the rigid foam described herein for thermal insulation. That is, the rigid foam of the present description may be used as a thermal insulation material in refrigeration equipment, as the combination of good thermal insulation and other properties described herein are particularly suitable herein. The rigid foam of the invention can be used, for example, as an intermediate layer of composite elements or for filling hollow spaces of refrigerators and freezers or refrigerated trailers. The foams of the present invention can also be used in the construction industry or for the thermal insulation of long-distance heating pipes and containers.

Accordingly, the present invention also provides a composite article comprising the rigid foam disclosed herein sandwiched between one or more facing substrates. In certain embodiments, the facing substrate may be plastic (e.g., polypropylene resin reinforced with continuous bidirectional glass fibers or polyester copolymer reinforced with glass fibers), paper, wood, or metal. For example, in certain embodiments, the composite article may be a refrigeration device, such as a refrigerator, freezer, or cooler having a metal outer shell and a plastic inner liner. In certain embodiments, the refrigeration equipment may be a trailer, and the composite article may include the foam produced according to the present invention for use in a sandwich composite for a trailer floor.

Surprisingly, it has been found that the specific isocyanate-reactive compositions described herein may be particularly suitable for discontinuous open casting applications, such as are often used to produce discontinuous panels or doors, such as garage doors. It will be appreciated that in this discontinuous process, the reaction mixture (mixture of isocyanate reactive component and isocyanate functional component) is poured into the mould cavity of the desired part, wherein the cavity is lined with a facing, which may be metal board, particle board, gypsum board, fibre cement or plastic. The foam adheres to the veneer as it reacts and cures. The resulting plaque is then removed from the cavity. To be effective for use in this process, the reaction mixture must have an appropriate level of reactivity (sufficient to allow the mixture to flow adequately) resulting from the desired balance of foaming and gelling reactivity. Accordingly, certain embodiments of the present invention relate to the use of the reaction mixtures described herein in the methods.

It has been found that the isocyanate-reactive components described herein and the rigid foams produced therefrom can have a particularly desirable combination of properties. First, the rigid foam has a thermal conductivity of less than 0.149BTU-in/h-ft at 75 ° F (24 ℃) ²- ° F, foam density at core 1.8 to 2.0 pounds per cubic foot (28.8 to 32.0 kg/m) according to ASTM C518-15³) And (4) performing upper measurement. Secondly, the isocyanate reactive composition is phase stable and has a long shelf life. Herein, when referring to the isocyanate-reactive composition having a "long" shelf life, it is meant that when the isocyanate-reactive composition is combined with the polyisocyanate after storage of the isocyanate-reactive composition at 60 ℃ for 15 days (360 hours), (a) the cream time and gel time of the foam so produced remains within 10% of the initial cream time and gel time (the cream time and gel time of the foam prepared immediately after production of the isocyanate-reactive composition rather than after storage at 60 ℃ for 15 days (360 hours)), and (b) the free rise density of the foam so produced remains within 10% of the initial free rise density (the free rise density of the foam prepared immediately after production of the isocyanate-reactive composition rather than after storage at 60 ℃ for 15 days (360 hours)), even when the isocyanate-reactive composition comprises 2.5 to 3% by weight of water and 9 to 13% by weight of HCFO, based on isocyanateThe same is true for the total weight of the acid ester reactive composition. In some cases, this initial gel time is 76 seconds ± 5 seconds, which is well suited for certain discontinuous plate applications. Third, the cream time and gel time and density of the foam were determined to match similar comparative formulations using hydrofluorocarbon blowing agents (HFC245 fa).

The following non-limiting and non-exhaustive examples are intended to further describe various non-limiting and non-exhaustive embodiments without limiting the scope of the embodiments described in this specification.

Examples

Example 1

The foam-forming compositions were prepared using the ingredients and amounts (in parts by weight) listed in table 1. The following materials were used:

polyol 1: aromatic polyester polyols having an OH number of 225 to 245mg KOH/g and a functionality of 2 available from InvistaHT 5500 is commercially available.

Polyol 2: a sucrose and propylene glycol initiated polyether polyol having an OH number of about 470mg KOH/g and a functionality of about 5.2, prepared by propoxylating a mixture of sucrose and water;

polyol 3: monoethanolamine-initiated polyether polyols having OH values of 685 to 715, a functionality of 3, and a nitrogen content of 5.8% by weight were prepared by propoxylation of monoethanolamine.

Polyol 4: an ethylenediamine-initiated polyether polyol having an OH number of 600 to 660, a functionality of 4, and a nitrogen content of 7.8 wt.% is prepared by propoxylation of ethylenediamine.

Polyol 5: a triethanolamine-initiated polyether polyol having an OH number of 140 to 160, a functionality of 3, and a nitrogen content of 1.3 wt.% is prepared by propoxylating triethanolamine.

Polyol 6: monoethanolamine-initiated polyether polyols having an OH number of340 to 360, a functionality of 3 and a nitrogen content of 2.9% by weight, are prepared by propoxylation of monoethanolamine.

Surface active agent: non-hydrolyzable polyether polydimethylsiloxane copolymers available from Evonik Industries under the trade name EvonikB8465 was purchased commercially.

Catalyst A: (2-hydroxypropyl) trimethyl ammonium formate available from Evonik Industries andTMR-2 is commercially available;

catalyst B: 2,2' -dimorpholinodiethyl ether (A)DMDEE, from Huntsman);

flame retardant A: reactive bromine-containing diester/ether diols of tetrabromophthalic anhydride, available from Albemarle CorporationRB-79 commercial

Flame retardant B: alkyl phosphate ester flame retardants based on tris (2-chloroisopropyl) phosphate, available from ICL Industrial Products and available in the literaturePCF commercial purchase

HCFO 1233zd(E): trans-1, 1, 1-trifluoro-3-chloropropene, hydrochlorofluoroolefin blowing agent with a boiling point of 19 ℃, available from Honeywell International IncLBA is purchased commercially;

isocyanates: high functionality polymeric diphenylmethane diisocyanate (PMDI) having an NCO content of 30.0 to 31.4% and a viscosity of 610 to 790 cps at 25 ℃.

In each case, a masterbatch was prepared by mixing the amounts of polyol, catalyst, surfactant, water, and blowing agent shown in table 1. Foams were prepared by mixing the masterbatch with the amount of isocyanate shown in table 1 and pouring the mixture into an 83 oz paper cup. Cream time, gel time, tack-free time and free-rise density ("FRD") were recorded. Foams were prepared immediately after the masterbatch was prepared and also after aging of the masterbatch at 60 ℃ for each time listed in table 2 to evaluate shelf life. The results are shown in table 2 (the reported results represent the average of three replicates). Flow was evaluated as described in U.S. patent No. 10,106,641B2 (column 12, lines 22-61, the cited portion of which is incorporated herein by reference), and the results are listed in table 3. Furthermore, a pressure sensor was located 10cm above the protruding metal plate edge, which recorded the foaming pressure during the process. The rise rate is derived from the foam height data as a function of time. Example 1 is an example of the present invention.

TABLE 1

TABLE 2

TABLE 3

Clearly, formulations 1-4 showed minimal change in cream time (5%), while a large difference in gel time was observed after aging (table 2). Formulations 1 and 3 gave excellent shelf life with net increases of 3.4% and 3.2%, respectively, after 15 days of aging, while formulations 2 and 4 showed greater increases in gel time, 6.5% and 8%, respectively. While all of these values are within the 10% shelf life window, formulation 2 resulted in a 10 second decrease in initial gel time (relative to formulation 1), while formulations 3 and 4 resulted in 19-20 seconds increase in initial gel time (relative to formulation 1), respectively. Such variation in gel time may be undesirable based on the manufacturing equipment and process requirements for producing the discontinuous foam boards. The balance of gel times becomes more complex due to the need to incorporate a certain amount of trimerization catalyst to achieve the desired flame retardancy. Formulation 1 exhibited desirable flow characteristics (high rise rate and final height), while formulation 2 exhibited a lower final height, although the maximum rise rate was higher (believed to be due to the much faster gel time) (table 3). While formulations 3 and 4 provided a higher final height, the rate of rise was lower and therefore the final height was considered to be a product with a much longer gel time.

Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.