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
  • C08J9/0014—Use of organic additives
  • C08J9/0023—Use of organic additives containing oxygen
• • 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
• • 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
• • 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
  • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
  • C08G18/72—Polyisocyanates or polyisothiocyanates
  • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
  • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
  • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
• • 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
  • C08J9/0014—Use of organic additives
  • C08J9/0019—Use of organic additives halogenated
• • 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
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/15—Heterocyclic compounds having oxygen in the ring
  • C08K5/151—Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
  • C08K5/1515—Three-membered rings
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
  • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
• • 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
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0041—Foam properties having specified density
  • C08G2110/005—< 50kg/m3

Definitions

• the present disclosure relates to the use of fluorinated oxiranes as nucleating agents in the production of polymeric foams and in particular in the production of polyurethane foams and phenolic foams.
• foamed plastic is defined as a plastic in which the apparent density decreases substantially with the presence of numerous cells disposed through its mass.
• the gas phase in a foamed plastic is generally distributed in cells which are preferably very fine to provide good thermal insulation
• Blowing agents produce gas used to generate cells in foamable polymeric materials, for example, to make foamed insulation.
• Physical blowing agents form cells by a phase change, for example, a liquid may be volatilized or a gas dissolved in a polymer under high pressure.
• liquid blowing agents include aliphatic and cycloaliphatic hydrocarbons and their chloro- and fluoro-derivatives.
• isomers of pentane, hexane, and heptane are used mainly in the production of very low density polystyrene foam. These liquids tend to be inexpensive and low in toxicity but they are highly flammable.
• Production of cellular plastic products, such as cellular polyurethane elastomers and flexible, semi-rigid or rigid polyurethane foams in the presence of catalysts, blowing agents, processing aids or additives is described in numerous patents and publications in the literature.
• blowing agents Essentially two types of blowing agents are used to produce cellular polyurethanes:
• low boiling inert liquids that evaporate under the influence of the exothermic polymerization process, for example, alkanes, such as butane, n-pentane, isopentane or cyclopentane, halogenated hydrocarbons or halogenated fluorocarbons, such as methylene chloride,
• foams produced with nonhalogenated blowing agents such as cyclopentane or C0 2 (produced in situ via the reaction of water with the isocyanate) typically exhibit thermal conductivities which are 10 to 15 percent higher than those produced with halogenated blowing agents such as HFC-245fa (CF 3 CH 2 CHF 2 ).
• nucleating agents can provide the initiating sites at which the blowing agent forms the voids. By selection of nucleating agent, foams with fewer relatively larger voids and a greater number of relatively smaller voids can be produced.
• C 6 F 14 , and C 5 F 11 NO can be used as a nucleating agent to cause generation of smaller cell sizes in foams. As a result, such foams can exhibit lower thermal conductivity.
• unsaturated perfluorinated compounds have been found to react with some of the tertiary amine catalysts used in foam formulations. Consequently, their use is limited to foam formulations containing compatible catalysts or processes in which the nucleating agent can be introduced in to the formulation immediately prior to foaming.
• a foamable composition for preparing polymeric foams, a process for preparing polymeric foam, a blowing agent composition for preparing polymeric foam, and foams made therewith.
• the provided foamable composition includes at least one blowing agent, at least one foamable polymer or a precursor composition thereof, and at least one nucleating agent as described herein.
• the provided process comprises a process for preparing polymeric foam comprising the step of vaporizing at least one liquid or gaseous blowing agent or generating at least one gaseous blowing agent in the presence of at least one foamable polymer or a precursor composition thereof and at least one nucleating agent as described herein.
• the provided blowing agent composition comprises at least one blowing agent and at least one nucleating agent as described herein.
• a foamable composition in one aspect, includes at least one blowing agent, at least one foamable polymer or a precursor composition thereof, and a nucleating agent wherein said nucleating agent comprises a fluorinated oxirane.
• the fluorinated oxirane can include up to a maximum of three hydrogen atoms.
• the fluorinated oxirane can contain substantially no hydrogen atoms bonded to carbon atoms.
• the fluorinated oxirane can have a total of from 4 to about 12 carbon atoms and, in some embodiments can have the formula:
• each of R f 1 , R f 2 , R f 3 and R f 4 are selected from a hydrogen atom, a fluorine atom or a fluoroalkyl group, and the sum of the carbon atoms of said R f groups is 2 to 10, and any two of said R f groups may be joined together to form a perfluorcycloalkyl ring.
• the nucleating agent and the blowing agent can be in a molar ratio of less than 1 :9.
• the blowing agent can be selected from the group consisting of aliphatic hydrocarbons having from about 5 to about 7 carbon atoms, cycloaliphatic hydrocarbons having from about 5 to about 7 carbon atoms, hydrocarbon esters and water.
• a process for preparing a polymeric foam includes the step of vaporizing at least one liquid or gaseous blowing agent or generating at least one gaseous blowing agent in the presence of at least one foamable polymer or a precursor composition thereof and a nucleating agent wherein said nucleating agent comprises a fluorinated oxirane.
• the fluorinated oxirane can have a composition as disclosed above.
• composition in yet another aspect, includes a blowing agent and a nucleating agent wherein the nucleating agent comprises a fluorinated oxirane.
• in-chain heteroatom refers to an atom other than carbon (for example, oxygen and nitrogen) that is bonded to carbon atoms in a carbon chain so as to form a carbon-heteroatom- carbon chain;
• int refers to chemical compositions that are generally not chemically reactive under normal conditions of use
• fluorinated refers to hydrocarbon compounds that have one or more C-H bonds replaced by C-F bonds;
• oxirane refers to a substituted hydrocarbon that contains at least one epoxy group; and "perfluoro-" (for example, in reference to a group or moiety, such as in the case of
• perfluoroalkylene or “perfluoroalkylcarbonyl” or “perfluorinated” means completely fluorinated such that, except as may be otherwise indicated, there are no carbon-bonded hydrogen atoms replaceable with fluorine.
• the fluorinated oxiranes useful herein can offer additional important benefits in safety of use and in environmental compatibility (e.g., zero ozone depletion potential and low atmospheric lifetime as compared to perfluoroalkanes).
• the fluorinated oxiranes described herein are non-ozone depleting and as a result of their degradation in the lower atmosphere, have short atmospheric lifetimes, and would not be expected to contribute significantly to global warming.
• polymeric foams produced in accordance with the invention have excellent thermal insulation properties.
• Fig. 1 is a graph of the fluoride ion concentration as a function of time of two comparative examples and two exemplary foamable compositions.
• Foamable compositions include at least one blowing agent, at least one foamable polymer or a precursor composition thereof, and a nucleating agent.
• the nucleating agent includes a fluorinated oxirane.
• blowing agents may be used in the provided formable compositions including liquid or gaseous blowing agents that are vaporized in order to foam the polymer or gaseous blowing agents that are generated in situ in order to foam the polymer.
• blowing agents include chlorofluorocarbons (CFCs),
• the blowing agent for use in the provided foamable compositions can have a boiling point of from about -45°C to about 100°C at atmospheric pressure. Typically, at atmospheric pressure the blowing agent has a boiling point of at least about 15°C, more typically between about 20°C and about 80°C. The blowing agent can have a boiling point of between about 30°C and about 65°C.
• C0 2 generated from the reaction of water with foam precursor such as an isocyanate can be used as a blowing agent.
• the provided foamable composition also includes at least one foamable polymer or a precursor composition thereof.
• Foamable polymers suitable for use in the provided foamable compositions include polyolefins, e.g., polystyrene, poly(vinyl chloride), and polyethylene. Foams can be prepared from styrene polymers using conventional extrusion methods.
• the blowing agent composition can be injected into a heat-plastified styrene polymer stream within an extruder and admixed therewith prior to extrusion to form foam.
• Suitable styrene polymers include the solid homopolymers of styrene, a-methylstyrene, ring-alkylated styrenes, and ring-halogenated styrenes, as well as copolymers of these monomers with minor amounts of other readily copolymerizable olefinic monomers, e.g., methyl methacrylate, acrylonitrile, maleic anhydride, citraconic anhydride, itaconic anhydride, acrylic acid, N-vinylcarbazole, butadiene, and divinylbenzene.
• Suitable vinyl chloride polymers include vinyl chloride homopolymer and copolymers of vinyl chloride with other vinyl monomers. Ethylene homopolymers and copolymers of ethylene with, e.g., 2-butene, acrylic acid, propylene, or butadiene are also useful. Mixtures of different types of polymers can be employed.
• Precursors of foamable polymers suitable for use in the provided foamable compositions include precursors of phenolic polymers, silicone polymers, and isocyanate -based polymers, e.g., polyurethane, polyisocyanurate, polyurea, polycarbodiimide, and polyimide. Typically, precursors of isocyanate-based polymers are utilized as the blowing for preparing polyurethane or polyisocyanurate foams.
• Polyisocyanates suitable for use in the provided foamable compositions include aliphatic, alicyclic, arylaliphatic, aromatic, or heterocyclic polyisocyanates, or combinations thereof. Any polyisocyanate which is suitable for use in the production of polymeric foams can be utilized. Of particular importance are aromatic diisocyanates such as toluene and diphenylmethane diisocyanates in pure, modified, or crude form.
• MDI variants diphenylmethane diisocyanate modified by the introduction of urethane, allophanate, urea, biuret, carbodiimide, uretonimine, or isocyanurate residues
• crude or polymeric MDI polymethylene polyphenylene polyisocyanates
• suitable polyisocyanates include ethylene diisocyanate, 1,4- tetramethylene diisocyanate, 1 ,6-hexamethylene diisocyanate, trimethyl hexamethylene diisocyanate, 1,12-dodecane diisocyanate, cyclobutane-l,3-diisocyanate, cyclohexane- 1,3- and -
• 1,4-diisocyanate (and mixtures of these isomers), diisocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane, 2,4- and 2,6-toluene diisocyanate (and mixtures of these isomers), diphenylmethane- 2,4'- and/or -4,4'-diisocyanate, naphthalene- 1,5-diisocyanate, the reaction products of four equivalents of the aforementioned isocyanate-containing compounds with compounds containing two isocyanate -reactive groups, triphenyl methane-4,4',4"-triisocyanate, polymethylene polyphenylene polyisocyanates, m- and p-isocyanatophenyl sulfonyl isocyanates, perchlorinated aryl polyisocyanates, polyisocyanates containing carbodiimide groups, norbornane diisocyanates, polyiso
• Distillation residues (obtained in the commercial production of isocyanates) having isocyanate groups can also be used alone or in solution in one or more of the above-mentioned
• Reactive hydrogen-containing compounds suitable for use in the preferred foamable compositions of the invention are those having at least two isocyanate-reactive hydrogen atoms, preferably in the form of hydroxyl, primary or secondary amine, carboxylic acid, or thiol groups, or a combination thereof.
• Polyols i.e., compounds having at least two hydroxyl groups per molecule, are especially preferred due to their desirable reactivity with polyisocyanates.
• Such polyols can be, e.g., polyesters, polyethers, polythioethers, polyacetals, polycarbonates, polymethacrylates, polyester amides, or hydroxyl-containing prepolymers of these compounds and a less than stoichiometric amount of polyisocyanate.
• Polyurethanes Part I, pages 32-54 and 65-88, Interscience, New York (1962). Mixtures of such compounds are also useful, and, in some cases, it is particularly advantageous to combine low- melting and high-melting polyhydroxyl-containing compounds with one another, as described in DE 2,706,297 (Bayer AG).
• Useful polyols include ethylene glycol, 1,2- and 1,3-propylene glycol, 1,4- and 2,3-butylene glycol, 1,5-pentane diol, 1,6-hexane diol, 1,8-octane diol, neopentyl glycol, l,4-bis(hydroxymethyl)cyclohexane, 2-methy 1- 1, 3 -propane diol, dibromobutene diol, glycerol, trimethylolpropane, 1 ,2,6-hexanetriol, trimethylolethane, pentaerythritol, quinitol, mannitol, sorbitol, diethylene glycol, triethylene glycol, tetraethylene glycol, higher polyethylene glycols, dipropylene glycol, higher polypropylene glycols, dibutylene glycol, higher polybutylene glycols, 4,4'-dihydroxydiphenyl propane
• polystyrene resin examples include the condensation products of polybasic acids and polyols such as polyethylene adipate and polycaprolactone -based polyols, as well as the mixtures of hydroxy aldehydes and hydroxy ketones (“formose”) and the polyhydric alcohols obtained therefrom by reduction (“formitol”) that are formed in the autocondensation of formaldehyde hydrate in the presence of metal compounds as catalysts and compounds capable of enediol formation as co-catalysts (see, e.g., U. S. Pat. No. 4,341,909 (Schneider et al.), U. S. Pat. No. 4,247,653 (Wagner), U. S. Pat. No.
• Phenolic polymer precursors suitable for use in the provided foamable compositions include the reaction product of a phenol and an aldehyde in the presence of a catalyst.
• Illustrative uses of phenolic foams of this invention include use for roofing insulation, as sheathing products for external wall insulation for building applications, and for shaped parts such as pipe and block insulation for industrial applications, as described in "Thermal Insulation,” Encyclopedia of Chemical Technology, vol. 14, pages 648-662 (4th ed., John Wiley & Sons, 1995).
• Typical polymeric foams can be prepared using the provided foamable compositions by vaporizing (e.g., by utilizing the heat of precursor reaction) at least one blowing agent in the presence of a nucleating agent as described above, at least one organic polyisocyanate and at least one compound containing at least two reactive hydrogen atoms.
• the polyisocyanate, reactive hydrogen-containing compound, and blowing agent composition can generally be combined, thoroughly mixed (using, e.g., any of the various known types of mixing head and spray apparatus), and permitted to expand and cure into a cellular polymer.
• the provided foamable compositions include a nucleating agent that includes a fluorinated oxirane.
• a nucleating agent that includes a fluorinated oxirane.
• Fluorinated oxiranes useful in the provided compositions and processes can be oxiranes that have a carbon backbone which is fully fluorinated (perfluorinated), i.e., substantially all of the hydrogen atoms in the carbon backbone have been replaced with fluorine or oxiranes that can have a carbon backbone which is fully or partially fluorinated having, in some embodiments, up to a maximum of three hydrogen atoms.
• the provided fluorinated oxiranes can be derived from fluorinated olefins that have been oxidized with epoxidizing agents.
• the carbon backbone includes the whole carbon framework including the longest hydrocarbon chain (main chain) and any carbon chains branching off of the main chain.
• there can be one or more catenated heteroatoms interrupting the carbon backbone such as oxygen, nitrogen, or sulfur atoms, for example ether or hexavalent sulfur functionalities.
• the catenated heteroatoms are not directly bonded to the oxirane ring. In these cases the carbon backbone includes the heteroatoms and the carbon framework attached to the heteroatom.
• halogen atoms attached to the carbon backbone are fluorine; most typically, substantially all of the halogen atoms are fluorine so that the oxirane is a perfluorinated oxirane.
• the provided fluorinated oxiranes can have a total of 4 to 12 carbon atoms.
• fluorinated oxirane compounds suitable for use in the provided processes and compositions include 2,3-difluoro-2,3-bis-trifluoromethyl-oxirane, 2,2,3-trifluoro-3- pentafluoroethyl-oxirane, 2,3-difluoro-2-(l,2,2,2-tetrafluoro- l-trifluoromethyl-ethyl)-3- trifluoromethyl-oxirane, 2-fluoro-2-pentafluoroethyl-3,3-bis-trifluoromethyl-oxirane,
• the provided fluorinated oxirane compounds can be prepared by epoxidation of the corresponding fluorinated olefin using an oxidizing agent such as sodium hypochlorite, hydrogen peroxide or other well known epoxidizing agent such as peroxycarboxylic acids such as meta- chloroperoxybenzoic acid or peroxyacetic acid.
• an oxidizing agent such as sodium hypochlorite, hydrogen peroxide or other well known epoxidizing agent such as peroxycarboxylic acids such as meta- chloroperoxybenzoic acid or peroxyacetic acid.
• the fluorinated olefinic precursors can be directly available as, for example, in the cases of 1 , 1 , 1 , 2,3, 4,4,4-octafluoro-but-2-ene (for making 2,3- difluoro-2,3-bis-trifluoromethyl oxirane), 1 , 1 , 1 ,2,3,4,4,5,5,5-decafluoro-pent-2-ene (for making 2,3-difluoro-2-trifluoromethyl-3-pentafluoroethyl oxirane) or 1 ,2,3,3,4,4,5,5,6,6 decafluoro- cyclohexene (for making 1 , 2,2,3,3,4,4,5, 5,6-decafluoro-7-oxa-bicyclo[4.1.0]heptane).
• 1 , 1 , 1 , 2,3, 4,4,4-octafluoro-but-2-ene for making 2,3- difluoro-2,3-bis-tri
• HFP oligomers can include oligomers of hexafluoropropene (HFP) and tetrafluoroethylene (TFE) such as dimers and trimers.
• HFP oligomers can be prepared by contacting 1 , 1 ,2,3, 3,3-hexafluoro- l-propene (hexafluoropropene) with a catalyst or mixture of catalysts selected from the group consisting of cyanide, cyanate, and thiocyanate salts of alkali metals, quaternary ammonium, and quaternary phosphonium in the presence of polar, aprotic solvents such as, for example, acetonitrile.
• a catalyst or mixture of catalysts selected from the group consisting of cyanide, cyanate, and thiocyanate salts of alkali metals, quaternary ammonium, and quaternary phosphonium in the presence of polar, aprotic solvents such as, for example
• HFP oligomers include HFP trimers or HFP dimers.
• HFP dimers include a mixture of cis- and trans- isomers of perfluoro-4-methyl-2-pentene as indicated in Table 1 in the Example section below.
• HFP trimers include a mixture of isomers of CgFig. This mixture has six main components that are also listed in Table 1 in the Example section.
• the provided fluorinated oxirane compounds can have a boiling point in a range of from about 0°C to about 170°C. In some embodiments, the fluorinated oxirane compounds can have a boiling point in the range of from about 0°C to about 130°C. In other embodiments, the fluorinated oxiranes compounds can have a boiling range of from about 20°C to about 55°C. Some exemplary materials and their boiling point ranges are disclosed in the Examples section below.
• Fluorooxiranes that are useful in the present invention include those oxiranes having mostly fluorine attached to the carbon backbone. More specifically, the instant fluorinated oxiranes are of formula:
• fluoroalkyl group preferably a fluorine atom or a perfluoroalkyl group, and the sum of the carbon atoms of said perfluorooxiranes is 2 to 10.
• any two of said R f groups may be joined together to form a fluorocycloalkyl ring, preferably a perfluorocycloalkyl ring.
• C4-C 12 fluoroxiranes have 3 or fewer hydrogen atoms, typically substantially no carbon-hydrogen bonds.
• Fluorooxiranes that are useful in the present invention can also include those oxiranes having one to three hydrogen atoms attached to the carbon backbone. More specifically, useful fluorinated oxiranes are of the formula (I) wherein each of R f 1 , R f 2 , R f 3 and R f 4 are selected from a fluorine atom, a hydrogen atom or a fluoroalkyl group; wherein the sum of the hydrogen atoms is 1 to 3 and: wherein the sum of the carbon atoms of the fluorinated oxirane is 4 to 12.
• R f 5 is a fluoroalkylene group of 2 to 5 carbon atoms, and the sum of the carbon atoms is 4 to 12.
• each of R f 1 and R f 4 are selected from a fluorine atom or a perfluoroalkyl group.
• R f 1 to R f 4 are each F, or monovalent fluoroalkyl groups having 1 to 5 fluorinated or perfluorinated carbon atoms, optionally, containing one or more catenary (in-chain) heteroatoms, such as divalent oxygen, hexavalent sulfur, or trivalent nitrogen bonded only to carbon atoms, such heteroatoms being a chemically stable link between fluorocarbon portions of the fluoroaliphatic group and which do not interfere with the inert character of the fluoroaliphatic group.
• R f 1 to R f 4 are fluorine atoms or perfluoroalkyl groups.
• the skeletal chain of R f 1 to R f 4 can be straight chain, branched chain, and if sufficiently large, cyclic, such as fluorocycloaliphatic groups, e.g. R as shown in Formula (II). In some embodiments at least one of R f 1 to R f 4 is a branched perfluoraliphatic group.
• a fluorine atom of one or more of the R f 1 to R groups may be replaced by one, two, or even three hydrogen atoms; e.g., a perfluoroalkyl or perfluoroalkylene group may be a mono-, di-, or tri-hydridoperfluoroalkyl or a mono-, di-, or
• the HFP oligomers can be prepared by contacting 1 , 1 ,2,3,3,3-hexafluoro- l -propene (hexafluoropropene) with a catalyst or mixture of catalysts selected from the group consisting of alkali metal, quaternary ammonium, and quaternary phosphonium salts of cyanide, cyanate, and thiocyanate of in the presence of polar, aprotic solvents such as, for example, acetonitrile.
• polar, aprotic solvents such as, for example, acetonitrile.
• Useful oligomers include HFP trimers or HFP dimers.
• HFP dimers include a mixture of isomers of CeFi 2 .
• HFP trimers include a mixture of isomers of CgFig.
• compositions that include one or more nucleating agents as described above and one or more blowing agents as discussed above.
• the molar ratio of nucleating agent to blowing agent is typically about 1 :9. Higher proportions of nucleating agent may be used in some embodiments (e.g., a molar ratio of about 1 :7), but will typically be more expensive. In some embodiments, lesser proportions of nucleating agent (e.g., 1 :25 or even 1 :50) may be used.
• foam formulations can, optionally, be present in the foamable compositions of the invention.
• foam-stabilizing agents or surfactants can be utilized.
• Other possible components include fillers (e.g., carbon black), colorants, fungicides, bactericides, antioxidants, reinforcing agents, antistatic agents, and other additives or processing aids known to those skilled in the art.
• the foamable compositions of the invention can include at least one surfactant.
• Suitable surfactants include fluorochemical surfactants, organosilicone surfactants, polyethylene glycol ethers of long chain alcohols, tertiary amine or alkanolamine salts of long chain alkyl acid sulfate esters, alkyl sulfonate esters, alkyl arylsulfonic acids, fatty acid alkoxylates, and mixtures thereof.
• Surfactant is generally employed in amounts sufficient to stabilize the foaming reaction mixture against collapse and the formation of large, uneven cells. Typically, from about 0.1 to about 5 percent by weight of surfactant is sufficient for this purpose.
• Organosilicone surfactants and fluorochemical surfactants are preferred.
• the surfactant can help to disperse or emulsify the nucleating agent into the foamable composition.
• the foamable composition typically also contains a catalyst.
• Catalysts suitable for use in the provided foamable compositions include compounds which greatly accelerate the reaction of the reactive hydrogen-containing compounds (or the cross-linking or chain- extending agents) with the polyisocyanates. When used, catalysts are generally present in amounts sufficient to be catalytically effective. Suitable catalysts include organic metal compounds (preferably, organic tin compounds), which can be used alone or, preferably, in combination with amines.
• Foams prepared from the provided foamable compositions can vary in texture from very soft types useful in upholstery applications to rigid foams useful as structural or insulating materials.
• the foams can be used, for example, in the automobile, shipbuilding, aircraft, furniture, and athletic equipment industries, and are especially useful as insulation materials in the construction and refrigeration industries.
• the product crude was then washed with 200 grams of water to remove solvent acetonitrile and then purified in a 40-tray Oldershaw fractionation column with condenser being cooled to 15°C.
• the fractionation column was operated in such a way so that the reflux ratio (the distillate flow rate going back to the fractionation column to the distillate flow rate going to the product collection cylinder) was at 10: 1.
• the final product was collected as the condensate when the head temperature in the fractionation column was between 52°C and 53°C.
• the product crude was then washed with 200 grams of water to remove solvent acetonitrile and then purified in a 40-tray Oldershaw fractionation column with condenser being cooled to 15°C.
• the fractionation column was operated in such a way so that the reflux ratio (the distillate flow rate going back to the fractionation column to the distillate flow rate going to the product collection cylinder) was at 10: 1.
• the final product was collected as the condensate when the head temperature in the fractionation column was between 120°C and 122°C.
• compositions used in Examples 1 -6 and Comparative Examples 1 -3 are shown in Tables 2 and 3.
• the fluorinated nucleating agent (3.5 grams) was emulsified in BAYTHERM VP- PU 1751 A/2 (1 18 g) and silicone surfactant B-8423 (3.5 g) using a high shear mixer at 6000 rpm.
• DESMODUR 44V-20 (225 g) was then added to this emulsion while mixing at 6000 rpm for 15 seconds.
• the resulting mixture was poured into a 350 cm x 350 cm x 60 cm aluminum mold that was preheated to 50°C. The reaction was allowed to continue in the mold for about 30 minutes.
• the polyurethane sample was demolded and cut .
• the thermal conductivity (lambda) values of the foams were measured on a 200 cm x 200 cm x 25 cm test sample, perpendicular to the foam rise direction.
• the thermal conductivity was measured at a temperature of 23 °C initially and after heat aging at 50°C for 2 weeks using a Hesto Lambda Control A-50 thermal conductivity analyzer with a reproducibility of
• the fluorinated nucleating agents were evaluated for reactivity with amine catalysts by forming an emulsion of nucleating agent within a polyol formulation and measuring the concentration of fluoride ion generated over time.
• a master batch of polyol was prepared containing water, surfactant and catalyst. From this master batch, samples were prepared by emulsifying a mixture of blowing agent and fluorinated nucleating agent into the polyol at their respective concentrations as shown in Table 4. The samples were then examined for generation of fluoride ion, with the initial measurement made immediately after sample preparation and additional measurements made over time as the samples age. Table 4
• the fluoride ion concentration was determined by diluting 1 g of polyol emulsion with 1 g of isopropanol and adding 0.5 ml of IN H 2 SO 4 . This was mixed and then further diluted with 1 g of water. 1 ml of this aqueous mixture was combined with 1 ml of TISAB II buffer (Total Ionic Strength Adjustment Buffer) for fluoride measurement using a fluoride specific electrode.
• TISAB II buffer Total Ionic Strength Adjustment Buffer
• HFPDO HFP dimer
• HFPTO HFP trimer
• Embodiment 1 is a foamable composition comprising at least one blowing agent, at least one foamable polymer or a precursor composition thereof, and a nucleating agent wherein said nucleating agent comprises a fluorinated oxirane.
• Embodiment 2 is a foamable composition according to embodiment 1 , wherein the fluorinated oxirane includes up to a maximum of three hydrogen atoms.
• Embodiment 3 is a foamable composition according to embodiment 2, wherein the fluorinated oxirane contains substantially no hydrogen atoms bonded to carbon atoms.
• Embodiment 4 is a foamable composition according to embodiment 1 , wherein the fluorinated oxirane has a total of from about 4 to about 12 carbon atoms.
• Embodiment 5 is a foamable composition according to embodiment 1 , wherein the fluorinated oxirane has the formula:
• each of R f 1 , R f 2 , R f 3 and R f 4 are selected from a hydrogen atom, a fluorine atom or a fluoroalkyl group, and the sum of the carbon atoms of said R f groups is 2 to 10, and any two of said R f groups may be joined together to form a perfluorcycloalkyl ring.
• Embodiment 6 is a foamable composition according to embodiment 1 , wherein the nucleating agent and the blowing agent are in a molar ratio of less than 1 :9.
• Embodiment 7 is a foamable composition according to embodiment 1 , wherein the blowing agent is selected from the group consisting of aliphatic hydrocarbons having from about 5 to about 7 carbon atoms, cycloaliphatic hydrocarbons having from about 5 to about 7 carbon atoms, hydrocarbon esters and water.
• the blowing agent is selected from the group consisting of aliphatic hydrocarbons having from about 5 to about 7 carbon atoms, cycloaliphatic hydrocarbons having from about 5 to about 7 carbon atoms, hydrocarbon esters and water.
• Embodiment 8 is a process for preparing polymeric foam comprising the step of vaporizing at least one liquid or gaseous blowing agent or generating at least one gaseous blowing agent in the presence of at least one foamable polymer or a precursor composition thereof and a nucleating agent wherein said nucleating agent comprises a fluorinated oxirane.
• Embodiment 9 is a process for preparing polymeric foam according to embodiment 8, wherein the fluorinated oxirane includes up to a maximum of three hydrogen atoms.
• Embodiment 10 is a process for preparing polymeric foam according to embodiment 9, wherein the fluorinated oxirane contains substantially no hydrogen atoms bonded to carbon atoms.
• Embodiment 1 1 is a process for preparing polymeric foam according to embodiment 8, wherein the fluorinated oxirane has a total of from about 4 to about 12 carbon atoms.
• Embodiment 12 is a process for preparing polymeric foam according to embodiment 8, wherein the fluorinated oxirane has the formula:
• each of R f 1 , R f 2 , R f 3 and R f 4 are selected from a hydrogen atom, a fluorine atom or a fluoroalkyl group, and the sum of the carbon atoms of said R f groups is 2 to 10, and any two of said R f groups may be joined together to form a perfluorcycloalkyl ring.
• Embodiment 13 is a process for preparing polymeric foam according to embodiment 8, wherein the nucleating agent and the blowing agent are in a molar ratio of less than 1 :9.
• Embodiment 14 is a composition comprising a blowing agent and a nucleating agent wherein the nucleating agent comprises a fluorinated oxirane.
• Embodiment 15 is a composition according to embodiment 14, wherein the fluorinated oxirane includes up to a maximum of three hydrogen atoms.
• Embodiment 16 is a composition according to embodiment 15, wherein the fluorinated oxirane contains substantially no hydrogen atoms bonded to carbon atoms.
• Embodiment 17 is a composition according to embodiment 14, wherein the fluorinated oxirane has a total of from about 4 to about 12 carbon atoms.
• Embodiment 18 is a composition according to embodiment 14, wherein the fluorinated oxirane has the formula:
• each of R f 1 , R f 2 , R f 3 and R f 4 are selected from a hydrogen atom, a fluorine atom or a fluoroalkyl group, and the sum of the carbon atoms of said R f groups is 2 to 10, and any two of said R f groups may be joined together to form a perfluorcycloalkyl ring.
• Embodiment 19 is a composition according to embodiment 14, wherein the nucleating agent and the blowing agent are in a molar ratio of less than 1 :9.
• Embodiment 20 is a foam made with the foamable composition according to embodiment
• Embodiment 21 is a foam made according to the process according to embodiment 8.
• Embodiment 22 is a foam made with the composition according to embodiment 14.

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