IE20080931A1

IE20080931A1 - Polyurethane or polyisocyanurate compositions and methods of producing same

Info

Publication number: IE20080931A1
Application number: IE20080931A
Authority: IE
Inventors: Eamonn Blair
Original assignee: Gates Patent Ltd
Priority date: 2007-11-21
Filing date: 2008-11-21
Publication date: 2009-07-08
Also published as: IES20070849A2; GB0821349D0; GB2454990A

Abstract

A composition for producing a polyurethane or polyisocyanurate rigid foam wherein the composition comprises at least one polyol, at least one isocyanate and an extender. The at least one polyol may comprise a polyisocyanurate which reacts with the isocyanate to produce polyisocyanurate rigid foam for use, particularly, in insulation application in walls and roofs. The extender used preferably comprises castor oil and the composition also preferably includes a reinforcing material which may be a fibre-reinforcing material or a particle reinforcing material.

Description

The present invention relates to compositions for producing polyurethane or polyisocyanurate foams particularly rigid foams, for use as insulation media.

BACKGROUND OF THE INVENTION Mixing liquid polyol’s and isocyanates produces compositions of varying elasticity ranging from very flexible elastomers to semi-rigid and rigid foams. It is well known that the polyols and isocyanates are so highly reactive when combined that they are kept separate until just when they are required to be combined together in situ. This separate storage of the polyol component and the isocyanate component is referred to as a two-component system including the polyol component (part A) and the isocyanate component (part B). Immediately after mixing the polyol and isocyanate, there is a chemical reaction, which is accompanied by a rise in temperature. Blowing agents in the polyol-isocyanate mix start to evaporate due to the heat of the reaction, causing the mixture to expand to between 30 and 50 times its original volume. The result is rigid polyurethane foam consisting of millions of closed cells, which tightly enclose the blowing agent. Catalysts are used to control the rate of the reaction.

There are a number of patent publications relating to the use of polyurethane and other single and two component systems suitable for use as an insulating media and as an impact absorbing material.

US Patent Specification Nos. 6,472,444 and 6,746,759 disclose the use of closed cell phenolic foams for use in the manufacture insulation media. While being flame resistant, the issue of the long-term structural integrity of phenolic foams is likely to give rise to problems in the future. Such problems may include overall structural integrity and insulation value, primarily due to the absorption or water. Water may be absorbed particularly if products made from phenolic foam are stored in wet or damp conditions. There is also evidence to suggest that phenolic foam will absorb water when used in the fabrication of insulated sandwich panels such as those found in wall and roof panels as used in building construction. fioeou US Patent Specification No. 6,743,483 discloses the use of polyurethane, polyisocyanurate and phenolic foams, which are commonly used in the manufacture of insulating boards for wall insulation. Notwithstanding the issues relating to the long-term integrity of phenolic foam, referred to above, the overall cost per kilo of both polyurethane and polyisocyanurate will have a significant impact on the use of these materials in the future.

US Patent Specification No. 4,190,547 discloses a composition of insulated sheets using perlite and vermiculite with either a melamine/formaldehyde or phenol/formaldehyde binder. The use of a cancer causing and environmentally negative agent such as formaldehyde in these types of material is a significant disadvantage associated with these materials.

US Patent Specification No. 4,885,206 discloses the use of melamine resin form laminates.

It should be noted that it is well understood within the art that polyisocyanurate foams are modified polyurethanes and generally it is understood by the skilled person in the art that references to the term, polyurethane(s) includes polyisocyanurates.

The present invention seeks to alleviate the disadvantages associated with the prior art.

The present invention accordingly provides a composition for producing polyurethane or polyisocyanurate foam wherein the composition comprises at least one polyol, at least one isocyanate and an extender.

In the compositions of the present invention, the polyol may comprise a polyisocyanurate.

The polyurethane and polyisocyanurate foams produced from the compositions of the present invention can comprise either open cell foams or closed cell foams. However, the foams produced from the compositions in accordance with the present invention are rigid foams (not flexible foams).

The present invention provides oil-extended, and fibre and/or particle reinforced rigid polyurethane compositions, methods of making same and uses thereof. «ο am f «080091 The present invention also provides oil-extended, and fibre and/or particle reinforced rigid polyisocyanurate compositions, methods of making same and uses thereof.

The present invention also provides a polyurethane or polyisocyanurate insulation media manufactured from the polyurethane and polyisocyanurate foam compositions of the present invention.

The polyol’s in the composition may comprise polyester polyol’s or polyether polyol’s, used separately or as blends thereof. The isocyanate may comprise polymeric diphenylmethane-4-4 Diisocyanate. Other organic polyisocyanates which could be used in the invention include hexamethylene Diisocyanate, polymethylene polyphenyl isocyanate, m-phenylene Diisocyanate, p-phenylene Diisocyanate, 3,3-dimethyl -4-4 diphenyl Diisocyanate, methylene (2-methyl-p-phenylene) Diisocyanate, 3,3-dimethoxy-4-4 biphenylene Diisocyanate, 2-2,4-4 tetramethyl-4-4 biphenylene Diisocyanate, 3,3dimethyl-4-4 diphenylamine Diisocyanate, 4’4-diphenyl isopropylidene Diisocyanate, T5naphthylene Diisocyanate and polymethylene polyphenyl isocyanate.

Preferably, the extender is an oil and most preferably the oil comprises castor oil. Ideally, the castor oil has an iodine value of 82 to 90, a saponification value of 170 to 190, and an acetyl value of 135 to 145.

The castor oil is preferably included in amounts of between 5% w/w to 55% w/w.

The technical advantage associated with using castor oil as the oil extender is that it chemically binds to the polyurethane or polyisocyanurate molecule and does not leach out over time.

More preferably, the castor oil is included in amounts of between 15% w/w to 37% w/w.

Castor oil is most preferably included in amounts of between 20% w/w to 30% w/w.

Advantageously, the composition comprises a reinforcing material and conveniently, the reinforcing material may comprise a fiber reinforcing material. «min Ho8oi3f The reinforcing material ideally comprises any one or more selected from the following group: Polyacronitrile fibres, polyamide fibres, polyester fibres, glass, mineral wool, rayon, uncoated or epoxy coated carbon filament, or jute fibres in a ground state.

Using these reinforcing materials has the advantage that the composition has a viscosity that is easy to work with, while on the other hand using jute fibres in an unground state was found to produce a polyurethane composition which was too thick and paste-like to provide good flow characteristics to enable spraying through a nozzle, as may be required for in situ applications.

The composition for insulation media in accordance with the present invention includes any of the above fibre materials either on their own or blended with each other. Ideally, the fibre material has an average particle length of preferably 0.1 to 30mm.

Preferably, the fibre material has a particle length of more preferably in the range, 5mm to 15mm.

Ideally, the fibre material has a particle size of most preferably 7mm to 11mm.

Advantageously, the above fibres or blends thereof are included in amounts from 0.5% w/w to 2.0% w/w, most preferably from 0.5 to 1.5% w/w. It was found that amounts in excess of 2.0% w/w reduced the flow properties of the mixture.

As an alternative to, or in addition to the fibre reinforcing material, the reinforcing material may comprise particle-reinforcing material, such as perlite, vermiculite, or glass microspheres, for instance.

Ideally, perlite included in the composition comprises expanded perlite having a particle size of 0.01 to 3 mm.

The expanded perlite has a most preferable particle size of 1.0mm to 2.0mm.

Alternatively, the reinforcing particle material comprises expanded vermiculite having a preferred particle size of 1.0mm to 2.0mm.

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The reinforcing material may comprise soda-lime borosilicate glass microspheres as a high strength reinforcing material, the microspheres preferably having an average particle size of 0.0001 μ to 0.001 μ. Such soda-lime borosilicate glass microspheres are available from 3M as Type K1 Microspheres. The glass microspheres have a separate function from perlite and vermiculite. The glass microspheres have been found to increase the tensile strength and impact resistance of the foam produced. This impact resistance will be beneficial where the foam is used in impact resistance bumpers as used in motor vehicles, crash barriers etc. The vermiculite is preferable in the manufacture of foam as used in manufacturing insulated sandwich panels. Vermiculite has a low specific gravity and does not detract measurably from the insulation value of the sandwich panels manufactured using it.

Preferably, the insulating media composition comprises a water scavenger which is selected from the group comprising micro porous potassium alumosilicate Zeolite water scavengers, calcium alumosilicate Zeolite water scavengers and sodium alumosilicate Zeolite water scavengers.

Ideally, the insulating media composition includes micro porous zeolites as moisture scavengers and these are included in amounts of 0.1 % w/w to 3% w/w.

Advantageously, the oil-extended fibre reinforced polyurethane insulating media may further comprise a flame retardant using the following materials as flame retardants either singularly or in blends: ammonium polyphosphate, ammonium polyphosphate microencapsulated with melamine, a non-halogenated phosphorus polyol, tris-225 chloroethyl phosphate or tris-2-chloroisopropyl phosphate.

Preferably, the flame retardant is included in the composition in an amount from 5% w/w to 25% w/w.

Most preferably, the flame retardant is included in amounts from 10% w/w to 20% w/w.

The water scavenger may comprise a reactive monofunctional isocyanate.

Preferably, the quantity of monofunctional isocyanate in the composition as a water scavenger, is most preferably, between 0.5% w/w and 4.0% w/w.

ISC «931 (Ιο9Hit The composition may also comprise a filler, preferably selected from one or more of the following group: wood sawdust, cocoa shells and cork, optionally in the form of cork chips.

Preferably, the insulating media composition comprises 5% to 10% w/w of the filler. Preferably the filler comprises wood sawdust and the sawdust may be composed of several types of timber, specifically medium density fibreboard (MDF), orientated strand board (OSB), chip board, pine or plywood.

Conveniently, if the filler comprises cocoa shells, the cocoa shells have a preferred particle size range of 1 to 2 mm.

The present invention also provides a method for producing a polyurethane or polyisocyanurate insulating media wherein the method comprises the following steps: (a) adding polyisocyanate or polyisocyanurate to a mixing chamber; and (b) adding extender.

Ideally, the method also includes the step of adding reinforcing material.

Preferably, the extender comprises an oil extender, most preferably castor oil.

Preferably, the method further includes the step of adding a tertiary amine catalyst such as 4,2, {1-methyl -2-(4-morpholinyl) ethoxy} -ethyl morpoline (MEMPE).

Ideally, the method includes the step of adding the catalyst at an addition level of between 0.1 % and 0.5% of the total formulation.

The method advantageously includes the step of adding a filler at an addition level of 10% to 20%.

/Ii 1 iheitjf Preferably, the filler comprises wood sawdust, cocoa shells and/or cork, optionally in the form of cork chips.

The method for producing an insulating media specifically for the manufacture of insulated wall and roof panels preferably includes the step wherein the castor oil is mixed in with the polyol/ isocyanate in the mixing chamber before it is cast onto a sheet of steel.

Thus, in accordance with the method of the invention, the reinforcing material added comprises fibre material selected from one or more of the following group: ground fibres such as polyacrylonitrile, polyamide, polyester, glass, mineral wool, rayon, uncoated or epoxy coated carbon filament, jute or chopped fibres such as polyacrylonitrile, polyamide, polyester, polypropylene and viscose. Thus, the chosen fibre reinforcing material may comprise one material chosen from the aforementioned group or two or more materials in combination.

Also, in accordance with the invention, the particle reinforcing material may comprise perlite or vermiculite preferably, having an average particle size of 1mm to 2mm.

An advantage of the present invention is that the use of extender oil in the formulation reduces the cost per litre (i.e. litre cost) of polyurethane and polyisocyanurate.

The advantage of the use of reinforcing fibre material in the formulation produces foam with increased flexural and tensile strength. Reinforcement by using the fibre reinforcing material also enables higher impact absorption. The use of reinforcing particle material (reinforcing particles) improves the workability of foam, particularly in insulating panelmanufacturing lines using the discontinuous process. Unlike the continuous process where panels are made in a continuous line using steel fed from two large coils, the discontinuous process is more suited towards small panel manufacturers. In this process, one lightly corrugated steel sheet is placed on a bed. Foam stoppers with breather holes in them are placed at each end of the corrugated bottom sheet. The foam stoppers are normally attached to the bottom sheet using double side tape. The top sheet is then bonded to the top edges of the foam stoppers. This in effect produces a hollow panel. The polyurethane or polyisocyanurate foam filling is then injected into the panel through the iionn Kobo»)! front breather holes, the back breather holes allow for the escape of air. The panel so formed is allowed to sit in the casting machine until the foam has solidified.

The reinforcing particle material also assists in minimizing breaking during curing.

The present invention relates to non-flammable insulation media which can be used as an insulating media in building construction, specifically in the manufacture of metal faced sandwich panels using either the continuous or discontinuous process. The product may also be used as insulating media in the manufacture of cold stores such as transport containers, fridges, ovens, etc. The composition may also be used as an insulating media in the manufacture of boilers, district heating pipes and water storage tanks. The product may also be used for in-situ insulation of ships holds, etc. Furthermore, the present invention may also be used in the manufacture of impact absorbing material for use in the packaging and automotive sector.

The invention will now be described more particularly with reference to the Examples hereinbelow, which provide by way of example only, a number of embodiments of compositions for producing the polyurethane and polyisocyanurate foams in accordance with the present invention.

Example 1 Component/Kiloqrams for polyurethane foam % (w/w) Part A (polyol component) Voracor CD 827 (Polyol) 31.50 No. 1 First Pressing Castor Oil 29.38 Polyacrylonitrile fibres PAC 8mm 3.00 Vermiculite 1.00 Part B (isocyanate component) Voracor CE 345 (Isocyanate) 35.12 Voracor CD 827 is a polyol with an NCO content of 31%.

Voracor CE 345 is an isocyanate crosslinking agent.

The No. 1 first pressing Castor Oil comprises fixed ricinus oil obtained from the seeds of Ricinus Communis (Euphorbiaceae). The polyacrylonitrile fibres comprise 6.7-dtex dumbbell shaped fibres having a fibre length of 8mm. Vermiculite comprises a hydrated magnesium-aluminium-iron silicate with the following composition, SiO2 38,64%, MgO 22.68%, AI2O3 14.94%, Fe2O3 9.29%, K2O 7.84%, CaO 1.23%, Cr2O3 0.29%, Mn3O4 0.11%, Cl 0.28%.

Alternatively, the No. 1 first pressing oil may be replaced with polyurethane castor oil.

To prepare the polyol resin mixture, which is one component (Part A) of the composition for producing polyurethane (PU) or polyisocyanurate (PIR) foams, the following process was used: 1. The mixer was charged with the Voracor CD 837 polyol. A P7 type mixing head was lowered into the polyol and set to run at 70 RPM. 2. After 60 seconds, the polyacrylonitrile fibres were slowly added to the polyol, being sure that all of the fibres were thoroughly wetted by the polyol before the next quantity was added. 3. After 120 seconds, the vermiculite was added to the polyol and allowed to mix for 120 seconds. 4. The No. 1 Pressing Castor Oil was finally added over a five minute period. The batch was allowed to cool before decanting.

Prior to using in situ, the part A component above is blended with part B, i.e. Voracor CE 25 345 (isocyanate) in the usual way, which may involve the two parts (part A and part B) of the composition being brought into contact with each other in the nozzle head of a spray dispenser. ΜΟβΗΠ Example 2 Component/Kiloqrams for polyisocyanurate foam % (w/w) Part A (polyol component) Voracor CD 846 (polyisocyanurate) 30.00 No. 1 First Pressing Castor Oil 23.80 Polyacrylonitrile fibres PAC 8mm 2.00 Vermiculite 1.00 Part B (isocyanate component) Voracor CE 345 (Isocyanate) 43.20 Voracor CD 846 is a polyisocyanurate in liquid form (thus, in Example 2 the polyol is a polyisocyanurate).

Voracor CE 345 is an isocyanate crosslinking agent.

To prepare the polyisocyanurate resin mixture (i.e. the part A component), the following process was used: 1. The mixer was charged with the CD 846 polyisocyanurate and set to run at 70 RPM using the P7 mixing head. 2. After 60 seconds, the polyacrylonitrile fibres were again slowly added. 3. After 120 seconds, the vermiculite was added and allowed to mix for 120 second. 4. The No. 1 Pressing Castor Oil was finally added over a five-minute period. The batch was allowed to cool before decanting.

I ί(|ο«3 9 3ΐ »089931 11 Prior to using in situ, the part A component above is blended with part B, i.e. Voracor CE 345 (isocyanate) in the usual way, which may involve the two parts (part A and part B) of the composition being brought into contact with each other in the nozzle head of a spray dispenser.

In addition to the above formulations, other reinforcing media may be added which increase the structural integrity of the foam produced while reducing its kilo cost. Such additional reinforcing media may consist of inert fillers (10% to 20% w/w) such as cork chips and/or cocoa shells.

In addition, it is possible to include in the insulating media composition of the present invention, a range of renewable raw materials in small but functional additions. Currently, these materials are committed to landfill and it has been found that they compatible with polyurethane and polyisocyanurate systems. Such materials may consist of wood, flax, hemp, sisal, jute and cotton. Fibrous materials, in particular, have shown to give increased flexural strength. These materials may be added in ranges or 5% to 12%.

In addition to the above materials, sawdust may be added as an inert filler. Tests have shown that the use of sawdust at an application level of 5% to 10% does not increase the flammability of the polyurethane rigid foam and does reduce the kilo cost of the system.

Application The polyol/isocyanate composition as detailed above may be applied using any of the currently used casting machines. For the manufacture of insulated wall and roof panels, using the continuous or discontinuous process, the standard application head may be used although it has been found through experiment that it is better to allow the No 1 castor oil mixtdre to mix with the polyol/isocyanate/additive package in the standard mixing chamber before it is cast onto steel sheets.

Ilo 8 09)1 Additional Formulae using Glass Spheres/ Fibres/ Vermiculite (All formulae % by weight) (Examples 3,4, 5 based on polyurethane, Examples 6, 7, 8 based on 5 polyisocyanurate) Example 3 Voracor CD 827 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 29.38 Polyacronitrile Fibres PAC 8mm 2.0 Vermiculite 1.0 3M Type K1 Microspheres 1.0 Example 4 Voracor CD 827 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 19.38 Polyacronitrile Fibres PAC 8mm 2.0 Cork chips (particle size 2mm-4mm) 11.0 3M Type K1 Microspheres 1.0 Example 5 Voracor CD 827 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 19.38 Polyacronitrile Fibres PAC 8mm 2.0 MDF/OSB (particle size 2.5mm-3.5mm) 11.0 3M Type K1 Microspheres 1.0 Method The method used in Examples 3, 4 and 5 is as described above for Example 1.

Example 6 Voracor CD 846 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 29.38 Polyacronitrile Fibres PAC 8mm 2.0 Vermiculite 1.0 3M Type K1 Microspheres 1.0 IE0S093H Example 7 Voracor CD 846 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 19.38 Polyacronitrile Fibres PAC 8mm 2.0 Cork chips (particle size 2mm-4mm) 11.0 3M Type K1 Microspheres 1.0 Example 8 Voracor CD 846 31.50 Voracor CE 345 35.12 No. 1 First Pressing Castor Oil 19.38 Polyacronitrile Fibres PAC 8mm 2.0 MDF/OSB (particle size 2.5mm-3.5mm) 11.0 3M Type K1 Microspheres 1.0 Method The method used in Examples 6, 7 and 8 is as described above for Example 2.

It is to be understood that the invention is not limited to the specific details described here which are given by way of example only and that various modification and alterations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

CLAIMS:

1. A composition for producing a polyurethane or a polyisocyanurate foam wherein the composition comprises at least one polyol, at least one isocyanate, an extender.

2. A composition as claimed in claim 1 wherein the at least one polyol comprises a polyisocyanurate.

3. A composition as claimed in any one of the preceding claims wherein the at least one isocyanate is selected from the group comprising: polymeric diphenylmethane-4-4 Diisocyanate, hexamethylene Diisocyanate, polymethylene polyphenyl isocyanate, mphenylene Diisocyanate, p-phenylene Diisocyanate, 3,3-dimethyl -4-4 diphenyl Diisocyanate, methylene (2-methyl-p-phenylene) Diisocyanate, 3,3-dimethoxy-4-4 biphenylene Diisocyanate, 2-2,4-4 tetramethyl-4-4 biphenylene Diisocyanate, 3,3dimethyl-4-4 diphenylamine Diisocyanate, 4’4-diphenyl isopropylidene Diisocyanate, 1’5naphthylene Diisocyanate and polymethylene polyphenyl isocyanate.

4. A composition as claimed in any one of the preceding claims wherein the at least one polyol in the composition for producing a polyurethane comprises a polyester polyol or a polyether polyol, used separately or as a blend thereof.

5. A composition as claimed in any preceding claim wherein the extender comprises an oil.

6. A composition as claimed in claim 5 wherein the extender comprises castor oil.

7. A composition as claimed in claim 6 wherein the castor oil has an iodine value of 82 to 90, a saponification value of 170 to 190, and an acetyl value of 135 to 145.

8. A composition as claimed in claim 6 or 7 wherein the castor oil is included in the composition in an amount of between 5% w/w to 55% w/w.

9. A composition as claimed in any one of claims 6 to 8, wherein the castor oil is included in the composition in an amount of between 15% w/w to 37% w/w.

10. A composition as claimed in any one of claims 6 to 9 wherein castor oil is included in the composition in an amount of between 20% w/w to 30% w/w.

11. A composition as claimed in any one of the preceding claims wherein the 5 composition further comprises a reinforcing material.

12. A composition as claimed in claim 11 wherein the reinforcing material comprises a fibre reinforcing material. 10

13. A composition as claimed in claim 11 or 12 wherein the reinforcing material comprises any one or more, either on its own or blended with another, selected from the following group: Polyacronitriie fibres, polyamide fibres, polyester fibres, glass fibres, mineral wool, rayon, uncoated or epoxy coated carbon filament, or jute fibres in a ground state.

14. A composition as claimed in any one of claims 12 or 13 wherein the fibre reinforcing material has an average particle length of between 0.1mm to 30mm.

15. A composition as claimed in any one of claims 12 to 14 wherein the fibre 20 reinforcing material has a particle length in the range of 5mm to 15mm.

16. A composition as claimed in any one of claims 12 to 15 wherein the fibre reinforcing material has a particle size in the range of 7mm to 11mm. 25

17. A composition as claimed in any one of claims 12 to 16 wherein the fibre reinforcing material is included in an amount of from 0.5% w/w to 2.0% w/w.

18. A composition as claimed in claim 17 wherein the fibre reinforcing material is included in an amount of from 0.5 w/w to 1.5 % w/w.

19. A composition as claimed in claims 11 or 12 wherein the reinforcing material comprises particle-reinforcing material. »08993

20. A composition as claimed in claim 19 wherein the particle reinforcing material comprises any one or more selected from the following group: perlite, vermiculite, or glass microspheres.

21. A composition as claimed in claim 20 wherein any perlite included in the composition comprises expanded perlite having a particle size of from 0.01 to 3 mm.

22. A composition as claimed in claim 21 wherein the expanded perlite has a particle size in the range of from 1.0mm to 2.0mm.

23. A composition as claimed in claim 20 wherein any vermiculite included in the composition comprises expanded vermiculite having a particle size in the range of from 1.0mm to 2.0mm.

24. A composition as claimed in claim 20 wherein the particle-reinforcing material comprises glass microspheres including soda-lime borosilicate glass microspheres as the high strength reinforcing material, and wherein the microspheres preferably have an average particle size of 0.0001 μ to 0.001 μ.

25. A composition as claimed in any one of the preceding claims wherein the composition further comprises a water scavenger.

26. A composition as claimed in claim 25 wherein the water scavenger is selected from any one or more of the group comprising: micro porous potassium alumosilicate Zeolite water scavengers, calcium alumosilicate Zeolite water scavengers and sodium alumosilicate Zeolite water scavengers.

27. A composition as claimed in claim 26 wherein the micro porous zeolites moisture scavengers are included in an amount of between 0.1% w/w to 3% w/w.

28. A composition as claimed in any one of the preceding claims wherein the composition further comprises a flame retardant.

29. A composition as claimed in claim 28 wherein the flame retardant is selected from any one or more of the following group: ammonium polyphosphate, ammonium If 0 8 0· polyphosphate microencapsulated with melamine, a non-halogenated phosphorus polyol, tris-2-chloroethyl phosphate or tris-2-chloroisopropyl phosphate.

30. A composition as claimed in claims 28 or 29 wherein the flame retardant is included in the composition in an amount of from 5% w/w to 25% w/w.

31. A composition as claimed in any one of claims 28 to 30 wherein the flame retardant is included in an amount of from 10% w/w to 20% w/w.

32. A composition as claimed in claim 26 wherein the water scavenger comprises a monofunctional isocyanate in an amount of between 0.5% w/w and 4.0% w/w.

33. A composition as claimed in any one of the preceding claims wherein the filler is selected from one or more of the following group: wood sawdust, cocoa shells and cork, optionally in the form of cork chips.

34. A composition as claimed in claim 33 wherein the composition comprises 5% to 10% w/w wood sawdust.

35. A composition as claimed in claim 33 or 34 wherein the sawdust comprises a plurality of types of timber, namely, medium density fibreboard (MDF), orientated strand board (OSB), chip board, pine or plywood.

36. A composition as claimed in claim 33 wherein the cocoa shells, having a particle size in the range of 1-2 mm.

37. A polyurethane or polyisocyanurate foam insulation media manufactured from the compositions as claimed in any one of the preceding claims.

38. A method of preparing a polyol component for producing a polyurethane or polyisocyanurate foam wherein the method comprises the following steps: (a) adding a polyisocyanate or polyisocyanurate in liquid form, to a mixing chamber; IE Ο 9 09 J1 (b) and adding extender, and optionally adding a reinforcing material.

39. A method as claimed in claim 38 wherein the extender comprises an oil extender, preferably, castor oil.

40. A method as claimed in claim 38 wherein the method further includes the step of adding a tertiary amine catalyst.

41. A method as claimed in claim 40 wherein the catalyst comprises 4,2, {1-methyl -210 (4-morpholinyl) ethoxy} -ethyl morpoline (MEMPE).

42. A method as claimed in claim 40 or 41 wherein the method includes the step of adding the catalyst at an addition level of between 0.1 % w/w and 0.5% w/w of the total composition.

43. A method as claimed in any one of claims 38 to 42 wherein the method includes the step of adding a filler at an addition level of 10% to 20% w/w.

44. A method as claimed in claim 43 wherein the filler is selected from any one or 20 more of the following group: wood sawdust, cocoa shells and cork, optionally in the form of cork chips.

45. A method as claimed in claim 39 wherein the method for producing a polyurethane or polyisocyanurate foam for use as an insulating media in insulated wall and roof panels, 25 includes the step of mixing the castor oil in with the polyol and isocyanate in the mixing chamber before it is cast onto a sheet of steel.

46. A method as claimed in claim 38 wherein the reinforcing material comprises fibre material selected from one or more of the following group: ground fibres such as 30 polyacrylonitrile fibres, polyamide fibres, polyester fibres, glass fibres, mineral wool, rayon, uncoated or epoxy coated carbon filament, jute or chopped fibres such as polyacrylonitrile, polyamide, polyester, polypropylene and viscose. ΙίΟβΟίή

47. A method as claimed in claim 46 wherein the particle reinforcing material comprises perlite or vermiculite, preferably, having an average particle size of 1mm to 2mm. 5

48. Rigid polyurethane foam compositions, methods of making same and uses thereof, substantially as herein described in the Examples.

49. Rigid polyisocyanurate foam compositions, methods of making same and uses thereof, substantially as herein described in the Examples.