Foam insulation with improved low temperature properties

Patent metadata

Field	Value
Publication number	US-10913235-B2
Application number	US-201916709671-A
Country	US
Kind code	B2
Filing date	Dec 10, 2019
Priority date	Sep 28, 2017
Publication date	Feb 9, 2021
Grant date	Feb 9, 2021

Abstract

A polyisocyanurate foam insulation product is produced from an isocyanate component, a polyol-containing component, and a blowing agent. The polyol-containing component includes a first polyol and a second polyol, a fire retardant, and one or more surfactants, wherein the first polyol and the second polyol have different hydroxyl numbers, or have different functionalities, or differ in both hydroxyl number and functionality. In some formulations, the polylol-containing component may include a fire retardant, a metallo-organinc compound, or combinations thereof. The cell size of the foam may be less than 120 microns. The polyol-containing component may include a mixture of polyols having different functionalities.

First claim

What is claimed is:

1. A polyisocyanurate foam insulation product produced from:
an isocyanate component; and
a polyol-containing component including a blowing agent;
wherein the polyol-containing component comprises a first polyol and a second polyol, a fire retardant, and one or more surfactants, wherein the first polyol and the second polyol have different hydroxyl numbers, or have different functionalities, or differ in both hydroxyl number and functionality.

2. The polyisocyanurate foam insulation product of claim 1 , wherein the polyol-containing component further comprises a metallo-organic compound.

3. The polyisocyanurate foam insulation product of claim 2 , wherein the polyol-containing component comprises between 0.1 and 1.0 weight percent of a compound containing zinc and an organic complex.

4. The polyisocyanurate foam insulation product of claim 2 , wherein the metallo-organic compound is a compound of bismuth.

5. The polyisocyanurate foam insulation product of claim 1 , wherein one of the polyols has a functionality of more than 2.20 and a hydroxyl number of more than 250, and the other polyol has a functionality of less than 2.20 and a hydroxyl number of less than 250.

6. The polyisocyanurate foam insulation product of claim 1 , wherein the first polyol and the second polyol have the same functionality.

7. The polyisocyanurate foam insulation product of claim 1 , wherein the polyisocyanurate foam insulation product is a rigid foam having a density of 2.0 lbs/ft 3 or less.

8. The polyisocyanurate foam insulation product of claim 1 , wherein the polyisocyanurate foam insulation product is a closed cell foam having a cell size of 120 μm or less.

9. The polyisocyanurate foam insulation product of claim 1 , wherein the polyol-containing component comprises two polyester polyols.

10. The polyisocyanurate foam insulation product of claim 1 , wherein the polyol-containing component comprises two polycarbonate polyols.

11. The polyisocyanurate foam insulation product of claim 1 , wherein the polyol-containing component comprises:
between 0.1 and 1.0 weight percent of a compound containing zinc and an organic complex; and
diethyl hydroxymethyl phosphonate (DEHMP).

12. The polyisocyanurate foam insulation product of claim 1 , wherein the blowing agent comprises a mixture of n-pentane and isopentane.

13. The polyisocyanurate foam insulation product of claim 1 , further comprising water, wherein the water reacts with isocyanate in the isocyanate component to form carbon dioxide, the carbon dioxide acting as a blowing agent.

14. A polyisocyanurate foam insulation product produced from:
an isocyanate component; and
a polyol-containing component including a blowing agent;
wherein the polyol-containing component comprises one or more polyols, a fire retardant, and one or more surfactants;
and wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 5.6 when measured at 40° F.

15. The polyisocyanurate foam insulation product of claim 14 , wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 6.0 when measured at 40° F.

16. The polyisocyanurate foam insulation product of claim 14 , wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 5.0 when measured at 25° F.

17. The polyisocyanurate foam insulation product of claim 14 , wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 5.5 when measured at 25° F.

18. The polyisocyanurate foam insulation product of claim 14 , wherein the polyol-containing component further comprises a metallo-organic compound.

19. The polyisocyanurate foam insulation product of claim 14 , wherein the polyol-containing component contains two polyols having different hydroxyl numbers, or having different functionalities, or differing in both hydroxyl number and functionality.

20. The polyisocyanurate foam insulation product of claim 14 , wherein one of the polyols has a functionality of more than 2.20 and a hydroxyl number of more than 250, and the other polyol has a functionality of less than 2.20 and a hydroxyl number of less than 250.

21. The polyisocyanurate foam insulation product of claim 14 , wherein the polyol-containing component contains two polyols having the same functionality.

22. The polyisocyanurate foam insulation product of claim 14 , wherein the polyisocyanurate foam insulation product is a rigid foam having a density of 2.0 lbs/ft 3 or less.

23. The polyisocyanurate foam insulation product of claim 14 , wherein the polyisocyanurate foam insulation product is a closed cell foam having a cell size of 120 μm or less.

24. The polyisocyanurate foam insulation product of claim 14 , wherein the polyol-containing component comprises:
between 0.1 and 1.0 weight percent of a compound containing zinc and an organic complex;
a first polyol having a functionality of more than 2.30 and a hydroxyl number of more than 275, and a second polyol having a functionality of less than 2.20 and a hydroxyl number of less than 250; and
diethyl hydroxymethyl phosphonate (DEHMP).

Assignees

• Johns Manville

Inventors

• Nandi Malay
• Wang Lance
• Asrar Jawed

Classifications

• B32B2307/304

  Insulating · CPC title

• E04D11/02

  Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition (gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17) · CPC title

• E04B1/80

  slab-shaped · CPC title

• B32B2419/06

  Roofs, roof membranes · CPC title

• B32B2266/08

  Closed cell foam · CPC title