Thermal insulation properties of polyiso foams

Patent metadata

Field	Value
Publication number	US-11549268-B2
Application number	US-202017062347-A
Country	US
Kind code	B2
Filing date	Oct 2, 2020
Priority date	Mar 29, 2017
Publication date	Jan 10, 2023
Grant date	Jan 10, 2023

Abstract

Embodiments may include an insulated structure. The insulated structure may include a plurality of structural support members coupled together to form a frame. The insulated structure may also include a plurality of first wall boards attached to an exterior side of the frame to form an exterior wall or surface of the structure. The insulated structure may further include a spray foam insulation positioned within at least one of the wall cavities of the structure. The spray foam insulation may have an insulative R-value greater than or equal to 6.0 per inch at 40° F. The spray foam formulation may be made from a formulation that includes a reaction product of a polyisocyanate compound and a polyol compound and a blowing agent. The blowing agent may include a mixture of n-pentane and isopentane, where the mixture is at least 75% isopentane.

First claim

What is claimed is:

1. A foam board comprising
a polyisocyanurate core produced from:
an isocyanate;
a polyol; and
a blowing agent comprising a mixture of n-pentane and isopentane, wherein:
the mixture is at least 50% isopentane, and
the polyisocyanurate core has an insulative R-value greater than or equal to 6.0 per inch at 40° F., and an inflection point having an insulative R-value greater than 6.3.

2. The foam board of claim 1 , further comprising a facer material applied to one surface of the polyisocyanurate core.

3. The foam board of claim 1 , wherein the polyisocyanurate core has a density from 1.5 to 2.5 pcf.

4. The foam board of claim 1 , wherein the polyisocyanurate core is produced from at least one of a halogenated fire retardant or a non-halogenated fire retardant.

5. The foam board of claim 1 , wherein the mixture is at least 90% isopentane.

6. The foam board of claim 1 , wherein the polyisocyanurate core has a PIR/PUR ratio greater than or equal to 2.0.

7. The foam board of claim 1 , wherein the polyisocyanurate core is a closed cell insulation with a cell size of 200 μm or less.

8. The foam board of claim 1 , wherein the polyisocyanurate core has an isocyanate index greater than or equal to 250.

9. The foam board of claim 1 , wherein the polyol comprises an aromatic polyol.

10. The foam board of claim 1 , wherein the polyisocyanurate core is a closed cell insulation having a density from about 2.0 to about 4.0 pcf.

11. The foam board of claim 1 , wherein the blowing agent is from 1 to 10 weight percent of the polyisocyanurate core.

12. The foam board of claim 1 , wherein the mixture is at least 75% isopentane.

13. The foam board of claim 1 , wherein the polyisocyanurate core has an insulative R-value greater than 6.0 at a temperature less than or equal to 30° F.

14. The foam board of claim 1 , wherein the polyisocyanurate core maintains an insulative R-value within 0.25 R/inch between an inflection point temperature and 40° F.

15. An insulated structure comprising:
a plurality of structural support members coupled together to form a frame; and
a plurality of first boards attached to an exterior side of the frame to form an exterior wall or surface of the insulated structure; wherein:
at least one of the plurality of first boards comprises a foam board,
the foam board includes a polyisocyanurate core produced from:
an isocyanate;
a polyol; and
a blowing agent comprising a mixture of n-pentane and isopentane, wherein:
the mixture is at least 50% isopentane by weight; and
the polyisocyanurate core has an insulative R-value greater than or equal to 6.0 per inch at 40° F., and an inflection point having an insulative R-value greater than 6.3.

16. The insulated structure of claim 15 , wherein the mixture is at least 90% isopentane.

17. The insulated structure of claim 15 , wherein the polyisocyanurate core has a PIR/PUR ratio greater than or equal to 2.0.

18. The insulated structure of claim 15 , wherein the polyisocyanurate core is a closed cell insulation with a cell size of 200 μm or less.

19. The insulated structure of claim 15 , wherein the polyisocyanurate core has an isocyanate index greater than or equal to 250.

20. A method of insulating a component of a building, comprising:
coupling a plurality of structural support members together to form a frame;
attaching a plurality of first boards to an exterior side of the frame to form an exterior wall or surface of a structure; and
attaching a plurality of second boards to an interior side of the frame to form an interior wall or surface of the structure, wherein the structural support members, the first boards, and the second boards define a plurality of wall cavities; wherein:
at least one of the plurality of first boards comprises a foam board,
the foam board includes a polyisocyanurate core produced from:
an isocyanate;
a polyol; and
a blowing agent comprising a mixture of n-pentane and isopentane, wherein:
the mixture is at least 50% isopentane by weight; and
the polyisocyanurate core has an insulative R-value greater than or equal to 6.0 per inch at 40° F., and an inflection point having an insulative R-value greater than 6.3.

21. The method of claim 20 , wherein the polyisocyanurate core is a closed cell insulation with a cell size of 200 μm or less.

22. The method of claim 20 , wherein the polyisocyanurate core has an isocyanate index greater than or equal to 250.

Assignees

• Johns Manville

Inventors

• Wang Lance
• Asrar Jawed

Classifications

• C08J2203/182

  of physical blowing agents, e.g. acetone and butane · CPC title

• E04D13/1662 Primary

  Inverted roofs or exteriorly insulated roofs · CPC title

• C08J2205/10

  Rigid foams · CPC title

• E04B1/80

  slab-shaped · CPC title

• E04B1/7654

  comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings · CPC title