IES20070849A2 - Polyurethane or polyisocyanurate compositions and methods of producing same - Google Patents

Polyurethane or polyisocyanurate compositions and methods of producing same

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Publication number
IES20070849A2
IES20070849A2 IE20070849A IES20070849A IES20070849A2 IE S20070849 A2 IES20070849 A2 IE S20070849A2 IE 20070849 A IE20070849 A IE 20070849A IE S20070849 A IES20070849 A IE S20070849A IE S20070849 A2 IES20070849 A2 IE S20070849A2
Authority
IE
Ireland
Prior art keywords
optionally
reinforcing material
composition
fibres
diisocyanate
Prior art date
Application number
IE20070849A
Inventor
Eamonn Blair
Original Assignee
Gates Patent Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Gates Patent Ltd filed Critical Gates Patent Ltd
Priority to IE20070849A priority Critical patent/IES20070849A2/en
Priority to GB0821349A priority patent/GB2454990A/en
Priority to IE20080931A priority patent/IE20080931A1/en
Publication of IES20070849A2 publication Critical patent/IES20070849A2/en

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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
    • C08G18/30—Low-molecular-weight compounds
    • C08G18/36—Hydroxylated esters of higher fatty acids
    • 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
    • C08G18/14—Manufacture of cellular 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
    • 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
    • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
    • C08G18/4288—Polycondensates having carboxylic or carbonic ester groups in the main chain modified by higher fatty oils or their acids or by resin acids
    • 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
    • C08G18/50—Polyethers having heteroatoms other than oxygen
    • C08G18/5021—Polyethers having heteroatoms other than oxygen having nitrogen
    • C08G18/5036—Polyethers having heteroatoms other than oxygen having nitrogen containing -N-C=O groups
    • C08G18/5045—Polyethers having heteroatoms other than oxygen having nitrogen containing -N-C=O groups containing urethane groups
    • 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
    • C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
    • C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
    • C08G18/6629—Compounds of groups C08G18/42, C08G18/48, or C08G18/52 with compounds of group C08G18/36 or hydroxylated esters of higher fatty acids of C08G18/38
    • 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
    • C08G18/83—Chemically modified polymers
    • C08G18/831—Chemically modified polymers by oxygen-containing compounds inclusive of carbonic acid halogenides, carboxylic acid halogenides and epoxy halides
    • 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
    • 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
    • C08G2115/00—Oligomerisation
    • C08G2115/02—Oligomerisation to isocyanurate groups

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

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 extended used preferably comprises castor oil and the composition also preferably included a reinforcing material which may be a fibre-reinforcing material or a particle reinforcing material.

Description

PRODUCING SAME The present invention relates to compositions for polyurethane or polyisocyanurate 5 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. 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.
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.
IE Ο 7 Ο 8 4 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 materiafs.
US Patent Specification No. 4,885,206 discloses the use of melamine resin form laminates.
The present invention seeks to alleviate the disadvantages associated with the prior art.
The present invention accordingly provides a polyurethane or polyisocyanurate composition wherein the composition comprises an extender and a reinforcing material, Thus, the present invention provides oil-extended, and fibre and/or particle reinforced rigid polyurethane compositions, methods of making same and uses thereof.
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 above compositions.
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 Diisocyanale, 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, Γ5naphthylene Diisocyanate and polymethylene polyphenyl isocyanate.
IE Ο 7 Ο 8 4 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 between5% 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 polytsocyan urate 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.
The reinforcing material may comprise a fiber reinforcing material.
The fibre material ideally comprises any one or more selected from the following group: Polyacronitrile, polyamide, polyester, glass, mineral wool, rayon, uncoated or epoxy coated carbon filament, or jute fibres either in a ground or unground state.
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.
IE 0 7 0 6 4 ^ 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 5mm, 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.
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, calcium and sodium alumosilicate Zeolite water scavenges.
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 IE Ο 7 ο 8 4 microencapsulated with melamine, a non-halogenated phosphorus polyol, tris-2chloroethyl phosphate or tris-2-chloroisopropyl phosphate.
Preferably, the flame retardant is included in the composition in an amount from 5% w/w 5 to 25% w/w.
Most preferably, the flame retardant is included in amounts from 10% w/w to 20% w/w.
The insulating media ideally comprises a reactive monofunctional isocyanate.
Preferably, the quantity of Monofunctional isocyanate in the composition, is most preferably, between 0.5% w/w and 4.0% w/w.
Preferably, the insulating media composition comprises 5% to 10% w/w wood sawdust. 15 Preferably, the sawdust is composed of several types of timber, specifically medium density fibreboard (MDF), orientated strand board (OSB), chip board, pine or plywood.
The composition may comprise cocoa shells.
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 mixer; (b) adding reinforcing material and (c) adding extender.
Preferably, the extender is 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 35 0.1 % and 0.5% of the total formulation.
IE 0 7 0 8 4 ^ The method advantageously includes the step of adding cork chips at an addition level of 10% to 20%.
The method may also include the step of adding cocoa shells at an addition level of 10% to 21%.
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 panel30 manufacturing 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 IE Ο 7 Ο 8 4 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 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 formulations for the insulation media of the present invention.
Example 1 Component/Kiloqrams for polyurethane foam % (w/w) Voracor CD 827 (Polyol) 31.50 Voracor CE 345 (Isocyanate) 35.12 No. 1 First Pressing Castor Oil 29.38 Polyacrylonitrile fibres PAC 8mm 3.00 Vermiculite 1.00 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 IE 07 0 8 4 ^ 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 polyurethane resin mixture, the following process was used: 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.
Example 2 Component/Kiloqrams for polyisocyanurate foam % fw/wl Voracor CD 846 (polyol) 30.00 Voracor CE 345 (Isocyanate) 43.20 No 1 First Pressing Castor Oil 23.80 Polyacrylonitrile fibres PAC 8mm 2,00 Vermiculite 1.00 Voracor CD 846 is a polyisocyanurate.
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%.
IE Ο 7 Ο 8 4 To prepare the polyisocyanurate resin mixture, 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.
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 cork chips (10% to 20%), cocoa shells (10% to 21%). Both of these materials are inert fillers.
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 mixture to mix with the polyol/isocyanate/additive package in the standard mixing chamber before it is cast onto steel sheets.
IE 0 7 0 8 4 β 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 84$ 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 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.
The following Claims were filed on 20th November 2008

Claims (5)

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: optionally wherein the at least one polyol comprises a polyisocyanurate; optionally wherein the at least one isocyanate is selected from the group comprising: polymeric diphenylmethane-4-4 Diisocyanate, hexamethylene Diisocyanate, 10 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, 3,3-dimethyl-4-4 diphenylamine Diisocyanate, 4’4-diphenyl isopropyl idene Diisocyanate, 1'5-naphthylene Diisocyanate and polymethylene 15 polyphenyl isocyanate; optionally 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; optionally wherein the extender comprises an oil; optionally wherein the extender comprises castor oil; 25 optionally 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; optionally wherein the castor oil is included in the composition in an amount of between 5% w/w to 55% w/w; optionally wherein the castor oil is included in the composition in an amount of between 15% w/w to 37% w/w; optionally wherein castor oil is included in the composition in an amount of 35 between 20% w/w to 30% w/w; IE 0 70 84 9 optionally wherein the composition further comprises a reinforcing material; optionally wherein the reinforcing material comprises a fibre reinforcing material; 5 optionally wherein the reinforcing material comprises any one or more, either on its own or blended with another, selected from the following group: Polyacronitrile fibres, polyamide fibres, polyester fibres, glass fibres, mineral wool, rayon, uncoated or epoxy coated carbon filament, or jute fibres in a ground state; 10 optionally wherein the fibre reinforcing material has an average particle length of between 0.1mm to 30mm; optionally wherein the fibre reinforcing material has a particle length in the range of 5mm to 15mm; optionally wherein the fibre reinforcing material has a particle size in the range of 7mm to 11mm; optionally wherein the fibre reinforcing material is included in an amount of from 20 0.5% w/w to 2.0% w/w; optionally wherein the fibre reinforcing material is included in an amount of from 0.5 w/w to 1.5 % w/w; 25 optionally wherein the reinforcing material comprises particle-reinforcing material; and optionally wherein the particle reinforcing material comprises any one or more selected from the following group: perlite, vermiculite, or glass microspheres.
2. A composition as claimed in claim 1 wherein Ihe composition further comprises a water scavenger; optionally wherein the water scavenger is selected from any one or more of the 35 group comprising: micro porous potassium alumosilicate Zeolite water scavengers, calcium alumosilicate Zeolite water scavengers and sodium alumosilicate Zeolite water scavengers: IE Ο 7 Ο 8 4 9 optionally wherein the water scavenger comprises a monofunctional isocyanate 5 included in an amount of between 0.5% w/w and 4.0% w/w; optionally wherein the micro porous zeolites moisture scavengers are included in an amount of between 0.1% w/w to 3% w/w; 10 optionally wherein the composition further comprises a flame retardant; optionally wherein the flame retardant is selected from any one or more of the following group: ammonium polyphosphate, ammonium polyphosphate microencapsulated with melamine, a non-halogenated phosphorus polyol, tris-215 chloroethyl phosphate or tris-2-chloroisopropyl phosphate; optionally wherein the flame retardant is included in the composition in an amount of from 5% w/w to 25% w/w; 20 optionally wherein the flame retardant is included in an amount of from 10% w/w to 20% w/w; optionally 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; optionally wherein the cocoa shells have a particle size in the range of 1-2 mm; optionally wherein the composition comprises 5% to 10% w/w wood sawdust; and 30 optionally wherein the sawdust comprises a plurality of types of timber, namely, medium density fibreboard (MDF), orientated strand board (OSB), chip board, pine or plywood. IE Ο 7 Ο 8 4 9
3. A polyurethane or polyisocyanurate foam insulation media manufactured from the compositions as claimed in any one of the preceding claims.
4. A method of preparing a polyol component for producing a polyurethane or 5. Polyisocyanurate foam wherein the method comprises the following steps: (a) adding a polyisocyanate or polyisocyanurate in liquid form, to a mixing chamber; (b) and adding extender, and optionally adding a reinforcing material; optionally wherein the extender comprises an oil extender, preferably, castor oil; optionally wherein the method further includes the step of adding a tertiary amine catalyst; optionally wherein the catalyst comprises 4,2, (1-methyl -2-(4-morpholinyl) ethoxy} -ethyl morpoline (MEMPE); optionally wherein the method includes the step of adding the catalyst at an 20 addition level of between 0.1 % w/w and 0.5% w/w of the total composition; optionally wherein the method includes the step of adding a filler at an addition level of 10% to 20% w/w; 25 optionally wherein the filler is selected from any one or more of the following group: wood sawdust, cocoa shells and cork, optionally in the form of cork chips; optionally wherein the reinforcing material comprises fibre material selected from one or more of the following group: ground fibres such as polyacrylonitrile fibres, 30 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; and optionally wherein the particle reinforcing material comprises perlite or vermiculite, 35 preferably, having an average particle size of 1mm to 2mm. ΙΕ Π 7 Ο 8 4 9
5. Rigid polyurethane or polyisocyanurate foam compositions and methods of making same, substantially as herein described in the Examples.
IE20070849A 2007-11-21 2007-11-21 Polyurethane or polyisocyanurate compositions and methods of producing same IES20070849A2 (en)

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