US20050070619A1 - Blowing agent enhancers for polyurethane foam production - Google Patents
Blowing agent enhancers for polyurethane foam production Download PDFInfo
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- US20050070619A1 US20050070619A1 US10/672,363 US67236303A US2005070619A1 US 20050070619 A1 US20050070619 A1 US 20050070619A1 US 67236303 A US67236303 A US 67236303A US 2005070619 A1 US2005070619 A1 US 2005070619A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/143—Halogen containing compounds
- C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
- C08J9/146—Halogen containing compounds containing carbon, halogen and hydrogen only only fluorine as halogen atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G18/12—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step using two or more compounds having active hydrogen in the first polymerisation step
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/2805—Compounds having only one group containing active hydrogen
- C08G18/2815—Monohydroxy compounds
- C08G18/283—Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds
- C08G18/2835—Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds having less than 5 ether groups
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/40—High-molecular-weight compounds
- C08G18/48—Polyethers
- C08G18/487—Polyethers containing cyclic groups
- C08G18/4883—Polyethers containing cyclic groups containing cyclic groups having at least one oxygen atom in the ring
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0025—Foam properties rigid
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/005—< 50kg/m3
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/12—Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2205/00—Foams characterised by their properties
- C08J2205/10—Rigid foams
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
Definitions
- the present invention relates to compositions and processes for making polyurethane foams. More particularly, it relates to compositions and processes incorporating compounds for enhancing the effectiveness of hydrohalocarbon blowing agents in making polyurethane foams.
- the invention is a composition for producing a polyurethane foam.
- the composition comprises a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH 2 CHR′′O) n —R′; wherein:
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is selected from the group consisting of R, hydrogen, acetyl, propionyl, and butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
- the invention is a method of making a polyurethane foam.
- the method comprises combining a polyol and a polyisocyanate in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH 2 CHR′′O) n —R′; wherein:
- the invention is a composition for producing a polyurethane foam.
- the composition comprises a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula ROH, wherein:
- the invention is a polyurethane composition
- a polyurethane composition comprising a product of a reaction between a polyol and a polyisocyanate.
- the reaction takes place in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH 2 CHR′′O) n —R′; wherein:
- the invention is a composition for producing a polyurethane foam.
- the composition comprises 1) one but not both of a polyol and a polyisocyanate, 2) a blowing agent comprising a hydrohalocarbon and 3) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH 2 CHR′′O) n —R′; wherein:
- the present invention involves the use of low molecular weight ethers and alcohols as blowing agent enhancers for improving the efficiency of hydrohalocarbon blowing agents in the preparation of rigid polyurethane and/or polyisocyanurate foam.
- polyurethane is intended to mean polyurethane and/or polyisocyanurate, as is understood in the art.
- a rigid polyurethane foam can be a rigid polyurethane and/or polyisocyanurate foam.
- hydrohalocarbon is used herein to mean a compound consisting of carbon, hydrogen, and one or both of fluorine and chlorine, and no other elements.
- enhancers are provided that are useful in the reaction of a polyisocyanate and a polyol in the presence of a blowing agent comprising a hydrohalocarbon.
- the reaction is performed in the presence of a urethane catalyst, and typically in the presence of a surfactant.
- the enhancer comprises a low molecular weight alcohol or ether, for example di(ethylene glycol) methyl ether.
- the process according to the invention can easily be carried out by conventional means for making rigid polyurethane foam, excepting that the general preparation of rigid polyurethane foam using a hydrohalocarbon blowing agent, preferably a C1-C4 hydrofluorocarbon, is carried out using the blowing agent enhancer according to the invention to improve the blowing agent efficiency.
- a hydrohalocarbon blowing agent preferably a C1-C4 hydrofluorocarbon
- Rigid polyurethane products made in accordance with the invention may be prepared using any suitable organic polyisocyanates well known in the art for making rigid polyurethane foam including, for example, hexamethylene diisocyanates, isophorone diisocyanates, phenylene diisocyanates, toluene diisocyanates (TDI) and 4,4′-diphenylmethane diisocyanates (MDI).
- TDI toluene diisocyanates
- MDI 4,4′-diphenylmethane diisocyanates
- Especially suitable are mixtures of diisocyanates known commercially as “crude MDI”, marketed as PAPI by Dow Chemical, which contain about 60% of 4,4′-diphenylmethane diisocyanates along with other isomeric and analogous higher polyisocyanates.
- isocyanates are the 2,4- and 2,6-TDl's individually or together as their commercially available mixtures. Also suitable are “prepolymers” of these polyisocyanates comprising a partially pre-reacted mixture of a polyisocyanate and a polyether or polyester polyol. Typically, the above polyisocyanates are used in an amount relative to the polyol to establish an isocyanate index in the range of 80 to 400.
- Suitable polyols are those typically used in the art for making rigid polyurethane foam, including for example polyalkylene ether and polyester polyols.
- Polyalkylene ether polyols include poly(ethylene oxide) and poly(propylene oxide) polymers and copolymers with terminal hydroxyl groups derived from polyhydric compounds, for example diols and/or triols.
- Such diols and triols include, as non-limiting examples, ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylol propane, sugars such as sucrose, and other low molecular weight polyols.
- amine polyether polyols which can be prepared by reacting an amine, such ethylenediamine, diethylenetriamine, tolylenediamine, diphenylmethanediamine, triethanolamine or the like, with ethylene oxide or propylene oxide.
- a single high molecular weight polyether polyol such as described above may be used.
- mixtures of such high molecular weight polyether polyols for example mixtures of different multifunctional materials and/or of compounds having different molecular weights or different chemical compositions, may be used.
- Useful polyester polyols include those produced by reacting a dicarboxylic acid with an excess of a diol, for example, adipic acid or phthalic acid anhydride with ethylene glycol or butanediol, or reacting a lactone such as caprolactone with an excess of a diol such as propylene glycol.
- hydrohalocarbon blowing agents used in the present invention for making rigid foams include, as nonlimiting examples, HCFC (hydrochlorofluorocarbon) compounds, HFC (hydrofluorocarbon) compounds, and mixtures of these.
- Hydrochlorofluorocarbon compounds comprise at least one atom of each of hydrogen, chlorine, and fluorine per molecule.
- Hydrofluorocarbon compounds comprise at least one atom of each of hydrogen and fluorine per molecule, and no chlorine atoms.
- Nonlimiting examples of suitable HCFC's include HCFC-123, HCFC-141b, HCFC-22, HCFC-142b, and mixtures of any of these.
- suitable HFC compounds include HFC-134a, HFC-245fa, HFC-245ca, HFC-236ea, HFC-365mfc, and mixtures of any of these.
- Preferred blowing agents include HCFC-141b, HFC-134a, HFC-245fa, and mixtures of two or more of these.
- third generation C1 —C4 HFC blowing agents with a molecular weight of 50 to 170 g/mole, a boiling point of ⁇ 60 to 50 C and preferably an Ozone Depletion Potential (ODP) of ⁇ 0.10, ODP as described by: Synthesis of the Reports of the Ozone Scientific Assessment Panel, Environmental Effect Assessment Panel Technology and Economic Assessment Panel, prepared by the Assessment Chairs for the Parties to the Montreal Protocol, November, 1991.
- HFC's meeting these criteria include HFC-134a, HFC-236ea, HFC-365mfc and most preferably HFC-245fa. Mixtures of these may also be used. Water may be included in the formulation at 0 to 4 pphp (parts per hundred parts of polyol).
- blowing agents which may optionally be used in combination with HFC blowing agents according to the invention include HCFC's, CFC's (chlorofluorocarbons), hydrocarbons such as pentanes, and the like.
- the blowing agent consists essentially of one or more hydrohalocarbons comprising at least one fluorine atom per molecule, either alone or in combination with one or more CFC.
- Blowing agent enhancers include compounds having a molecular weight less than about 500 g/mol and a molecular formula according to Structure I: RO—(CH 2 CHR′′O) n —R′ I wherein R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is R, hydrogen, acetyl, propionyl, or butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
- R′′ is hydrogen or C1-C5 alkyl group; and n is an integer greater than or equal to
- Suitable C1-C5 alkyl groups useful for R′′ include methyl, ethyl, n-propyl, isopropyl, n-butyl, 2-butyl, isobutyl, n-pentyl, 2-methylbutyl, and 3-methylbutyl.
- Suitable C1-C10 aliphatic groups comprising a nitrogen atom or oxygen atom, and C5-C10 cycloaliphatic groups comprising a nitrogen atom or oxygen atom include groups wherein a nitrogen atom is incorporated in the form of an amine group and groups where an oxygen atom is incorporated as an ether group, a hydroxyl group, or a carbonyl group.
- Suitable C7-C10 araliphatic groups comprising a nitrogen atom or oxygen atom include groups wherein a nitrogen atom is incorporated in the form of an amine group or as a member of a heterocyclic ring, and groups where an oxygen atom is incorporated as an ether group, a hydroxyl group, a carbonyl group, or as a member of a heterocyclic ring.
- Exemplary compounds according to Structure I include those with two terminal ether groups, compounds with one terminal ether group and one terminal hydroxyl group, and acetyl, propionyl, or butyryl esters of the latter compounds.
- Preferred enhancers comprise oxyethylene —(CH 2 CH 2 O)— and/or oxypropylene —(CH 2 CH(CH 3 )O)—groups.
- Blowing agent enhancers according to Structure I containing two terminal ether groups include, in one exemplary embodiment, dipropylene glycol dimethyl ether.
- Blowing agent enhancers according to Structure I containing one terminal ether group and one terminal hydroxyl group include, for example, ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, and tripropylene glycol monobutyl ether.
- propylene glycol monomethyl ether propylene glycol monopropyl ether and propylene glycol monobutyl ether.
- One preferred blowing agent enhancer is diethylene glycol monomethyl ether.
- Blowing agent enhancers according to Structure I containing one terminal ether group and a terminal ester group include acetyl, propionyl, or butyryl esters of compounds containing one terminal ether group and a terminal hydroxyl group, for example propylene glycol monomethyl ether acetate.
- Suitable blowing agent enhancers according to the invention also include compounds having a molecular weight less than about 500 g/mol and a molecular formula ROH, wherein R is as defined above.
- Suitable exemplary compounds in this category include methanol, ethanol, and any isomer of propanol, butanol, pentanol, hexanol, heptanol, octanol, nonanol, and decanol.
- blowing agent enhancer or mixture of blowing agent enhancers, constitutes at least 2 pphp of the composition, typically at least 4 pphp, and even more typically at least 5 pphp. Typically, it constitutes at most 12 pphp, more typically at most 7 pphp, and even more typically at most 6 pphp.
- a catalyst may be used to promote the reactions forming polyurethane foams according to the invention.
- the catalyst composition may be any catalyst well known in the urethane art such as tertiary amines, organotin compounds, and carboxylate urethane catalysts (gelling and/or blowing).
- Typical examples of useful catalysts are amine catalysts such as triethylenediamine, dimethylcyclohexylamine, tetramethylhexanediamine, bis(dimethylaminoethyl) ether, tri(dimethylaminopropyl)hexahydrotriazine, 1-isobutyl-2-methylimidazole, 1,2-dimethylimidazole, dimethylaminoethanol, diethylaminoethanol, pentamethyldiethylenetriamine, pentamethyldipropylenetriamine, methylmorpholine, ethylmorpholine, quaternary ammonium salts, salts of an organic acid and tin catalysts such as dibutyltin dilaurate and the like.
- amine catalysts such as triethylenediamine, dimethylcyclohexylamine, tetramethylhexanediamine, bis(dimethylaminoethyl) ether, tri(dimethylaminoprop
- a catalytically effective amount of the catalyst composition is used in the polyurethane formulation. More specifically, suitable amounts of the catalyst composition typically ranges from about 0.01 to 10 parts by weight per 100 parts polyol (0.01 to 10 pphp) in the polyurethane formulation, preferably 0.5 to 4 pphp.
- a surfactant may be used in polyurethane foam compositions and processes according to the invention.
- a number of surfactants suitable for use in controlling foam properties in polyurethane production are known in the art.
- Exemplary surfactants include silicone-based surfactants such as are disclosed in U.S. Pat. No. 5,883,142 to Chojnacki et al.
- Typical agents that may be used in the polyurethane rigid foam formulations include flame retardants and chain extenders such as ethylene glycol and butanediol.
- NCO Index means isocyanate index, as that term is commonly used in the polyurethane art. Use of this term in a table of formulations indicates that the appropriate amount of polyisocyanate should be used in order to achieve a formulation having the indicated NCO index.
- Foam flow was determined by measuring the % fill of the L mold when a constant amount of foam formulation (475 grams) was introduced into the mold, with a higher % fill indicating better flow for samples of equal mass. In addition to comparing flow and density, foam from each of the formulas was evaluated to determine k-factor and compression strength. The top 12 inches of the foams were cut into three sections then stored at ⁇ 30° C. for 72 hours to measure volume change, to verify that there was less than two percent change, indicating sufficient dimensional stability according to commonly accepted industry standards. The next section of the foam was used to cut a core sample to measure the k-factor or heat flow in a Lasercomp Fox 200 heat flow meter.
- Table 4 is a summary of foam performance data for a number of blowing agent enhancers according to the invention. For each enhancer, the corresponding % fill in the L-mold and k-factor were recorded. TABLE 4 Performance of Blowing Agent Enhancers K-Factor ID Compound % Fill (W/mK) 1 Control 92.5 0.0206 (No enhancer) 2 Diethylene glycol monomethyl ether 99.2 0.0206 3 Tripropylene glycol monobutyl ether 95.6 0.0206 4 Propylene glycol monobutyl ether 97.7 0.0209 5 Dipropylene glycol monopropyl ether 94.8 0.0212 6 Propylene glycol monomethyl ether 98.0 0.0208 acetate 7 Propylene glycol monomethyl ether 99.0 0.0212 8 Ethylene glycol monobutyl ether 96.1 0.0221 9 Dipropylene glycol dimethyl ether 97.2 0.0222 10 Dipropylene glycol monobutyl ether 96.1 0.0215 11 Dipropylene glycol mono
- blowing agent enhancers 2-14 all showed improved flow (higher value for % fill), with comparable to only slightly worse (higher numerical value) k factors.
- the blowing agent enhancer that yielded the best flow and k-factor was (2), or di(ethylene glycol) methyl ether.
- Table 5 collects foam performance data using di(ethylene glycol) methyl ether at 6 pbw in the formula from Table 3.
- the objective of this example was to match the density and foam performance of the control while maximizing HFC-245fa reduction.
- the table clearly shows that the di(ethylene glycol) methyl ether blowing agent enhancer allows for lower HFC-245fa concentrations, with no significant penalties to foam thermal properties and an improvement to the compression strengths.
- Compression strength values are a measure of the force needed to physically crush the foam until failure. Higher force relates to improved foam mechanical properties, giving the final product (e.g. a refrigerator) structural integrity.
- Table 5 illustrates that a 19% reduction of HFC-245fa is attainable by use of di(ethylene glycol) methyl ether as a blowing agent enhancer to achieve foams of equivalent k-factor, while maintaining equal or even improved compression strength.
- KPa Blowing Agent Use Level Compression Minimum Strength Fill
- Enhancer HFC-245fa Density K-Factor Perp./ Formula (pphp) (pphp) Kg/m 3 ) (W/mK) Parallel 1 None 35.2 32.84 0.0195 138/159 2 6.0 28.5 32.68 0.0195 165/193 3 6.0 28.5 32.04 0.0198 159/200 4 6.0 28.5 33.00 0.0196 152/186
- blowing agent enhancers in the production of rigid polyurethane foams using a hydrohalocarbon blowing agent, particularly HFC-245fa, use of blowing agent enhancers according to the invention allows the production of foams with a reduced amount of blowing agent, while retaining at least equal physical properties to a reference foam with a higher level of blowing agent and none of the enhancer. In some cases, compression strength is improved with use of the enhancer.
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Abstract
Rigid polyurethane blowing agent enhancers, methods for using them, and the products produced by these methods are disclosed. The enhancers are low molecular weight alcohols and/or ethers that assist the action of blowing agents comprising a hydrohalocarbon compound.
Description
- The present invention relates to compositions and processes for making polyurethane foams. More particularly, it relates to compositions and processes incorporating compounds for enhancing the effectiveness of hydrohalocarbon blowing agents in making polyurethane foams.
- The manufacture of rigid polyurethane foams has been significantly impacted by restrictions on the use of certain prior art blowing agents, which may be environmentally harmful. Although new, more environmentally acceptable blowing agents have come into use (typically hydrohalocarbons), these are generally not as effective as those commonly used previously and there is therefore a continuing need for enhancements in the process of making rigid polyurethane foams and/or in the properties of the foams themselves. The present invention addresses that need with compounds which are believed to enhance the effectiveness of blowing agents used in making rigid polyurethane foams.
- In one aspect, the invention is a composition for producing a polyurethane foam. The composition comprises a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH2CHR″O)n—R′; wherein:
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is selected from the group consisting of R, hydrogen, acetyl, propionyl, and butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
-
- R″ is hydrogen or a C1-C5 alkyl group; and
- n is an integer greater than or equal to 1.
- In another aspect, the invention is a method of making a polyurethane foam. The method comprises combining a polyol and a polyisocyanate in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH2CHR″O)n—R′; wherein:
-
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is selected from the group consisting of R, hydrogen, acetyl, propionyl, and butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
- R″ is hydrogen or a C1-C5 alkyl group; and
- n is an integer greater than or equal to 1.
- In yet another aspect, the invention is a composition for producing a polyurethane foam. The composition comprises a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula ROH, wherein:
-
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom, provided that the at least one compound comprises only one hydroxyl group per molecule.
- In a further aspect, the invention is a polyurethane composition comprising a product of a reaction between a polyol and a polyisocyanate. The reaction takes place in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH2CHR″O)n—R′; wherein:
-
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is selected from the group consisting of R, hydrogen, acetyl, propionyl, and butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
- R″ is hydrogen or a C1 —C5 alkyl group; and
- n is an integer greater than or equal to 1.
- In a still further aspect, the invention is a composition for producing a polyurethane foam. The composition comprises 1) one but not both of a polyol and a polyisocyanate, 2) a blowing agent comprising a hydrohalocarbon and 3) a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula of RO—(CH2CHR″O)n—R′; wherein:
-
- R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom;
- R′ is selected from the group consisting of R, hydrogen, acetyl, propionyl, and butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule;
- R″ is hydrogen or a C1-C5 alkyl group; and
- n is an integer greater than or equal to 1.
- The present invention involves the use of low molecular weight ethers and alcohols as blowing agent enhancers for improving the efficiency of hydrohalocarbon blowing agents in the preparation of rigid polyurethane and/or polyisocyanurate foam. As used herein, the term “polyurethane” is intended to mean polyurethane and/or polyisocyanurate, as is understood in the art. Thus a rigid polyurethane foam can be a rigid polyurethane and/or polyisocyanurate foam. The term “hydrohalocarbon” is used herein to mean a compound consisting of carbon, hydrogen, and one or both of fluorine and chlorine, and no other elements.
- In accordance with the invention, enhancers are provided that are useful in the reaction of a polyisocyanate and a polyol in the presence of a blowing agent comprising a hydrohalocarbon. Typically, the reaction is performed in the presence of a urethane catalyst, and typically in the presence of a surfactant. The enhancer comprises a low molecular weight alcohol or ether, for example di(ethylene glycol) methyl ether.
- The process according to the invention can easily be carried out by conventional means for making rigid polyurethane foam, excepting that the general preparation of rigid polyurethane foam using a hydrohalocarbon blowing agent, preferably a C1-C4 hydrofluorocarbon, is carried out using the blowing agent enhancer according to the invention to improve the blowing agent efficiency.
- Polyisocyanate
- Rigid polyurethane products made in accordance with the invention may be prepared using any suitable organic polyisocyanates well known in the art for making rigid polyurethane foam including, for example, hexamethylene diisocyanates, isophorone diisocyanates, phenylene diisocyanates, toluene diisocyanates (TDI) and 4,4′-diphenylmethane diisocyanates (MDI). Especially suitable are mixtures of diisocyanates known commercially as “crude MDI”, marketed as PAPI by Dow Chemical, which contain about 60% of 4,4′-diphenylmethane diisocyanates along with other isomeric and analogous higher polyisocyanates. Other suitable isocyanates are the 2,4- and 2,6-TDl's individually or together as their commercially available mixtures. Also suitable are “prepolymers” of these polyisocyanates comprising a partially pre-reacted mixture of a polyisocyanate and a polyether or polyester polyol. Typically, the above polyisocyanates are used in an amount relative to the polyol to establish an isocyanate index in the range of 80 to 400.
- Polyol
- Suitable polyols are those typically used in the art for making rigid polyurethane foam, including for example polyalkylene ether and polyester polyols. Polyalkylene ether polyols include poly(ethylene oxide) and poly(propylene oxide) polymers and copolymers with terminal hydroxyl groups derived from polyhydric compounds, for example diols and/or triols. Such diols and triols include, as non-limiting examples, ethylene glycol, propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylol propane, sugars such as sucrose, and other low molecular weight polyols. Also useful are amine polyether polyols which can be prepared by reacting an amine, such ethylenediamine, diethylenetriamine, tolylenediamine, diphenylmethanediamine, triethanolamine or the like, with ethylene oxide or propylene oxide.
- In the practice of this invention, a single high molecular weight polyether polyol such as described above may be used. Also, mixtures of such high molecular weight polyether polyols, for example mixtures of different multifunctional materials and/or of compounds having different molecular weights or different chemical compositions, may be used. Useful polyester polyols include those produced by reacting a dicarboxylic acid with an excess of a diol, for example, adipic acid or phthalic acid anhydride with ethylene glycol or butanediol, or reacting a lactone such as caprolactone with an excess of a diol such as propylene glycol.
- Blowing Agent
- The hydrohalocarbon blowing agents used in the present invention for making rigid foams include, as nonlimiting examples, HCFC (hydrochlorofluorocarbon) compounds, HFC (hydrofluorocarbon) compounds, and mixtures of these. Hydrochlorofluorocarbon compounds comprise at least one atom of each of hydrogen, chlorine, and fluorine per molecule. Hydrofluorocarbon compounds comprise at least one atom of each of hydrogen and fluorine per molecule, and no chlorine atoms.
- Nonlimiting examples of suitable HCFC's include HCFC-123, HCFC-141b, HCFC-22, HCFC-142b, and mixtures of any of these. Nonlimiting examples of suitable HFC compounds include HFC-134a, HFC-245fa, HFC-245ca, HFC-236ea, HFC-365mfc, and mixtures of any of these. Preferred blowing agents include HCFC-141b, HFC-134a, HFC-245fa, and mixtures of two or more of these. More preferred are third generation C1 —C4 HFC blowing agents with a molecular weight of 50 to 170 g/mole, a boiling point of −60 to 50 C and preferably an Ozone Depletion Potential (ODP) of <0.10, ODP as described by: Synthesis of the Reports of the Ozone Scientific Assessment Panel, Environmental Effect Assessment Panel Technology and Economic Assessment Panel, prepared by the Assessment Chairs for the Parties to the Montreal Protocol, November, 1991. HFC's meeting these criteria include HFC-134a, HFC-236ea, HFC-365mfc and most preferably HFC-245fa. Mixtures of these may also be used. Water may be included in the formulation at 0 to 4 pphp (parts per hundred parts of polyol). Other blowing agents which may optionally be used in combination with HFC blowing agents according to the invention include HCFC's, CFC's (chlorofluorocarbons), hydrocarbons such as pentanes, and the like. In one embodiment of the invention, the blowing agent consists essentially of one or more hydrohalocarbons comprising at least one fluorine atom per molecule, either alone or in combination with one or more CFC.
- Blowing Agent Enhancer
- Blowing agent enhancers according to the invention include compounds having a molecular weight less than about 500 g/mol and a molecular formula according to Structure I:
RO—(CH2CHR″O)n—R′ I
wherein R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom; R′ is R, hydrogen, acetyl, propionyl, or butyryl, provided that the at least one compound has no more than one hydroxyl group per molecule; R″ is hydrogen or C1-C5 alkyl group; and n is an integer greater than or equal to 1. Typically, n is between 1 and 7, inclusive. Mixtures of compounds according to Structure I may also be used. - Suitable C1-C5 alkyl groups useful for R″ include methyl, ethyl, n-propyl, isopropyl, n-butyl, 2-butyl, isobutyl, n-pentyl, 2-methylbutyl, and 3-methylbutyl. Suitable C1-C10 aliphatic groups comprising a nitrogen atom or oxygen atom, and C5-C10 cycloaliphatic groups comprising a nitrogen atom or oxygen atom, include groups wherein a nitrogen atom is incorporated in the form of an amine group and groups where an oxygen atom is incorporated as an ether group, a hydroxyl group, or a carbonyl group. Suitable C7-C10 araliphatic groups comprising a nitrogen atom or oxygen atom include groups wherein a nitrogen atom is incorporated in the form of an amine group or as a member of a heterocyclic ring, and groups where an oxygen atom is incorporated as an ether group, a hydroxyl group, a carbonyl group, or as a member of a heterocyclic ring.
- Exemplary compounds according to Structure I include those with two terminal ether groups, compounds with one terminal ether group and one terminal hydroxyl group, and acetyl, propionyl, or butyryl esters of the latter compounds. Preferred enhancers comprise oxyethylene —(CH2CH2O)— and/or oxypropylene —(CH2CH(CH3)O)—groups.
- Blowing agent enhancers according to Structure I containing two terminal ether groups include, in one exemplary embodiment, dipropylene glycol dimethyl ether.
- Blowing agent enhancers according to Structure I containing one terminal ether group and one terminal hydroxyl group include, for example, ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, and tripropylene glycol monobutyl ether.
- Particularly useful are propylene glycol monomethyl ether, propylene glycol monopropyl ether and propylene glycol monobutyl ether. One preferred blowing agent enhancer is diethylene glycol monomethyl ether.
- Blowing agent enhancers according to Structure I containing one terminal ether group and a terminal ester group include acetyl, propionyl, or butyryl esters of compounds containing one terminal ether group and a terminal hydroxyl group, for example propylene glycol monomethyl ether acetate.
- Suitable blowing agent enhancers according to the invention also include compounds having a molecular weight less than about 500 g/mol and a molecular formula ROH, wherein R is as defined above. Suitable exemplary compounds in this category include methanol, ethanol, and any isomer of propanol, butanol, pentanol, hexanol, heptanol, octanol, nonanol, and decanol.
- Mixtures of any of any of these with any of the enhancers represented by Structure I may also be used. Any amount of enhancer may be used, depending upon the desired properties of the resultant foam. Typically, however, the blowing agent enhancer, or mixture of blowing agent enhancers, constitutes at least 2 pphp of the composition, typically at least 4 pphp, and even more typically at least 5 pphp. Typically, it constitutes at most 12 pphp, more typically at most 7 pphp, and even more typically at most 6 pphp.
- Catalyst
- A catalyst may be used to promote the reactions forming polyurethane foams according to the invention. The catalyst composition may be any catalyst well known in the urethane art such as tertiary amines, organotin compounds, and carboxylate urethane catalysts (gelling and/or blowing). Typical examples of useful catalysts are amine catalysts such as triethylenediamine, dimethylcyclohexylamine, tetramethylhexanediamine, bis(dimethylaminoethyl) ether, tri(dimethylaminopropyl)hexahydrotriazine, 1-isobutyl-2-methylimidazole, 1,2-dimethylimidazole, dimethylaminoethanol, diethylaminoethanol, pentamethyldiethylenetriamine, pentamethyldipropylenetriamine, methylmorpholine, ethylmorpholine, quaternary ammonium salts, salts of an organic acid and tin catalysts such as dibutyltin dilaurate and the like.
- A catalytically effective amount of the catalyst composition is used in the polyurethane formulation. More specifically, suitable amounts of the catalyst composition typically ranges from about 0.01 to 10 parts by weight per 100 parts polyol (0.01 to 10 pphp) in the polyurethane formulation, preferably 0.5 to 4 pphp.
- Surfactant
- A surfactant may be used in polyurethane foam compositions and processes according to the invention. A number of surfactants suitable for use in controlling foam properties in polyurethane production are known in the art. Exemplary surfactants include silicone-based surfactants such as are disclosed in U.S. Pat. No. 5,883,142 to Chojnacki et al.
- Other Ingredients
- Other typical agents that may be used in the polyurethane rigid foam formulations include flame retardants and chain extenders such as ethylene glycol and butanediol.
- A typical range of prior art rigid foam formulations (Table 1) having a 1.5-2.5 lb/ft3 (24-40 kg/m3) density (e.g., appliance foam) containing a blowing agent enhancer according to the invention and a third generation blowing agent, for example HFC-245fa, may comprise the following components in parts by weight (pbw):
TABLE 1 General Rigid Foam Formulation Component pbw Polyol 100 Silicone Surfactant 1-3 Blowing Agent 20-40 Water 0-3 Catalyst 1-3 Polyisocyanate NCO Index = 80-400 - As used in Table 1 and hereinafter, the term “NCO Index” means isocyanate index, as that term is commonly used in the polyurethane art. Use of this term in a table of formulations indicates that the appropriate amount of polyisocyanate should be used in order to achieve a formulation having the indicated NCO index.
- In the following examples, a specific rigid polyurethane foam formulation (shown in Table 2) was used as a Control formulation for foam production. Blowing agent enhancers were incorporated into formulations as shown in Table 3, and the experimental results from foam production with the formulations of Tables 2 and 3 are compared in Table 4.
TABLE 2 Control Formulation Component pbw Polyol* 100.0 Silicone Surfactant 4.0 HFC-245fa 35.0 Water 1.3 Amine Catalyst** 2.3 Polyisocyanate*** NCO Index = 105
*Sucrose-initiated ethylene oxide/propylene oxide copolymer with a hydroxyl number of about 350 to 400.
**A 2:1 wt/wt mixture of Polycat ® 5 and Polycat ® 41, available from Air Products and Chemicals, Inc. of Allentown, PA.
***Polymeric MDI, sold under the name Rubinate ® M by Huntsman Polyurethanes of West Deptford, New Jersey.
-
TABLE 3 Example Formulation Component pbw Polyol 100.0 Silicone Surfactant 4.0 HFC-245fa 35.0 Water 1.3 Amine Catalyst 2.3 Blowing Agent Enhancer 6.0 Polyisocyanate NCO Index = 105 - The ingredients in Tables 2 and 3, except for the polymeric MDI, were combined and incubated at 10° C. until the mixtures had equilibrated to temperature. The resin was weighed into a paper cup, the polymeric MDI was added to the cup in an amount such that the isocyanate (NCO) index was 105. The mixture was stirred with a high speed mixer for eight seconds, and the cup with the foaming mass was then placed into an L-mold designed for measuring foam flow and other physical properties. The L-mold was heated to 49° C. and was used for initial screening of blowing agent enhancers. The control formula (Table 2) was used to prepare a reference foam to measure foam flow and foam density for comparison with foams containing a blowing agent enhancer (Table 3).
- Foam flow was determined by measuring the % fill of the L mold when a constant amount of foam formulation (475 grams) was introduced into the mold, with a higher % fill indicating better flow for samples of equal mass. In addition to comparing flow and density, foam from each of the formulas was evaluated to determine k-factor and compression strength. The top 12 inches of the foams were cut into three sections then stored at −30° C. for 72 hours to measure volume change, to verify that there was less than two percent change, indicating sufficient dimensional stability according to commonly accepted industry standards. The next section of the foam was used to cut a core sample to measure the k-factor or heat flow in a Lasercomp Fox 200 heat flow meter.
- Table 4 is a summary of foam performance data for a number of blowing agent enhancers according to the invention. For each enhancer, the corresponding % fill in the L-mold and k-factor were recorded.
TABLE 4 Performance of Blowing Agent Enhancers K-Factor ID Compound % Fill (W/mK) 1 Control 92.5 0.0206 (No enhancer) 2 Diethylene glycol monomethyl ether 99.2 0.0206 3 Tripropylene glycol monobutyl ether 95.6 0.0206 4 Propylene glycol monobutyl ether 97.7 0.0209 5 Dipropylene glycol monopropyl ether 94.8 0.0212 6 Propylene glycol monomethyl ether 98.0 0.0208 acetate 7 Propylene glycol monomethyl ether 99.0 0.0212 8 Ethylene glycol monobutyl ether 96.1 0.0221 9 Dipropylene glycol dimethyl ether 97.2 0.0222 10 Dipropylene glycol monobutyl ether 96.1 0.0215 11 Dipropylene glycol monomethyl ether 96.7 0.0212 12 Propylene glycol monopropyl ether 97.7 0.0212 13 Ethylene glycol phenyl ether 95.9 0.0215 14 Tripropylene glycol monopropyl ether 95.7 0.0216 - Compared with the control (1), blowing agent enhancers 2-14 all showed improved flow (higher value for % fill), with comparable to only slightly worse (higher numerical value) k factors. The blowing agent enhancer that yielded the best flow and k-factor was (2), or di(ethylene glycol) methyl ether.
- To further demonstrate the efficacy of di(ethylene glycol) methyl ether for blowing agent reduction, larger scale high-pressure machine evaluations were conducted. The ingredients in Table 3, except for the polymeric MDI, were combined in a five-gallon pressurized day tank and incubated at 26.7° C. until the mixture had equilibrated to temperature. The polymeric MDI was incubated in a separate five gallon pressurized day tank and also incubated to 26.7° C. After the ingredients in both day tanks had been equilibrated, they were mixed together through a high-pressure impingement mix head at 13,790 KPa (2000 psi). This reacting mass was poured into a 200×20×5 cm mold heated to 49° C.
- Enough of the foaming mixture was added to the mold to yield panels at multiple densities, including minimum fill. Several over-packed densities were produced to determine the lowest density which passed physical property requirements. The foam panels were removed from the mold after six minutes and aged at 23° C. for 18-24 hours. A 20.3×20.3×2.54 cm (8×8×1 inch) portion was cut from the bottom of the panels and the k-factor was evaluated for each in a Lasercomp Fox 200 heat flow meter. Four samples were cut from the top of the panels 20.3×10.2×5.1 cm (8×4×2 inch) for determining the density at which dimensional stability was achieved.
- Table 5 collects foam performance data using di(ethylene glycol) methyl ether at 6 pbw in the formula from Table 3. The objective of this example was to match the density and foam performance of the control while maximizing HFC-245fa reduction. The table clearly shows that the di(ethylene glycol) methyl ether blowing agent enhancer allows for lower HFC-245fa concentrations, with no significant penalties to foam thermal properties and an improvement to the compression strengths. Compression strength values are a measure of the force needed to physically crush the foam until failure. Higher force relates to improved foam mechanical properties, giving the final product (e.g. a refrigerator) structural integrity. Table 5 illustrates that a 19% reduction of HFC-245fa is attainable by use of di(ethylene glycol) methyl ether as a blowing agent enhancer to achieve foams of equivalent k-factor, while maintaining equal or even improved compression strength.
TABLE 5 Reduction of Blowing Agent Use Level Compression Minimum Strength Fill (KPa) Enhancer HFC-245fa (Density K-Factor Perp./ Formula (pphp) (pphp) Kg/m3) (W/mK) Parallel 1 None 35.2 32.84 0.0195 138/159 2 6.0 28.5 32.68 0.0195 165/193 3 6.0 28.5 32.04 0.0198 159/200 4 6.0 28.5 33.00 0.0196 152/186 - The foregoing experimental data indicate that, in the production of rigid polyurethane foams using a hydrohalocarbon blowing agent, particularly HFC-245fa, use of blowing agent enhancers according to the invention allows the production of foams with a reduced amount of blowing agent, while retaining at least equal physical properties to a reference foam with a higher level of blowing agent and none of the enhancer. In some cases, compression strength is improved with use of the enhancer.
- Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, it is intended that the scope of the claims that follow includes various modifications that may be made in the details while nevertheless achieving the effects of this invention.
Claims (24)
1. A composition for producing a polyurethane foam, the composition comprising a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound
selected from the group consisting of ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monopropyl ether, propylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether, or a mixture of any of these.
2. A composition for producing a polyurethane foam, the composition comprising a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having no hydroxyl groups and having a molecular weight less than about 500 q/mol and a molecular formula of RO—(CH2CHR″O)n—R′; wherein:
R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group, a C1-C10 aliphatic group comprising a nitrogen atom or oxygen atom, a C5-C10 cycloaliphatic group comprising a nitrogen atom or oxygen atom, and a C7-C10 araliphatic group comprising a nitrogen atom or oxygen atom:
R′ is selected from the group consisting of R, acetyl, propionyl, and butyryl;
R″ is hydrogen or a C1-C5 alkyl group: and
n is an integer greater than or equal to 1.
3. The composition of claim 2 , wherein RΔ is hydrogen or methyl.
4. The composition of claim 1 , wherein the at least one compound comprises dipropylene glycol dimethyl ether.
5. The composition of claim 1 , wherein the at least one compound comprises propylene glycol monomethyl ether, propylene glycol monopropyl ether, propylene glycol monobutyl ether, or a mixture of any of these.
6. The composition of claim 1 , wherein the at least one compound comprises diethylene glycol monomethyl ether.
7. The composition of claim 1 , wherein the hydrohalocarbon comprises at least one fluorine atom per molecule.
8. The composition of claim 1 , wherein the blowing agent comprises HCFC-123, HCFC-141b, HCFC-22, HCFC-142b, HFC-134a, HFC-245fa, HFC-245ca, HFC-236ea, HFC-365mfc, or a mixture of any of these.
9. The composition of claim 1 , wherein the blowing agent comprises HCFC-141b, HFC-134a, HFC-245fa, or a mixture of any of these.
10. The composition of claim 1 , wherein the blowing agent comprises a C1 —C4 hydrofluorocarbon having a molecular weight between 50 and 170 g/mol, a boiling point between −60° C. and 50° C., and an Ozone Depletion Potential less than 0.10.
11. The composition of claim 1 , wherein the blowing agent comprises HFC-134a, HFC-236ea, HFC-365mfc, HFC-245fa, or a mixture of any of these.
12. The composition of claim 1 , wherein the blowing agent comprises HFC-245fa.
13. The composition of claim 1 , additionally comprising a catalyst.
14. The composition of claim 1 , additionally comprising a surfactant.
15. A composition for producing a polyurethane foam, the composition comprising a polyol, a polyisocyanate, HFC-245fa, and one or both of diethylene glycol monomethyl ether and dipropylene glycol dimethyl ether.
16. A method of making a polyurethane foam, the method comprising combining a polyol and a polyisocyanate in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer comprising at least one compound
selected from the group consisting of ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, diethylene glycol monomethyl ether, Dropylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monoprovyl ether, propylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether.
17. The method of claim 16 , wherein the hydrohalocarbon comprises at least one fluorine atom per molecule.
18. A composition for producing a polyurethane foam, the composition comprising a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound having a molecular weight less than about 500 g/mol and a molecular formula ROH, wherein:
R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, and a C7-C10 araliphatic group.
19. The composition of claim 18 , wherein the hydrohalocarbon comprises at least one fluorine atom per molecule.
20. The composition of claim 18 , wherein the at least one compound is selected from the group consisting of methanol, ethanol, isomers of propanol, isomers of butanol, isomers of pentanol, isomers of hexanol, isomers of heptanol, isomers of octanol, isomers of nonanol, isomers of decanol, and mixtures of any of these.
21. A polyurethane composition comprising a product of a reaction between a polyol and a polyisocyanate, the reaction taking place in the presence of 1) a blowing agent comprising a hydrohalocarbon and 2) a blowing agent enhancer
selected from the group consisting of ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monopropyl ether, Propylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether.
22. A composition for producing a polyurethane foam, the composition comprising 1) one but not both of a polyol and a polyisocyanate, 2) a blowing agent comprising a hydrohalocarbon and 3) a blowing agent enhancer comprising at least one compound
selected from the group consisting of ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, diethylene glycol monomethyl ether, Propylene glycol monomethyl ether, Propylene glycol monomethyl ether acetate, Propylene glycol monopropyl ether, Propylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether.
23. The composition of claim 22 , wherein the hydrohalocarbon comprises at least one fluorine atom per molecule.
24. A composition for producing a polyurethane foam, the composition comprising a polyol, a polyisocyanate, a blowing agent comprising a hydrohalocarbon, and a blowing agent enhancer comprising at least one compound selected from the group consisting of ethylene glycol monomethyl ether, ethylene glycol monobutyl ether, ethylene glycol phenyl ether, diethylene glycol monomethyl ether, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monopropyl ether, propylene glycol monobutyl ether, dipropylene glycol dimethyl ether, dipropylene glycol monomethyl ether, dipropylene glycol monopropyl ether, dipropylene glycol monobutyl ether, tripropylene glycol monopropyl ether, tripropylene glycol monobutyl ether and compounds having a molecular weight less than about 500 g/mol and a molecular formula of ROH wherein:
R is selected from the group consisting of a C1-C10 aliphatic group, a C5-C10 cycloaliphatic group, a C7-C10 araliphatic group.
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US10/672,363 US20050070619A1 (en) | 2003-09-26 | 2003-09-26 | Blowing agent enhancers for polyurethane foam production |
US10/700,163 US6921779B2 (en) | 2003-09-26 | 2003-11-03 | Blowing agent enhancers for polyurethane foam production |
BR0403991-2A BRPI0403991A (en) | 2003-09-26 | 2004-09-22 | Useful composition for producing a polyurethane foam |
EP04022538A EP1520873A3 (en) | 2003-09-26 | 2004-09-22 | Blowing agent enhancers for polyurethane foam production |
MXPA04009244A MXPA04009244A (en) | 2003-09-26 | 2004-09-23 | Blowing agent enhancers for polyurethane foam production. |
KR1020040076225A KR100587875B1 (en) | 2003-09-26 | 2004-09-23 | Blowing agent enhancers for polyurethane foam production |
CNB2004100874736A CN100344668C (en) | 2003-09-26 | 2004-09-24 | Blowing agent enhancers for polyurethane foam production |
JP2004280219A JP2005105272A (en) | 2003-09-26 | 2004-09-27 | Blowing agent enhancer for polyurethane foam |
US12/915,385 US9321892B2 (en) | 2003-09-26 | 2010-10-29 | Blowing agent enhancers for polyurethane foam production |
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US10/700,163 US6921779B2 (en) | 2003-09-26 | 2003-11-03 | Blowing agent enhancers for polyurethane foam production |
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US10/672,363 Abandoned US20050070619A1 (en) | 2003-09-26 | 2003-09-26 | Blowing agent enhancers for polyurethane foam production |
US10/700,163 Expired - Lifetime US6921779B2 (en) | 2003-09-26 | 2003-11-03 | Blowing agent enhancers for polyurethane foam production |
US12/915,385 Expired - Lifetime US9321892B2 (en) | 2003-09-26 | 2010-10-29 | Blowing agent enhancers for polyurethane foam production |
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US10/700,163 Expired - Lifetime US6921779B2 (en) | 2003-09-26 | 2003-11-03 | Blowing agent enhancers for polyurethane foam production |
US12/915,385 Expired - Lifetime US9321892B2 (en) | 2003-09-26 | 2010-10-29 | Blowing agent enhancers for polyurethane foam production |
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US (3) | US20050070619A1 (en) |
EP (1) | EP1520873A3 (en) |
JP (1) | JP2005105272A (en) |
KR (1) | KR100587875B1 (en) |
CN (1) | CN100344668C (en) |
BR (1) | BRPI0403991A (en) |
MX (1) | MXPA04009244A (en) |
Cited By (6)
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US20050267228A1 (en) * | 2004-05-28 | 2005-12-01 | Andrew Gary D | Fast demold/extended cream time polyurethane formulations |
US20090305876A1 (en) * | 2006-06-26 | 2009-12-10 | Honeywell International, Inc. | Compositions and Methods Containing Fluorine Substituted Olefins |
US20130035021A1 (en) * | 2010-03-26 | 2013-02-07 | Toyo Tire & Rubber Co., Ltd. | Polishing pad, manufacturing method therefor, and method for manufacturing a semiconductor device |
US20130072594A1 (en) * | 2010-05-27 | 2013-03-21 | The Yokohama Rubber Co., Ltd. | Liquid coagulant and tire puncture sealing material set |
US9079289B2 (en) | 2011-09-22 | 2015-07-14 | Toyo Tire & Rubber Co., Ltd. | Polishing pad |
US20160326330A1 (en) * | 2013-12-19 | 2016-11-10 | Basf Se | Composition that is suitable for producing polyurethane foams and that contains at least one nucleating agent |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20050070619A1 (en) * | 2003-09-26 | 2005-03-31 | Miller John William | Blowing agent enhancers for polyurethane foam production |
CN101704937B (en) * | 2009-11-10 | 2011-12-28 | 航天材料及工艺研究所 | Low-fluoride polyurethane foaming plastic for insulating heat at low temperature |
US20130217797A1 (en) * | 2011-08-23 | 2013-08-22 | Basf Se | Microemulsions |
CN102863602B (en) * | 2012-10-22 | 2014-06-11 | 株洲时代新材料科技股份有限公司 | Product of foaming-type polyurethane shock pad and manufacturing method thereof |
DE102013226575B4 (en) | 2013-12-19 | 2021-06-24 | Evonik Operations Gmbh | Composition suitable for the production of polyurethane foams, containing at least one unsaturated fluorocarbon or unsaturated fluorocarbon as blowing agent, polyurethane foams, processes for their production and their use |
WO2018074257A1 (en) * | 2016-10-18 | 2018-04-26 | 東レ・ダウコーニング株式会社 | Polyether-modified silicone composition, surfactant, foam stabilizer, polyurethane foam forming composition, and cosmetic preparation including said composition, and method for producing said composition |
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US9181386B2 (en) * | 2010-03-26 | 2015-11-10 | Toyo Tire & Rubber Co., Ltd. | Polishing pad, manufacturing method therefor, and method for manufacturing a semiconductor device |
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US9676979B2 (en) | 2010-05-27 | 2017-06-13 | The Yokohama Rubber Co., Ltd. | Liquid coagulant and tire puncture sealing material set |
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US10988593B2 (en) * | 2013-12-19 | 2021-04-27 | Basf Se | Composition that is suitable for producing polyurethane foams and that contains at least one nucleating agent |
Also Published As
Publication number | Publication date |
---|---|
US20110039963A1 (en) | 2011-02-17 |
CN1626562A (en) | 2005-06-15 |
EP1520873A2 (en) | 2005-04-06 |
BRPI0403991A (en) | 2005-05-24 |
KR20050030568A (en) | 2005-03-30 |
KR100587875B1 (en) | 2006-06-12 |
US20050070618A1 (en) | 2005-03-31 |
EP1520873A3 (en) | 2007-07-04 |
MXPA04009244A (en) | 2005-03-31 |
CN100344668C (en) | 2007-10-24 |
US6921779B2 (en) | 2005-07-26 |
JP2005105272A (en) | 2005-04-21 |
US9321892B2 (en) | 2016-04-26 |
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