HCFO-containing isocyanate-reactive compositions, related foam-forming compositions and flame retardant PUR-PIR foams

Patent metadata

Field	Value
Publication number	US-11970565-B2
Application number	US-202318214598-A
Country	US
Kind code	B2
Filing date	Jun 27, 2023
Priority date	Jun 8, 2021
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

HCFO-containing isocyanate-reactive compositions, foam-forming compositions containing such isocyanate-reactive compositions, rigid PUR-PIR foams made using such foam-forming compositions, and methods for producing such foams, including use of such foams as insulation in discontinuous foam panel applications. The isocyanate-reactive composition includes a polyol blend, a blowing agent composition, and a tertiary amine catalyst. The polyol blend includes: (1) an aromatic polyester polyol having a functionality of 1.5 to less than 2.5 and an OH number of 150 to 360 mg KOH/g; (2) an aromatic polyester polyol having a functionality of at least 2.5 and an OH number greater than 360 mg KOH/g, which is present in an amount of at least 10% by weight, based on the total weight of the aromatic polyester polyol in the polyol blend; and (3) an amine-initiated polyether polyol having an OH number of at least 500 mg KOH/g and a functionality of 2.5 to 4. The blowing agent composition includes a hydrochlorofluoroolefin and a carbon dioxide generating chemical blowing agent.

First claim

What is claimed is:

1. A foam-forming reaction mixture comprising:
(a) a polyisocyanate;
(b) a polyol blend comprising:
(1) an aromatic polyester polyol (I) having a functionality of 1.5 to less than 2.5 and an OH number of 150 to 360 mg KOH/g;
(2) an aromatic polyester polyol (II) having a functionality of at least 2.5 and an OH number greater than 360 mg KOH/g, which is present in an amount of at least 10% by weight, based on total weight of the aromatic polyester polyol in the polyol blend; and
(3) an amine-initiated polyether polyol having an OH number of at least 500 mg KOH/g and a functionality of 2.5 to 4,
wherein aromatic polyester polyol is present in an amount of at least 50% by weight, based on total weight of the polyol blend;

(c) a blowing agent composition comprising:
(1) a hydrochlorofluoroolefin; and
(2) a carbon dioxide generating chemical blowing agent; and

(d) a tertiary amine catalyst,
wherein the reaction mixture has an isocyanate index of 90 to 150.

2. The foam-forming reaction mixture of claim 1 , wherein aromatic polyester polyol (I) has an OH number of 200 to 335 mg KOH/g and a functionality of 1.8 to 2.2 and aromatic polyester polyol (II) has an OH number of no more than 500 mg KOH/g and a functionality of 2.8 to 3.2.

3. The foam-forming reaction mixture of claim 1 , wherein aromatic polyester polyol (I) and aromatic polyester polyol (II) are present in a relative ratio, by weight, of 0.5:1.0 to 2.0:1.0.

4. The foam-forming reaction mixture of claim 1 , wherein the amine-initiated polyether polyol comprises an alkanolamine-initiated polyether polyol present in an amount of 0.1 to 10%, based upon the total weight of the polyol blend and aromatic polyester polyol and the alkanolamine-initiated polyether polyol are present in a weight ratio of at least 10:1.

5. The foam-forming reaction mixture of claim 1 , wherein the polyol blend further comprises a saccharide-initiated polyether polyol having an OH number of 200 to 600 mg KOH/g and a functionality of 4 to 6 that is present in an amount of 1 to 20% by weight, based on total weight of the polyol blend.

6. The foam-forming reaction mixture of claim 5 , wherein the saccharide-initiated polyether polyol is present in an amount such that the ratio, by weight, of aromatic polyester polyol to saccharide-initiated polyether polyol is at least 2:1 and the saccharide-initiated polyether polyol and the amine-initiated polyether polyol are present in a weight ratio of 0.5:1 to 4:1.

7. The foam-forming reaction mixture of claim 1 , wherein the hydrochlorofluoroolefin comprises 1-chloro-3,3,3-trifluoropropene and the carbon dioxide generating chemical blowing agent comprises water, wherein the hydrochlorofluoroolefin and water are present in an amount of at least 90% by weight, based on total weight of the blowing agent composition.

8. The foam-forming reaction mixture of claim 1 , wherein
(a) the tertiary amine catalyst comprises:
(1) 80 to 99% by weight, based on total weight of the tertiary amine catalyst composition, of a morpholine; and
(2) 1 to 20% by weight, based on total weight of the tertiary amine catalyst composition, of an imidazole; and

(b) the foam-forming reaction mixture further comprises a quaternary ammonium salt present in an amount of from 0.25 to 3.0% by weight, based on total weight of the isocyanate-reactive composition.

9. A foam comprising the reaction product of the foam-forming reaction mixture of claim 1 .

10. The foam-forming reaction mixture of claim 1 , wherein aromatic polyester polyol (II) has an OH number of 365 to 385 mg KOH/g, and a functionality of 2.8 to 3.2.

11. The foam-forming reaction mixture of claim 1 , wherein aromatic polyester polyol present in an amount of 70 to 90% by weight, based on total weight of the polyol blend.

12. The foam-forming reaction mixture of claim 3 , wherein aromatic polyester polyol (I) and aromatic polyester polyol (II) are present in a relative ratio, by weight, of 0.8:1.0 to 1.2:1.0.

13. The foam-forming reaction mixture of claim 1 , wherein the amine-initiated polyether polyol has an OH number of 600 to 800 mg KOH/g and a functionality of 2.5 to 3.5.

14. The foam-forming reaction mixture of claim 6 , wherein the saccharide-initiated polyether polyol is present in an amount such that the ratio, by weight, of aromatic polyester polyol to saccharide-initiated polyether polyol is 2.0:1.0 to 20.0:1.0, and the saccharide-initiated polyether polyol and amine-initiated polyether polyol are present in a weight ratio of 1:1 to 4:1.

15. The foam-forming reaction mixture of claim 1 , wherein the polyol blend has a weighted average functionality of 2 to 4 and a weighted average hydroxyl number of 300 to 400 mg KOH/g.

16. The foam-forming reaction mixture of claim 1 , wherein the polyol blend comprises less than 1% by weight, of ethylene oxide, based on the total weight of polyether polyol that is present in the polyol blend.

17. The foam-forming reaction mixture claim 1 , wherein the hydrochlorofluoroolefin and carbon dioxide generating chemical blowing agent are present in an amount of at least 95% by weight, based on the total weight of the blowing agent composition.

18. The foam-forming reaction mixture of claim 1 , wherein the polyisocyanate comprises a methylene-bridged polyphenyl polyisocyanate and/or a prepolymer of methylene-bridged polyphenyl polyisocyanates having an average functionality of 2.0 to 3.1 isocyanate moieties per molecule and an NCO content of 25 to 32 weight percent.

19. The foam-forming reaction mixture of claim 1 , further comprising a trimerization catalyst present in an amount of from 0.25 to 3.0% by weight, based on the total weight of the foam-forming reaction mixture except for the weight of the polyisocyanate.

20. The foam of claim 9 , wherein the foam achieves an ASTM E-84 Class A fire rating.

Assignees

• Covestro Llc

Inventors

• Bell Michael H
• Parks Brandon W
• Giles Eric C

Classifications

• C08G18/4018 Primary

  Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48 · CPC title

• C08G18/2081

  containing at least two non-condensed heterocyclic rings · CPC title

• C08G18/7685

  containing two or more non-condensed aromatic rings directly linked to each other · CPC title

• C08J9/08

  developing carbon dioxide · CPC title

• C08J9/125

  Water, e.g. hydrated salts · CPC title