Process for producing isocyanate-based foam construction boards

Patent metadata

Field	Value
Publication number	US-2018355136-A1
Application number	US-201615779887-A
Country	US
Kind code	A1
Filing date	Dec 3, 2016
Priority date	Dec 8, 2015
Publication date	Dec 13, 2018
Grant date	—

Abstract

A process for producing a polyurethane or polyisocyanurate construction board, the process comprising: (i) providing an A-side reactant stream that includes an isocyanate-containing compound; (ii) providing a B-side reactant stream that includes a polyol, where the B-side reactant stream includes a blowing agent that includes a pentane and a blowing agent additive that has a Hansen Solubility Parameter (8t) that is greater than 17 MPa°′ 5 ; and (iii) mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture.

First claim

1 .- 33 . (canceled)

34 . A process for producing a polyurethane or polyisocyanurate construction board, the process comprising:
(i) providing an A-side reactant stream that includes an isocyanate-containing compound; (ii) providing a B-side reactant stream that includes a polyol, where the B-side reactant stream includes a blowing agent that includes a pentane and a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 17 MPa − 0.5; and (iii) mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture.

35 . The process of claim 34 , further comprising the step of exposing the reaction mixture to heat.

36 . The process of claim 35 , where the reaction mixture is deposited onto a facer.

37 . The process of claim 36 , where the reaction is formed into a foam construction board within a laminator.

38 . The process of claim 34 , where the B-side reactant stream includes at least 0.9 parts by weight blowing agent additive per 100 parts by weight polyol.

39 . The process of claim 34 , where the B-side reactant stream includes at least 5.0 wt % blowing agent additive based upon the total weight of the blowing agent employed.

40 . The process of claim 34 , where the process produces a construction board having an index of at least 220 and a density of 1.0 to 2.5 lbs/ft 3 .

41 . The process of claim 34 , where the blowing agent additive has a Hansen Solubility Parameter of from 17.5 to 28.0 MPa −0.5 .

42 . The process of claim 34 , where the blowing agent additive has a boiling point, at one atmosphere, of from about 5° C. to about 150° C.

43 . The process of claim 34 , where the blowing agent consists of the acyclic pentane, the blowing agent additive, and optionally a chemical blowing agent.

44 . The process of claim 43 , where the A-side stream and the B-side stream include less than 1.5 parts by weight chemical blowing agent per 100 parts by weight polyol.

45 . The process of claim 43 , where the molar ratio of blowing agent additive to acyclic pentane is from about 1:20 to about 1:1.

46 . The process of claim 43 , where the acyclic pentane and the blowing agent additive form a physical blowing agent mixture, and where the physical blowing agent mixture includes from about 7 to about 35 mole % of the blowing agent additive based on the total moles of physical blowing agent mixture.

47 . The process of claim 34 , where the blowing agent additive is selected from the group consisting of ketones, aldehydes, ethers, esters, halogenated hydrocarbons, and aromatics.

48 . The process of claim 47 , where the blowing agent additive is an aldehyde or a ketone.

49 . The process of claim 47 , where the blowing agent additive is an ester.

50 . The process of claim 47 , where the polyol is an aromatic polyester polyol.

51 . A process for producing a polyurethane or polyisocyanurate construction board, the process comprising:
(i) combining polyol, isocyanate, an acyclic pentane blowing agent, a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 17 MPa −0.5 , and less than 1.5 parts by weight water per 100 parts by weight polyol to form a foam-forming mixture where the ratio of polyol to isocyanate provides a closed-cell foam having an Index of at least 210, and where the amount of acyclic pentane, blowing agent additive, and any water present provide a closed-cell foam having a density of 1.0 to 2.5 lbs/ft 3 , and where the acyclic pentane and blowing agent additive form a blowing agent mixture, and where the blowing agent mixture includes from about 7 to about 35 mole % blowing agent additive based on the total moles of blowing agent mixture; (ii) depositing the foam-forming mixture on a facer; and (iii) heating the foam-forming mixture to form a closed-cell foam.

52 . A method of improving the R-Value of a construction board at a median temperature of 40° F. relative to the R-Value of the construction board at a median temperature of 75° F., the method comprising:
preparing a polyisocyanurate construction board by forming a foam-forming mixture by combining an isocyanate, an aromatic polyester polyol, less than 1.5 parts by weight water per 100 parts by weight polyol, and a physical blowing agent including an acyclic pentane and a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 17 MPa −0.5 , where the physical blowing agent mixture includes from about 7 to about 30 mole % of the blowing agent additive based on the total moles of the physical blowing agent mixture.

Assignees

• Firestone Building Prod Co Llc

Inventors

• Letts John
• Yao Chunhua
• Hubbard Michael

Classifications

• B32B2266/08

  Closed cell foam · CPC title

• C08G18/7671

  containing only one alkylene bisphenyl group · CPC title

• C08J2203/14

  Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons · CPC title

• C08J2205/052

  Closed cells, i.e. more than 50% of the pores are closed · CPC title

• C08J9/0023 Primary

  containing oxygen · CPC title