Isocyanate-reactive formulation for rigid polyurethane foam

Patent metadata

Field	Value
Publication number	US-10144797-B2
Application number	US-201615557518-A
Country	US
Kind code	B2
Filing date	Mar 2, 2016
Priority date	Mar 17, 2015
Publication date	Dec 4, 2018
Grant date	Dec 4, 2018

Abstract

A storage stable isocyanate-reactive composition includes a reactive component including (a) 5 wt % to 30 wt % of at least one Novolac-type polyoxypropylene polyether polyol having a hydroxyl functionality from 2 to 5 and a hydroxyl number from 130 to 450 mg KOH/g, (b) 20 wt % to 60 wt % of at least one high functional polyether polyol having a hydroxyl functionality from 6 to 8 and a hydroxyl number from 300 to 700 mg KOH/g, (c) 2 wt % to 30 wt % of at least one low functional polyether polyol having a hydroxyl functionality from 2 to 5 and a hydroxyl number from 50 to 400 mg KOH/g, (d) 2 wt % to 30 wt % of at least one amine initiated polyol having a hydroxyl number from 250 to 600 mg KOH/g, and (e) 1 wt % to 25 wt % of one or more additives; and a hydrocarbon physical blowing agent component in an amount of at least 10 parts by weight for each 100 parts by weight of the reactive component.

First claim

The invention claimed is:

1. A storage stable isocyanate-reactive composition for forming a rigid polyurethane foam, the composition comprising:
a reactive component including, based on the total weight of the reactive component, from:
(a) 5 wt % to 30 wt % of at least one Novolac-type polyoxypropylene polyether polyol having a nominal hydroxyl functionality from 2 to 5 and a hydroxyl number from 130 to 450 mg KOH/g,
(b) 20 wt % to 60 wt % of at least one high functional polyether polyol having a nominal hydroxyl functionality from 6 to 8 and a hydroxyl number from 300 to 700 mg KOH/g,
(c) 2 wt % to 30 wt % of at least one low functional polyether polyol having a nominal hydroxyl functionality from 2 to 5 and a hydroxyl number from 50 to 400 mg KOH/g,
(d) 2 wt % to 30 wt % of at least one amine initiated polyol having a hydroxyl number from 250 to 600 mg KOH/g, the amine initiated polyol being an aromatic amine initiated polyol, a cycloaliphatic amine initiated polyol, or an aromatic and cycloaliphatic amine initiated polyol, and
(e) 1 wt % to 25 wt % of one or more additives selected from a catalyst, a chemical blowing agent, and a surfactant; and
a hydrocarbon physical blowing agent component present in an amount of at least 10 parts by weight for each 100 parts by weight of the reactive component,
wherein the isocyanate-reactive composition does not exhibit phase separation, as determined by unenhanced visual inspection, for a period of at least 7 days at ambient conditions.

2. The composition as claimed in claim 1 , wherein the composition excludes any polyester polyols.

3. The composition as claimed in claim 1 , wherein the amount of hydrocarbon physical blowing agent is at least 16 parts by weight and less than 20 parts by weight for each 100 parts by weight of the reactive component.

4. The composition as claimed in claim 1 , wherein the reactive component includes a diol and a triol as low functional polyether polyols, each of the diol and triol being present in an amount less than 10 wt %, based on the total weight of the reactive component.

5. The composition as claimed in a claim 1 , wherein the hydrocarbon physical blowing agent includes one or more of isopentane, n-pentane, cyclopentane, cyclohexane, n-hexane, and 2-methyl pentane.

6. A reaction system for forming a rigid polyurethane foam, the system comprising:
(a) the storage stable isocyanate-reactive composition for forming a rigid polyurethane foam as claim 1 ; and
(b) an isocyanate component, the reaction system having an isocyanate index from 100 to 300.

7. A rigid polyurethane foam prepared using the reaction system as claimed in claim 6 .

8. An appliance that includes the rigid polyurethane foam of claim 7 .

Assignees

• Dow Global Technologies Llc

Inventors

• Micheletti Davide
• Riccio Rossella
• Masy Jean-Paul
• Parenti Vanni

Classifications

• C08G18/163

  covered by C08G18/18 and C08G18/22 · CPC title

• C08G18/7664

  containing alkylene polyphenyl groups · CPC title

• C08G18/5033

  containing carbocyclic groups (C08G18/5024 takes precedence) · CPC title

• C08G18/482 Primary

  Mixtures of polyethers containing at least one polyether containing nitrogen · CPC title

• C08G18/4879

  containing aromatic groups · CPC title