Foaming agents, foamable compositions, foams and articles containing fluorine substitued halogens, and methods of making same

Patent metadata

Field	Value
Publication number	US-9303162-B2
Application number	US-86209807-A
Country	US
Kind code	B2
Filing date	Sep 26, 2007
Priority date	Oct 25, 2002
Publication date	Apr 5, 2016
Grant date	Apr 5, 2016

Abstract

Various uses of chloro, fluoroalkenes, particularly (HFCO-1233) in a variety of applications, including as blowing agents are disclosed.

First claim

What is claimed is:

1. A foamable composition for forming a thermal insulating foam having a K-factor (BTU in/hr ft 2 ° F.) at 40° F. of not greater than about 0.12, said foamable composition comprising: (a) a foam forming agent for forming a thermal insulation foam comprising a plurality of closed cells; and (b) a blowing agent for forming said closed cells, said blowing agent comprising at least about 15% by weight of CF3CH═CHCl (HFCO-1233zd), wherein from 95% to 100% of said HFCO-1233zd in the foamable composition is trans-CF3CH═CHCl (transHFCO-1233zd), whereby upon formation of thermal insulating foam from said foamable composition said foam has a K-factor (BTU in/hr ft 2 ° F.) at 40° F. of not greater than about 0.12.

2. The foamable composition of claim 1 wherein said foam forming agent comprises at least one thermoset component.

3. The foamable composition of claim 1 wherein said at least one thermoset component comprises a composition capable of forming polyurethane foam.

4. The foamable composition of claim 2 wherein said at least one thermoset component comprises a composition capable of forming polyisocyanurate foam.

5. The foamable composition of claim 2 wherein said at least one thermoset component comprises a composition capable of forming phenolic foam.

6. The foamable composition of claim 1 wherein said foam forming agent comprises at least one thermoplastic foam component.

7. The foamable composition of claim 6 wherein said at least one thermoplastic foam component comprises a thermoplastic polymer.

8. The foamable composition of claim 6 wherein said at least one thermoplastic component comprises a polyolefin.

9. The foamable composition of claim 8 wherein said polyolefin is selected from the group consisting of monovinyl aromatic compounds, ethylene-based compounds, propylene-based polymers, and combinations of these.

10. The foamable composition of claim 8 wherein said polyolefin is selected from the group consisting of polystyrene, ethylene homopolymers, polypropylene, polyethyleneterepthalate (PET) and combinations of these.

11. The foamable composition of claim 1 wherein said blowing agent further comprises a compound selected from the group consisting of C1-C5 alcohols, C1-C4 ethers, C4-C6 hydrocarbon; CO2 and combinations of two or more of these.

12. The foamable composition of claim 6 wherein said blowing agent further comprises at least one compound selected from the group consisting of CO2, isopentane, normal pentane, cyclopentane, ethanol.

13. The foamable composition of claim 6 wherein said blowing agent further comprises a compound selected from the group consisting of dimethyl ether, diethyl ether and combinations of these.

14. The foamable composition of claim 2 wherein said blowing agent further comprises at least one compound selected from the group consisting of CO2, isopentane, normal pentane, cyclopentane, and methyl formate.

15. A method of forming a foam having a K-factor (BTU in/hr ft 2 ° F.) at 40° F. of not greater than about 0.12, said method comprising: (a) adding a blowing agent to a foamable and/or foaming composition; (b) forming a thermal insulating foam comprising a plurality of closed cells from said foamable and/or foaming composition wherein said blowing agent forms closed cells in said foam, said blowing agent comprising at least about 50% by weight of 3 3 3-trifluoro-1,chloropropene (HFCO-1233zd), wherein from 95% to 100% of said HFCO-1233zd in the foamable or foaming composition is trans-CF 3 CH═CHCl (transHFCO-1233zd), whereby upon formation of thermal insulating foam from said foamable composition said foam has a K-factor (BTU in/hr ft 2 ° F.) at 40° F. of not greater than about 0.12.

16. The method of claim 15 further comprising reacting the foamable composition under conditions effective to form said closed cell structure.

17. The method of claim 16 wherein said foamable composition comprises isocyanate.

18. The method of claim 16 wherein said foamable composition comprises polyol.

19. The method of claim 16 wherein said foamable composition comprises at least one additional component selected from the group consisting of catalysts, surfactants, flame retardants, colorants, and combinations of these.

20. A thermal insulating foam comprising a plurality of closed polymeric cells and a composition contained in a plurality of said closed cells, said composition comprising at least about 50% by weight of 3 3 3-trifluoro-1,chloropropene (HFCO-1233zd), wherein from 95% to 100% of said HFCO-1233zd in said composition is trans-CF 3 CH═CHCl (transHFCO-1233zd), whereby upon formation of thermal insulating foam from said foamable composition said foam has a K-factor (BTU in/hr ft 2 ° F.) at 40° F. of not greater than about 0.12.

21. An article selected from the group consisting of block, slabs, pour-in-place panel foam, and laminate comprising the foam of claim 20 .

22. The foam of claim 20 being in a form selected from the group consisting of rigid foam, flexible foam, spray applied foam, one component foam, froth foam, and integral skin foam.

23. A refrigerator comprising the foam of claim 20 .

24. A freezer comprising the foam of claim 20 .

25. The foam of claim 20 having a k-factor K-factor (BTU in/hr ft 2 ° F.) at 75° F. of not greater than about 0.16.

26. A foam formed from the foamable composition of claim 3 in a form selected from the group consisting of rigid foam flexible foam, froth, spray applied foam and integral skin foam.

27. The foamable composition of claim 1 wherein said blowing agent consists of trans-CF 3 CH═CHCl (transHFCO-1233zd).

28. The foamable composition of claim 1 further comprising at least one co-blowing agent comprising trans-dichloroethylene.

29. A refrigerator comprising thermal insulating foam comprising
a plurality of closed polymeric cells and a composition contained in a plurality of said closed cells, said composition having a Global Warming Potential (GWP) of not greater than about 500 and comprising at least about 50% by weight of 3,3,3-trifluoro-1,chloropropene (HFCO-1233zd), wherein from 95% to 100% of said HFCO-1233zd in said composition is transHFCO-1233zd, said foam having a K-factor (BTU in/hr ft2° F.) at 40° F. of not greater than about 0.12.

30. The foamable composition of claim 1 wherein said HFCO-1233zd consists of trans-HFCO-1233zd.

31. The foamable composition of claim 30 wherein said blowing agent has a GWP of not greater than about 150.

32. The foamable composition of claim 30 herein said blowing agent has a GWP of not greater than about 75.

33. The method of claim 15 wherein said HFCO-1233zd consists of trans-1233zd.

34. The method of claim 33 wherein said blowing agent has a GWP of not greater than about 150.

35. The method of claim 33 wherein said blowing agent has a GWP of not greater than about 75.

36. The foam of claim 20 wherein said HFCO-1233zd consists of trans-1233zd.

37. The foam of claim 36 wherein said blowing agent has a GWP of not greater than about 150.

38. The foam of claim 36 wherein said blowing agent has a GWP of not greater than about 75.

39. The refrigerator of claim 29 wherein said HFCO-1233zd cons

Assignees

• Bowman James M
• Williams David J
• Singh Rajiv R
• Shankland Ian
• Honeywell Int Inc

Inventors

• Bowman James M
• Williams David J
• Singh Rajiv R
• Shankland Ian

Classifications

• C08J9/125

  Water, e.g. hydrated salts · CPC title

• C08J9/127

  Mixtures of organic and inorganic blowing agents · CPC title

• C08G2101/00

  Manufacture of cellular products · CPC title

• C09K5/045

  containing only fluorine as halogen · CPC title

• C08J2207/04

  Aerosol, e.g. polyurethane foam spray · CPC title