Two-component polyurethane or polyisocyanurate low pressure spray foam composition containing a gaseous blowing agent comprising pressurized carbon dioxide

Patent metadata

Field	Value
Publication number	US-12365779-B2
Application number	US-202418647320-A
Country	US
Kind code	B2
Filing date	Apr 26, 2024
Priority date	Mar 11, 2019
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

Abstract

Storage-stable two-component polyurethane or polyisocyanurate spray foam compositions are disclosed, said compositions comprising: (a) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and (b) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent; wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.

First claim

What is claimed:

1. A storage-stable two-component polyurethane or polyisocyanurate spray foam composition comprising:
a) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and
b) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent, and further comprising a catalyst;
wherein the A-side component is contained in an A-side component container and the B-side component is contained in a B-side component container; and further
wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.

2. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the pressurized gaseous carbon dioxide in the B-side component is present at a level of from 0.5 wt. % to 10 wt. % carbon dioxide, based on the total weight of the B-side component.

3. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the pressurized gaseous carbon dioxide in the B-side component provides a pressure of from 0.14 MPa to 4.00 MPa (21 psig to 580 psig) on the B-side component as measured at ambient temperature.

4. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the one or more liquid blowing agent in the B-side component is present at a level of from 10 wt. % to 40 wt. %, based on the total weight of the B-side component.

5. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrohaloolefin.

6. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 5 , wherein the one or more blowing agent in the A-side component is or comprises a hydrohaloolefin gaseous blowing agent.

7. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrofluoroolefin, hydrochloroolefin or a hydrofluorochloroolefin.

8. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises (E)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd).

9. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein both the one or more blowing agent in the A-side component and the one or more liquid blowing agent in the B-side component comprise a hydrohaloolefin blowing agent.

10. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein both the A-side component and the B-side component comprise one or more liquid blowing agent.

11. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein both the A-side component and the B-side component comprise one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent.

12. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the catalyst comprises a morpholino compound.

13. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 12 , wherein the morpholino compound is 4-(2-hydroxyethyl)morpholine, dimorpholinodiethyl ether, 4-(2-chloroethyl)morpholine, 4-ethylmorpholine, 4-methylmorpholine or 4-(2-aminoethyl)morpholine, or a combination thereof.

14. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 1 , wherein the B-side component further comprises a flame retardant that is an alkylphosphate, an alkylphosphonate, or combination thereof.

15. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of claim 14 , wherein the B-side component comprises one flame retardant that is either the alkylphosphate or the alkylphosphonate.

16. A method of providing a space filling layer or space filling volume adjacent to or on a surface, the method comprising:
(a) providing a foamable composition comprising:
(i) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and
(ii) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent, and further comprising a catalyst;

wherein the A-side component is contained in an A-side component container and the B-side component is contained in a B-side component container;
wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.;
(b) applying a foamed sample, or pre-foamed sample that generates a foamed sample, of the foamable composition to said surface; and
(c) allowing the foamed sample of foamable composition to cure to a foam having a density of less than 48 kg/m 3 .

17. The method of claim 16 , wherein the pressurized gaseous carbon dioxide in the B-side component is present at a level of from 0.5 wt. % to 10 wt. % carbon dioxide, based on the total weight of the B-side component.

18. The method of claim 16 , wherein the pressurized gaseous carbon dioxide in the B-side component provides a pressure of from 0.14 MPa to 4.00 MPa (21 psig to 580 psig) on the B-side component as measured at ambient temperature.

19. The method of claim 16 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrohaloolefin.

20. The method of claim 16 , wherein the one or more liquid blowing agent in the B-side component is or comprises (E)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd).

21. The method of claim 16 , wherein the step of applying the foamed sample is performed by spraying the foamable composition.

22. The method of claim 16 , wherein the catalyst comprises a morpholino compound.

23. The method of claim 22 , wherein the morpholino compound is 4-(2-hydroxyethyl)morpholine, dimorpholinodiethyl ether, 4-(2-chloroethyl)morpholine, 4-ethylmorpholine, 4-methylmorpholine or 4-(2-aminoethyl)morpholine, or a combination thereof.

24. The method of claim 16 , wherein the B-side component further comprises a flame retardant that is an alkylphosphate, an alkylphosphonate, or combination thereof.

25. The method of claim 24 , wherein the B-side component comprises one flame retardant that is either the alkylphosphate or the alkylphosphonate.

Assignees

• Ddp Speciatly Electronic Mat Us Llc
• Ddp Specialty Electronic Materials Us Llc

Inventors

• Thomas Megan Marie
• Koh Kyoung Moo
• Rickard Mark Alan

Classifications

• C09D175/08

  from polyethers · CPC title

• C09D5/021

  Aerosols (aerosol compositions C09K3/30) · CPC title

• C08J2375/08

  from polyethers · CPC title

• C08J2203/162

  Halogenated unsaturated hydrocarbons, e.g. H2C=CF2 · CPC title

• C08J2201/022

  premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming · CPC title