Classifications

• • 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
• • 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
• • 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
  • 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
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
• • 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
  • C08G2101/00—Manufacture of cellular products
• • 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

• Fluorocarbons (Attorney Docket No. FL1184 US NA) and further related to co-filed and jointly owned application also titled Blowing Agents for
• the disclosure herein relates to blowing agent compositions comprising unsaturated fluorocarbons and/or unsaturated hydrofluorocarbons.
• the disclosure herein further relates to the use of the blowing agent compositions in the process for manufacturing plastic foams.
• Closed-cell polyisocyanate-based foams are widely used for insulation purposes, for example, in building construction and in the manufacture of energy efficient electrical appliances.
• polyurethane (polyisocyanurate) board stock is used in roofing and siding for its insulation and load-carrying capabilities.
• Poured and sprayed polyurethane foams are widely used for a variety of applications including insulating roofs, insulating large structures such as storage tanks, insulating appliances such as refrigerators and freezers, insulating refrigerated trucks and railcars, etc. All of these various types of polyurethane foams require blowing (expansion) agents for their manufacture.
• Insulating foams depend on the use of halocarbon blowing agents, not only to foam the polymer, but primarily for their low vapor thermal conductivity, a very important characteristic for insulation value.
• polyurethane foams used CFCs (chlorofluorocarbons, for example CFC-11 , trichlorofluoromethane) and HCFCs (hydrochlorofluorocarbons, for example HCFC-141b, 1 ,1- dichloro-1-fluoroethane) as the primary blowing agent.
• HFCs hydrofluorocarbons
• An example of an HFC employed in this application is HFC-245fa (1,1 ,1 ,3,3-pentafluoropropane).
• thermoplastic foam primarily polystyrene foam.
• Polyolefin foams polystyrene, polyethylene, and polypropylene are widely used in insulation and packaging applications. These thermoplastic foams were generally made with CFC-12 (dichlorodifluoromethane) as the blowing agent. More recently HCFCs (HCFC-22, chlorodifluoromethane) or blends of HCFCs (HCFC-22/HCFC- 142b) or HFCs (HFC-152a) have been employed as blowing agents for polystyrene.
• a third important type of insulating foam is phenolic foam. These foams, which have very attractive flammability characteristics, were generally made with CFC-11 (trichlorofluoromethane) and CFC-113 (1 ,1 ,2- trichloro-1 ,2,2-trifluoroethane) blowing agents
• open-cell foams are also of commercial interest, for example in the production of fluid-absorbent articles.
• U.S. Patent 6,703,431 (Dietzen, et. al.) describes open-cell foams based on thermoplastics polymers that are useful for fluid- absorbent hygiene articles such as wound contact materials.
• U.S. Patent 6,071 ,580 (Bland, et. al.) describes absorbent extruded thermoplastic foams which can be employed in various absorbency applications.
• Open- cell foams have also found application in evacuated or vacuum panel technologies, for example in the production of evacuated insulation panels as described in U.S. Patent 5,977,271 (Malone).
• open-cell foams in evacuated insulation panels, it has been possible to obtain R values of 10 to 15 per inch of thickness depending upon the evacuation or vacuum level, polymer type, cell size, density, and open cell content of the foam.
• These open-cell foams have traditionally been produced employing CFCs, HCFCs, or more recently, HFCs as blowing agents.
• Multimodal foams are also of commercial interest, and are described, for example, in U.S. Patent 6,787,580 (Chonde, et. al.) and U.S. Patent 5,332,761 (Paquet, et. al.).
• a multimodal foam is a foam having a multimodal cell size distribution, and such foams have particular utility in thermally insulating articles since they often have higher insulating values (R-values) than analogous foams having a generally uniform cell size distribution.
• R-values insulating values
• These foams have been produced employing CFCs, HCFCs, and, more recently, HFCs as the blowing agent.
• CFCs As discussed above, the production of various types of foams historically employed CFCs as the blowing agent. In general, the CFCs produce foams exhibiting good thermal insulation, low flammability and excellent dimensional stability. However, despite these advantages the CFCs have fallen into disfavor due to their implication in the destruction of stratospheric ozone, as well as their implication in contributing to global warming.
• HCFCs have been proposed as CFC substitutes, and are currently employed as foam blowing agents. However, the HCFCs have also been shown to contribute to the depletion of stratospheric ozone, and as a result their use has come under scrutiny, and the widespread use of HCFCs is scheduled for eventual phase out under the Montreal Protocol.
• HFCs More recently HFCs have been proposed and employed as foam blowing agents.
• the HFCs do not contribute to the destruction of stratospheric ozone, but are of concern due to their contribution to the "greenhouse effect", i.e., they contribute to global warming.
• the HFCs have come under scrutiny, and their widespread use may also be limited in the future.
• Hydrocarbons have also been proposed as foam blowing agents.
• these compounds are flammable, and many are photochemically reactive, and as a result contribute to the production of ground level ozone (i.e., smog).
• ground level ozone i.e., smog
• Such compounds are typically referred to as volatile organic compounds (VOCs), and are subject to environmental regulations.
• Another aspect is for a closed cell foam prepared by foaming a foamable composition in the presence of a blowing agent described above.
• a further aspect is for a foamable composition comprising a polyol and a blowing agent described above.
• Another aspect is for a foam premix composition comprising a polyol and a blowing agent described above.
• t Additionally, one aspect is for a method of forming a foam comprising:
• a further aspect is for a method of forming a polyisocyanate-based foam comprising reacting at least one organic polyisocyanate with at least one active hydrogen-containing compound in the presence of a blowing agent described above. Another aspect is for a polyisocyanate foam produced by said method.
• R 1 and R 2 are, independently, Ci to C 6 perfluoroalkyl groups.
• R 1 and R 2 groups include, but are not limited to, CF 3 , C 2 F 5 , CF 2 CF 2 CF 3 , CF(CF 3 ) 2) CF 2 CF 2 CF 2 CF 3 , CF(CF 3 )CF 2 CF 3 , CF 2 CF(CFs) 2 , C(CF 3 ) 3 , CF 2 CF 2 CF 2 CF 2 CF 3 , CF 2 CF 2 CF(CFs) 2 , C(CFs) 2 C 2 F 5 , CF 2 CF 2 CF 2 CF 2 CFS, CF(CF 3 ) 5 CF 2 CF 2 C 2 F 5 , and C(CF 3 ) 2 CF 2 C 2 F 5 .
• Exemplary, non-limiting Formula I compounds are
• Suitable reaction vessels include those fabricated from stainless steels, in particular of the austenitic type, and the well-known high nickel alloys such as Monel® nickel-copper alloys, Hastelloy® nickel based alloys and Inconel® nickel-chromium alloys.
• reaction may be conducted in semi-batch mode in which the perfluoroalkyltrihydroolefin reactant is added to the perfluoroalkyl iodide reactant by means of a suitable addition apparatus such as a pump at the reaction temperature.
• a suitable addition apparatus such as a pump at the reaction temperature.
• the ratio of perfluoroalkyl iodide to perfluoroalkyltrihydroolefin should be between about 1 :1 to about 4:1 , preferably from about 1.5:1 to 2.5:1. Ratios less than 1.5:1 tend to result in large amounts of the 2:1 adduct as reported by Jeanneaux, et al. in Journal of Fluorine Chemistry, Vol. 4, pages 261-270 (1974).
• Preferred temperatures for contacting of said perfluoroalkyl iodide with said perfluoroalkyltrihydroolefin are preferably within the range of about 150°C to 300°C, preferably from about 170 0 C to about 250 0 C, and most preferably from about 180 0 C to about 23O 0 C.
• Suitable contact times for the reaction of the perfluoroalkyl iodide with the perfluoroalkyltrihydroolefin are from about 0.5 hour to 18 hours, preferably from about 4 to about 12 hours.
• the trihydroiodoperfluoroalkane prepared by reaction of the perfluoroalkyl iodide with the perfluoroalkyltrihydroolefin may be used directly in the dehydroiodination step or may preferably be recovered and purified by distilled prior to the dehydroiodination step.
• the dehydroiodination step is carried out by contacting the trihydroiodoperfluoroalkane with a basic substance.
• Suitable basic substances include alkali metal hydroxides (e.g., sodium hydroxide or potassium hydroxide), alkali metal oxide (for example, sodium oxide), alkaline earth metal hydroxides (e.g., calcium hydroxide), alkaline earth metal oxides (e.g., calcium oxide), alkali metal alkoxides (e.g., sodium methoxide or sodium ethoxide), aqueous ammonia, sodium amide, or mixtures of basic substances such as soda lime.
• alkali metal hydroxides e.g., sodium hydroxide or potassium hydroxide
• alkali metal oxide for example, sodium oxide
• alkaline earth metal hydroxides e.g., calcium hydroxide
• alkaline earth metal oxides e.g., calcium oxide
• alkali metal alkoxides e.g., sodium methoxide or sodium ethoxide
• aqueous ammonia sodium amide
• Preferred basic substances are sodium hydroxide and potassium hydro
• Solvents suitable for the dehydroiodination step include one or more polar organic solvents such as alcohols (e.g., methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, and tertiary butanol), nitriles (e.g., acetonitrile, propionitrile, butyronitrile, benzonitrile, or adiponitrile), dimethyl sulfoxide, N,N-dimethylformamide, N,N-dimethylacetamide, or sulfolane.
• solvent may depend on the boiling point of the product and the ease of separation of traces of the solvent from the product during purification.
• the dehydroiodination reaction may be carried out by addition of one of the reactants (either the basic substance or the trihydroiodoperfluoroalkane) to the other reactant in a suitable reaction vessel.
• Said reaction vessel may be fabricated from glass, ceramic, or metal and is preferably agitated with an impellor or stirring mechanism.
• Temperatures suitable for the dehydroiodination reaction are from about 10°C to about 100°C, preferably from about 2O 0 C to about 70°C.
• the dehydroiodination reaction may be carried out at ambient pressure or at reduced or elevated pressure.
• dehydroiodination reactions in which the compound of Formula I is distilled out of the reaction vessel as it is formed.
• the dehydroiodination reaction may be conducted by contacting an aqueous solution of said basic substance with a solution of the trihydroiodoperfluoroalkane in one or more organic solvents of lower polarity such as an alkane (e.g., hexane, heptane, or octane), aromatic hydrocarbon (e.g., toluene), halogenated hydrocarbon (e.g., methylene chloride, ethylene dichloride, chloroform, carbon tetrachloride, or perchloroethylene), or ether (e.g., diethyl ether, methyl tert-butyl ether, tetrahydrofuran, 2-methyl tetrahydrofuran, dioxane, dimethoxyethane, diglyme, or tetraglyme) in the presence of a phase transfer catalyst.
• an alkane e.g., hexane, heptan
• Suitable phase transfer catalysts include quaternary ammonium halides (e.g., tetrabutylammonium bromide, tetrabutylammonium hydrosulfate, triethylbenzylammonium chloride, dodecyltrimethylammonium chloride, and tricaprylylmethylammonium chloride), quaternary phosphonium halides (e.g., triphenylmethylphosphonium bromide and tetraphenylphosphonium chloride), and cyclic ether compounds known in the art as crown ethers (e.g., 18-crown-6 and 15-crown-5).
• the dehydroiodination reaction may be conducted in the absence of solvent by adding the trihydroiodoperfluoroalkane to a solid or liquid basic substance.
• Suitable reaction times for the dehydroiodination reactions are from about 15 minutes to about six hours or more depending on the solubility of the reactants. Typically the dehydroiodination reaction is rapid and requires about 30 minutes to about three hours for completion.
• the compound of formula I may be recovered from the dehydroiodination reaction mixture by phase separation after addition of water, by distillation, or by a combination thereof.
• the compositions disclosed herein may comprise a single compound of Formula I, for example, one of the compounds in Table 1 , or may comprise a combination of compounds of Formula I.
• compounds presented in Table 2 can be used as blowing agents.
• bromine-containing fluorocarbons or hydrofluorocarbons presented in Table 3 can be used as blowing agents. TABLE 3
• 1-Bromo-3,3,4,4,4-pentafluoro-1-butene may be prepared by a three step sequence beginning with reaction of phosphorous tribromide with 3,3 ,4,4,4-pentafluoro-1-butanol to give 4- bromo-1 ,1 ,1 ,2,2- pentafluorobutane.
• Thermal bromination of 4- bromo-1, 1 ,1 , 2,2- pentafluorobutane at 350-400 0 C gives 4,4-dibromo-1 ,1,1,2,2- pentafluorobutane which may in turn be heated with powdered potassium hydroxide to give the desired bromobutene.
• 2-Bromo-3,4,4,4-tetrafluoro-3-(trifluoromethyl)-1-butene may be prepared by addition of bromine to 3,4,4-tetrafluoro-3-(trifluoromethyl)-1- butene followed by treatment of the resulting dibromide with ethanolic potassium hydroxide.
• HFC-1225ye may exist as one of two configurational isomers, E or Z.
• HFC-1225ye as used herein refers to the isomers, E-HFC-1225ye (CAS reg no. 5595-10-8) or Z-HFC-1225ye (CAS reg. no. 5528-43-8), as well as any combinations or mixtures of such isomers.
• Blowing agents can comprise a single compound as listed, for example, in Table 2, or may comprise a combination of compounds from Table 2 or, alternatively, a combination of compounds from Table 1 , Table 2, Table 3, and/or Formula I.
• FCs fluorocarbons
• HFCs hydrogen fluorocarbons
• the amount of the fluorocarbons (FCs) or HFCs contained in the present compositions can vary widely, depending the particular application, and compositions containing more than trace amounts and less than 100% of the compound are within broad the scope of the present disclosure.
• compositions disclosed herein may be prepared by any convenient method to combine the desired amounts of the individual components.
• a preferred method is to weigh the desired component amounts and thereafter combine the components in an appropriate vessel. Agitation may be used, if desired.
• foamable compositions and preferably thermoset or thermoplastic foam compositions, prepared using the compositions of the present disclosure.
• one or more of the present compositions are included as or part of a blowing agent in a foamable composition, which composition preferably includes one or more additional components capable of reacting and/or foaming under the proper conditions to form a foam or cellular structure.
• foam, and preferably closed cell foam prepared from a polymer foam formulation containing a blowing agent comprising the compositions of the present disclosure.
• the present disclosure further relates to a method for replacing or substituting for the blowing agent in a foamable composition having a GWP of about 150 or more, or a high GWP blowing agent, with a composition having a lower GWP.
• One method comprises providing a composition comprising at least one fluoroolefin of the present invention as the replacement.
• the foamable composition of the present invention having a lower GWP than the composition being replaced or substituted is used to produce thermoplastic or thermoset foams.
• Global warming potentials are an index for estimating relative global warming contribution due to atmospheric emission of a kilogram of a particular greenhouse gas compared to emission of a kilogram of carbon dioxide.
• GWP can be calculated for different time horizons showing the effect of atmospheric lifetime for a given gas.
• the GWP for the 100 year time horizon is commonly the value referenced.
• a high GWP blowing agent would be any compound capable of functioning as a blowing agent having a GWP at the 100 year time horizon of about 1000 or greater, alternatively 500 or greater, 150 or greater, 100 or greater, or 50 or greater.
• Foam expansion agents that are in need of replacement, based upon GWP calculations published by the
• Intergovernmental Panel on Climate Change include but are not limited to HFC-134a and HFC-227ea.
• the present disclosure will provide compositions that have zero or low ozone depletion potential and low global warming potential (GWP).
• the fluoroolefins of the present invention or mixtures of fluoroolefins of this invention with other blowing agents or foamable compositions will have global warming potentials that are less than many hydrofluorocarbon blowing agents or foamable compositions currently in use.
• the fluoroolefins of the present invention are expected to have GWP of less than about 25.
• One aspect of the present invention is to provide a blowing agent with a global warming potential of less than 1000, less than 500, less than 150, less than 100, or less than 50.
• Another aspect of the present invention is to reduce the net GWP of foamable compositions by adding fluoroolefins to said mixtures.
• the present invention further relates to a method for lowering the
• GWP of the methods for manufacturing open, closed and multi-modal foams comprising combining at least one fluoroolefin of the present invention with a resin (for thermoplastic foams) or into a B-side mixture (thermoplastic) to produce a foamable composition with a GWP of lower than 25.
• the GWP of may be determined that the GWP of a mixture or combination of compounds may be calculated as a weighted average of the GWP for each of the pure compounds.
• the present compositions also preferably have an Ozone Depletion Potential (ODP) of not greater than 0.05, more preferably not greater than 0.02 and even more preferably about zero.
• ODP Ozone Depletion Potential
• Certain embodiments provide foam premixes, foamable compositions, and preferably polyurethane or polyisocyanate foam compositions, and methods of preparing foams.
• one or more of the compositions of the present disclosure are included as a blowing agent in a foamable composition, which foamable composition preferably includes one or more additional components capable of reacting and/or foaming under the proper conditions to form a foam or cellular structure.
• foamable composition preferably includes one or more additional components capable of reacting and/or foaming under the proper conditions to form a foam or cellular structure.
• ingredients in preparing foams.
• additional ingredients are catalysts, surfactants, flame retardants, preservatives, colorants, antioxidants, reinforcing agents, filler, antistatic agents, nucleating agents and the like.
• Polyurethane foams are generally prepared by combining and reacting an isocyanate with a polyol in the presence of a blowing or expanding agent and auxiliary chemicals added to control and modify both the polyurethane reaction itself and the properties of the final polymer.
• these materials can be premixed into two non- reacting parts typically referred to as the "A-side” and the "B-side".
• the term "B-side” is intended to mean polyol or polyol containing mixture.
• a polyol containing mixture usually includes the polyol, the blowing or expanding agent and auxiliary chemicals, like catalysts, surfactants, stabilizers, chain extenders, cross-linkers, water, fire retardants, smoke suppressants, pigments, coloring materials, fillers, etc.
• A-side is intended to mean isocyanate or isocyanate containing mixture.
• An isocyanate containing mixture may include the isocyanate, the blowing or expanding agent and auxiliary chemicals, like catalysts, surfactants, stabilizers, chain extenders, cross-linkers, water, fire retardants, smoke suppressants, pigments, coloring materials, fillers, etc.
• A-side and B-side are then combined to react.
• a surfactant may comprise a liquid or solid organosilicone compound.
• Other, less preferred surfactants include polyethylene glycol ethers of long chain alcohols, tertiary amine or alkanolamine salts of long chain alkyl acid sulfate esters, alkyl sulfonic esters and alkyl arylsulfonic acids.
• the surfactants are employed in amounts sufficient to stabilize the foaming reaction mixture against collapse and to prevent the formation of large, uneven cells. About 0.2 to about 5 parts or even more of the surfactant per 100 parts by weight of polyol are usually sufficient.
• One or more catalysts for the reaction of the polyol with the polyisocyanate may also be used. Any suitable urethane catalyst may be used, including tertiary amine compounds and organometaliic compounds. Such catalysts are used in an amount which measurably increases the rate of reaction of the polyisocyanate. Typical amounts are about 0.1 to about 5 parts of catalyst per 100 parts by weight of polyol.
• Useful flame retardants include, for example, tri(2- chloroethyl)phosphate, tri(2-chloropropyl)phosphate, tri(2,3- dibromopropyl)-phosphate, tri(1 ,3-dichloropropyl) phosphate, diammonium phosphate, various halogenated aromatic compounds, antimony oxide, aluminum trihydrate, polyvinyl chloride, and the like.
• the methods of forming a foam generally comprise providing a blowing agent composition of the present disclosure, adding (directly or indirectly) the blowing agent composition to a foamable composition, and reacting the foamable composition under the conditions effective to form a foam or cellular structure.
• a blowing agent composition of the present disclosure adding (directly or indirectly) the blowing agent composition to a foamable composition, and reacting the foamable composition under the conditions effective to form a foam or cellular structure.
• Polyisocyanate-based foams are prepared, e.g., by reacting at least one organic polyisocyanate with at least one active hydrogen-containing compound in the presence of the blowing agent composition described herein-above.
• An isocyanate reactive composition can be prepared by blending at least one active hydrogen-containing compound with the blowing agent composition.
• the blend contains at least 1 and up to 50, preferably up to 25 weight percent of the blowing agent composition, based on the total weight of active hydrogen-containing compound and blowing agent composition.
• Active hydrogen-containing compounds include those materials having two or more groups which contain an active hydrogen atom which reacts with an isocyanate. Preferred among such compounds are materials having at least two hydroxyl, primary or secondary amine, carboxylic acid, or thiol groups per molecule. Polyols, i.e., compounds having at least two hydroxyl groups per molecule, are especially preferred due to their desirable reactivity with polyisocyanates. Additional examples of suitable active hydrogen containing compounds can be found in U.S. Patent 6,590,005, incorporated herein by reference.
• suitable polyester polyols include those prepared by reacting a carboxylic acid and/or a derivative thereof or a polycarboxylic anhydride with a polyhydric alcohol.
• the polycarboxylic acids may be any of the known aliphatic, cycloaliphatic, aromatic, and/or heterocyclic polycarboxylic acids and may be substituted, (e.g., with halogen atoms) and/or unsaturated.
• Suitable polycarboxylic acids and anhydrides include oxalic acid, malonic acid, glutaric acid, pimelic acid, succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid, trimellitic acid anhydride, pyromellitic dianhydride, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride acid, mal ⁇ ic acid, maleic acid anhydride, fumaric acid, and dimeric and trimeric fatty acids, such as those of oleic acid which may be in admixture with monomeric fatty acids.
• Simple esters of polycarboxylic acids may also be used such as terephthalic acid dimethylester, terephthalic acid bisglycol and extracts thereof.
• the polyhydric alcohols suitable for the preparation of polyester polyols may be aliphatic, cycloaliphatic, aromatic, and/or heterocyclic.
• the polyhydric alcohols optionally may include substituents which are inert in the reaction, for example, chlorine and bromine substituents, and/or may be unsaturated.
• Suitable amino alcohols such as monoethanolamine, diethanolamine or the like may also be used.
• Suitable polyhydric alcohols include ethylene glycol, propylene glycol, polyoxyalkylene glycols (such as diethylene glycol, polyethylene glycol, dipropylene glycol and polypropylene glycol), glycerol and trimethylolpropane.
• Suitable additional isocyanate-reactive materials include polyether polyols, polyester polyols, polyhydroxy-terminated acetal resins, hydroxyl- terminated amines and polyamines, and the like. These additional isocyanate-reactive materials include hydrogen terminated polythioethers, polyamides, polyester amides, polycarbonates, polyacetals, polyolefins, polysiloxanes, and polymer polyols.
• polyols include alkylene oxide derivatives of Mannich condensates, and aminoalkylpiperazine-initiated polyethers as described in U.S. Patent Nos. 4,704,410 and 4,704,411.
• the low hydroxyl number, high equivalent weight alkylene oxide adducts of carbohydrate initiators such as sucrose and sorbitol may also be used.
• the polyol(s), polyisocyanate and other components are contacted, thoroughly mixed and permitted to expand and cure into a cellular polymer.
• the particular mixing apparatus is not critical, and various types of mixing head and spray apparatus are conveniently used. It is often convenient, but not necessary, to preblend certain of the raw materials prior to reacting the polyisocyanate and active hydrogen-containing components. For example, it is often useful to blend the polyol(s), blowing agent, surtactant(s), catalyst(s) and other components except for polyisocyanates, and then contact this mixture with the polyisocyanate.
• all the components may be introduced individually to the mixing zone where the polyisocyanate and polyol(s) are contacted. It is also possible to pre-react all or a portion of the polyol(s) with the polyisocyanate to form a prepolymer.
• blowing agent composition employed when preparing a foam is sufficient to give a desired density to the foam.
• blowing agent composition preblends the blowing agent composition with the active hydrogen-containing compound before contacting the resulting blend with the polyisocyanate. It is also possible to simultaneously blend together the polyisocyanate, active hydrogen- containing compound and blowing agent composition in one operation resulting in the production of polyisocyanate-based foam. Preferably the blowing agent composition is blended with the active hydrogen-containing compound before contacting with the polyisocyanate. f
• One aspect is for a rigid, closed-celled polyisocyanate-based foam.
• the rigid closed-cell celled polyisocyanate-based foams are useful in spray insulation, as foam-in-place appliance foams, rigid insulating board stock, or in laminates.
• the blowing agents are used to blow thermoplastic foams, such as polystyrene, polyethylene foams, including low-density polyethylene foams, or polypropylene foams. Any of a wide range of conventional methods for blowing such thermoplastic foams can be adapted for use herein.
• a foamable composition comprising thermoplastic foams, such as polystyrene, polyethylene (PE), preferably low density PE, or polypropylene (PP).
• thermoplastic foam bodies are conveniently produced by using conventional equipment comprising an extruder and associated means for (1) melting the resin; (2) homogeneously blending the blowing agent composition with the melt to form a plasticized mass at nonfoaming temperatures and pressures; (3) passing the plasticized mass at a controlled rate, temperature and pressure through a die having a desired shape, e.g., slit die for producing rectangular slabs of foam board having desired thickness and surface area, into an expansion zone; (4) allowing the extrudate to foam in the expansion zone maintainable at suitable temperatures and low pressures; (5) maintaining the expanding extrudate under such temperatures and pressures for a time sufficient for the viscosity of the extrudate to increase such that the cell size and density of the foam remain substantially unchanged and substantially free of ruptured cells at ambient temperature; e.g., 25 0 C and atmospheric pressure; and (6) recovering the extruded foam body.
• nucleating agents serve primarily to increase cell count and decrease cell size in the foam, and may be used in an amount of about 0.1 to about 10 parts by weight per 100 parts by weight of the resin.
• Typical nucleating agents comprise at lease one member selected from the group consisting of talc, sodium bicarbonate- citric acid mixtures, calcium silicate, carbon dioxide, among others.
• the foaming amount of the blowing agent is in the range of from about 1 to about 30 weight percent based on the total weight of the resin plus blowing agent mixture, typically about 2 to 20 weight percent, and normally about 2 to about 10 weight percent.
• the proper amount of blowing agent or resultant characteristics of the foam for any desired end-use is readily determined by a skilled person in this art.
• the resin is melted at a temperature of about 200 to about 235 °C depending upon the grade employed, and at nonfoaming pressures of about 600 psig or higher.
• the plasticized resin- blowing agent mixture is cooled under nonfoaming pressure to a temperature of about 115 to 150 0 C, normally 130 "C 1 and extruded into the expansion zone at or below ambient temperature and at or below atmospheric pressure.
• the product was washed with 50 ml_ portions of 10 wt % aqueous sodium bisulfite and water, dried over calcium chloride, and then distilled at atmospheric pressure.
• the product, F24E (128.7 gm, 63%) boils at 95.5 0 C.
• polyurethane and polyisocyanurate foam samples were prepared by hand-mixing, using the two basic polyurethane foam formulations described in Example 4 and Example 5 below.
• the blowing agents may be generally premixed with the polyol or B-side for convenience.
• Foams may be prepared either as free-rise or molded samples. For free-rise foams, the reaction mixture is poured into an open, round cardboard container. For molded foams, the reaction mixture is poured into a 2 V- ⁇ x 13" x 15" (6.35 cm x 30.02 cm x 38.1 cm) heated aluminum mold.
• Example 4 Polvisocvanurate Foam
• polysiloxane surfactant (Dabco DC-193) 1.8 potassium octanoate catalyst (Hexcem 977) 3.2
• the core sample was about 2.2 pounds/ft 3 (PCF) (35.2 kg/m 3 ) density, had an exceptionally fine cell structure, and remained dimensionally stable. Magnified photographs of the foam showed a uniform, highly closed cell structure and cell sizes about 200-300 microns ( ⁇ ).
• initial insulation value R-value was measured at 7.4/inch (thermal conductivity of 19.5 milliW/(mK) at a mean temperature of 24.0 0 C or 0.135 BTU-in/hr- ft 2 -°F at a mean temperature of 75.2°F).
• silicone surfactant (Witco L-6900) 3.0 ⁇ ;H-b ⁇ rh' ⁇ thylcyc!bn"exylamine catalyst 1.7
• the core sample was about 2.0 pounds/ft 3 (PCF) (32.0 kg/m 3 ) density, had a good cell structure though it did contain some voids, and remained dimensionally stable. Magnified photographs of the foam showed a uniform, highly closed cell structure, excluding the voids, and cell sizes about 200-300 microns ( ⁇ ).
• initial insulation value was measured at 4.9/inch (29.5 miHiW/(mK) at a mean temperature of 24.0 0 C or thermal conductivity of 0.2044 BTU-in/hr-ft 2 -°F at a mean temperature of 75.2°F),
• the blowing agent was not mixed as thoroughly in the B- side. In this case, voids were observed in the foam, but the cell structure excluding the voids remained small and consistent. The resultant insulation value was acceptable despite the voids, demonstrating that these unsaturated fluorocarbons can improve cell structure and foam properties such as to overcome potential processing difficulties that otherwise would detrimentally impact foam performance.
• thermoplastic foam insulation specifically a polystyrene insulation foam
• a commercial tandem extruder equipped with die designed for insulation board foam
• Such a configuration employs a primary extruder and a secondary extruder, with a slit die.
• a typical polystyrene resin would be Shell NX600 general purpose, 2.5 melt index, and a typical nucleator would be magnesium silicate talc.
• polystyrene foam sheet is prepared using unsaturated fluorocarbons as the blowing agent.
• the polystyrene foam sheet is ultimately thermoformed into food service packaging, like egg cartons, hamburger cartons, meat trays, plates, etc.
• Foam sheet is produced using a conventional tandem extrusion system. Foam is extruded through an annular die, stretched over a mandrel about 4 times the die's diameter, and slit to produce a single sheet.
• a typical formulation is:
• the polystyrene sheet is typically extruded to a thickness of 50 to 300 mils and at a rate of approximately 1 ,000 pounds of plastic per hour. Typical extruder conditions range from 1 ,000 to 4,000 psi (70.3 kg/cm to 281.3 kg/cm) and 200 0 F to 400 0 F (93.3 0 C to 204.4 0 C).
• the blowing agent concentration in the feed material will change depending on the desired thickness (thicker product requires more blowing agent).
• the rolls of foam are thermoformed, producing the desired type of end-product (e.g., clam-shell containers, plates, etc.).
• HFC-1225ye 1 ,2,3,3,3-pentafluoro-1-propene (HFC-1225ye), 1 ,1- difluoroethane (HFC-152a) and 1 ,1 ,1 ,2-tetrafluoroethane (HFC-134a) were all analyzed by GC/MS prior to the testing and were found to be 100% pure.
• test data show that HFC-1225ye was surprisingly as stable as HFC- 134a and more stable than HFC-152a under extrusion conditions.
• the steel coupons from runs 32a, 32b and 24d were analyzed by Electron Spectroscopy for Chemical Analysis (ESCA). Fluoride ions (F " ) were observed on the surface of all coupons. Estimated concentrations of fluoride ion are shown in the table below.

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