Polyurethane and polyisocyanurate rigid foams suitable for roofing insulation

Patent metadata

Field	Value
Publication number	US-2017058092-A1
Application number	US-201615351623-A
Country	US
Kind code	A1
Filing date	Nov 15, 2016
Priority date	Oct 2, 2012
Publication date	Mar 2, 2017
Grant date	—

Abstract

Polyurethane foams having a NFPA 101 Class B rating (ASTM E-84) which pass the FM 4450 calorimeter Test are produced by reacting: (a) an organic polyisocyanate, (b) at least one polyether polyol or polyester polyol with a nominal hydroxyl functionality of at least 2.0, (c) a blowing agent composition and (d) at least one halogen-free flame retardant. The blowing agent composition includes: (1) no more than 10% by weight, based on total weight of the foam-forming composition, of one or more hydrocarbons having an LEL less than 2% by volume in air, and/or (2) a hydrocarbon having an LEL greater than 2% by volume in air, and (3) up to 1% by weight, based on total weight of foam-forming composition, of water.

First claim

1 - 15 . (canceled)

16 . A polyurethane foam having a NFPA 101 Class B rating (ASTM E-84) and which passes an FM 4450 calorimeter Test comprising the reaction product of a polyurethane foam-forming composition comprising:
a) at least 55% by weight based on total weight of foam-forming, composition of an organic polyisocyanate, b) isocyanate-reactive composition comprising at least one polyether polyol or polyester polyol with a nominal hydroxyl functionality of at least 2.0, c) a blowing agent composition comprising:
(1) greater than 0 to no more than 10% byeight, based on total weight of foam-forming composition, of one or more hydrocarbons having an LEL less than 2% by volume in air, and
(2) greater than 0 and up to 1% by weight, based on total weight of foam-forming composition, of water, and
d) at least one halogen-free flame retardant: wherein the polyurethane foam-forming composition contains no halogenated flame retardant or halogenated blowing agent, and wherein the polyurethane foam has a density of less than 1.8 pounds per cubic foot,

17 . The foam of claim 16 , wherein the halogen-free flame retardant comprises un polyphosphate, melamine or a derivative thereof, a borate, aluminum trihydrate, magnesium hydroxide, a silicate, a graphite, nanoclay, triethyl phosphate, a polymerization product of triethylphosphate with ethylene oxide and phosphorus oxide, tributyl phosphate, resorcinol bis(diphenyl phosphate) bisphenol A bis(diphenyl phosphate, dimethyl propane phosphonate, dimethyl methyl phosphonate, diethyl ethyl phosphonate, diethyl N,N′-bis(2-hydroxyethyl) aminomethyl phosphonate or some combination thereof.

18 . The foam of claim 16 , wherein the halogen-fee flame retardant comprises an isocyanate reactive phosphonate.

19 . The foam of claim 16 , wherein the hydrocarbon having an LEL less than 2% by volume in air comprises n-pentane, isopentane, cyclopentane, butane, hexane, 2,2-dimethylpropane, 2,2-dimethylbutane, 2-methylpentane, a hexene, a pentene or a combination thereof.

20 . The foam of claim 16 , wherein the hydrocarbon having an LEL less than 2% by volume in air comprises n-pentane, isopentane, and/or cyclopentane.

21 . The foam of claim 16 , wherein the isocyanate-reactive composition comprises a polyester polyol having a hydroxyl number of from 100 mg KOH/gm to 1000 mg KOH/gm.

22 . The foam of claim 21 , wherein the polyester polyol is present in an amount of 10 to 45% by weight, based on the total weight of the foam-forming composition.

23 . The foam of claim 24 , wherein the polyester polyol is present in an amount of 20 to 40% by weight, based on the total weight of the foam-farming composition.

24 . The that of claim 23 , wherein the polyester polyol is present in an amount of 25 to 40% by weight, based on the total, weight of the foam-forming composition.

25 . The foam of claim 16 , wherein the organic polyisocyanate comprises polymeric MDI having a functionality of from 2.2 to 3.0 and a viscosity less than about 800 mPas at 25° C.

26 . The foam of claim 25 , wherein the polymeric MDI is present in an amount of 55% to 75%, based on the total weight of the foam-forming composition.

27 . The foam of claim 26 , wherein the polymeric MDI is present in an amount of 55% to 67%, based on the total weight of the foam-forming composition.

28 . The foam of claim 16 , wherein, the one or more hydrocarbons having an LEL less than 2% by volume in air is present in an amount of no more than 8% by weight, based on total weight of the foam-forming composition.

29 . The foam of claim 16 wherein the one or more hydrocarbons having an LEI, less than 2% by volume in air is present in an amount of from 5 to 10% by weight, based on thetotal weight of the foam-forming composition.

30 . The foam of claim 16 , wherein the one or more hydrocarbons having an LEL less than 2% by volume in air is present in an amount of from 2 to 8% by weight, based on the total weight of the foam-forming composition.

31 . The foam of claim 16 , wherein water is present in an amount of 0.10 to 0.80% by weight, by weight, based on total weight of foam-forming composition.

32 . The foam of claim 16 , wherein water is present in an amount of 0.10 to 0.40% by weight, by weight, based on total weight of foam-forming composition.

33 . The foam of claim 16 , with the proviso that the polyurethane foam-forming composition contains no ammonium polyphosphate.

33 . The foam of claim 16 , wherein the foam has isocyanurate linkages.

34 . An insulated roof assembly comprising:
(a) a deck; (b) insulation panels mechanically attached to the deck, wherein the insulation panels comprise the foam of claim 33 .

Assignees

• Covestro Llc

Inventors

• Combs George G
• Pigott Susan C

Classifications

• E04B1/942

  slab-shaped · CPC title

• C08J2375/04

  Polyurethanes · CPC title

• C08G18/42

  Polycondensates having carboxylic or carbonic ester groups in the main chain · CPC title

• C08J9/149

  Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143 · CPC title

• C08J2375/06

  from polyesters · CPC title