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
  • C08J9/0019—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
• • 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
• • 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
  • C08J9/0042—Use of organic additives containing silicon
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
  • C08J9/142—Compounds containing oxygen but no halogen atom
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
  • C08J9/143—Halogen containing compounds
  • C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
  • C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
  • C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
  • C08J9/149—Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L59/00—Thermal insulation in general
  • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
  • F16L59/028—Compositions for or methods of fixing a thermally insulating material
• • 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
  • C08J2201/00—Foams characterised by the foaming process
  • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
  • C08J2201/022—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/12—Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/16—Unsaturated hydrocarbons
  • C08J2203/162—Halogenated unsaturated hydrocarbons, e.g. H2C=CF2
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2203/00—Foams characterized by the expanding agent
  • C08J2203/18—Binary blends of expanding agents
  • C08J2203/182—Binary blends of expanding agents of physical blowing agents, e.g. acetone and butane
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2205/00—Foams characterised by their properties
  • C08J2205/04—Foams characterised by their properties characterised by the foam pores
  • C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
• • 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
  • C08J2207/00—Foams characterised by their intended use
  • C08J2207/04—Aerosol, e.g. polyurethane foam spray
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
  • C08J2375/04—Polyurethanes

Definitions

• the present invention pertains to blowing agents, to foams, to articles made from foams and to methods for the preparation thereof, and in particular to polyurethane and polyisocyanurate foams and methods for the preparation and uses thereof.
• the class of foams known as low density, rigid to semi-rigid polyurethane or polyisocyanurate foams has utility in a wide variety of insulation applications, including roofing systems, building panels, building envelope insulation, spray applied foams, one and two component froth foams, insulation for refrigerators and freezers. Such foams are also used as so called integral skin foam for cushioning and safety application such as steering wheels and other automotive or aerospace cabin parts, shoe soles, amusement park restraints, and the like.
• An important factor in the large-scale commercial success of many rigid to semi-rigid polyurethane foams has been the ability of such foams to provide a good balance of properties, including performance, environmental and safety properties.
• rigid polyurethane and polyisocyanurate foams should provide outstanding thermal insulation, excellent fire resistance properties, and superior structural properties at reasonably low densities.
• blowing agents are used to form the cellular structure required for such foams. It has been common to use certain liquid fluorocarbon blowing agents because of their ease of use, among other factors. Certain fluorocarbons are capable of not only acting as blowing agents by virtue of their volatility, but also are encapsulated or entrained in the closed cell structure of the foam and are generally the major contributor to the thermal conductivity properties of the rigid urethane foams.
• the k-factor associated with the foam produced provides a measure of the ability of the foam to resist the transfer of heat through the foam material. As the k-factor decreases, this is an indication that the material is more resistant to heat transfer and therefore a better foam for insulation purposes. Thus, materials that produce lower k-factor foams are generally desirable and advantageous.
• the present invention relates to a thermal insulating foam including a thermoset polymer having a plurality of closed cells and a gaseous composition contained in a plurality of said closed cells, said gaseous composition including from about 50 mole to less than about 100 mole trans-l-chloro-3,3,3-trifluoropropene and from greater than about 0 mole to about 50 mole % of methyl formate.
• Applicants have found that certain important advantages can be unexpectedly achieved by the selection of methyl formate as a co- blowing agent within carefully selected concentration ranges.
• blowing agents that comprise from about 50 mole to less than about 95 mole trans-l-chloro-3,3,3-trifluoropropene and from greater than about 5 mole to about 50 mole % of methyl formate, even more preferably in certain embodiments such advantages are achieved for blowing agents that comprise from about 50 mole to less than about 75 mole trans-l-chloro-3,3,3-trifluoropropene and from greater than about 25 mole to about 50 mole % of methyl formate, and in even more preferred embodiments for blowing agents that comprise from about 50 mole to about 70 mole trans-l-chloro-3,3,3-trifluoropropene and from about 30 mole to about 50 mole % of methyl formate.
• the mole percentages for % trans- 1- chloro-3,3,3-trifluoropropene and methyl formate are based on the total of said trans- 1-chloro- 3,3,3-trifluoropropene and methyl formate.
• the thermal insulating foam in certain preferred aspects, has a K-value after 28 days of aging at 55 °F of not greater than about 0.14; a K-value after 28 days of aging at 40 °F of not greater than about 0.13; and/or a K-value after 28 days of aging at 20 °F of not greater than about 0.13.
• methyl formate is present in an amount of from greater than about 25 mole % to about 50 mole % or in certain embodiments from about 30 mole % to about 50 mole %
• the present invention also relates to a pour-in-place foam panel that includes a foam composition according to the present invention.
• the gaseous composition contained in a plurality of the cells in said foam includes methyl formate in an amount of from greater than about 5 mole % to about 50 mole % and from about 50 mole to less than about 95 mole trans-l-chloro-3,3,3-trifluoropropene, in certain embodiments more preferably from greater than about 25 mole % to about 50 mole % methyl formate and from about 50 mole to less than about 75 mole trans-l-chloro-3,3,3-trifluoropropene, and in even further embodiments from about 30 mole % to about 50 mole % methyl formate and from about 50 mole to about 70 mole trans-l-chloro-3,3,3-trifluoropropene.
• the present invention also relates to a thermal insulating article comprising any of the foams provided herein.
• the present invention relates to a polyol premix for forming an polyurethane or polyisocyanurate pour-in-place foam panel including a blowing agent composition according to the present invention.
• the premix composition comprises a blowing agent that comprises from about 50 mole to less than about 100 mole trans-l-chloro-3,3,3-trifluoropropene and greater than about 0 mole to about 50 mole % of methyl formate, even more preferably from about 50 mole to less than about 95 mole trans-l-chloro-3,3,3-trifluoropropene and greater than about 5 mole to about 50 mole % of methyl formate, even more preferably from about 50 mole to less than about 75 mole trans-l-chloro-3,3,3-trifluoropropene and from greater than about 25 mole to about 50 mole % of methyl formate, and even more preferably from about 50 mole to about 70 mole trans- 1- chloro
• the polyol component may be present in preferred embodiments an amount of from about 60 wt.% to about 95 wt.% of the premix and the blowing agent composition in accordance with the present invention is present in the premix in an amount of from about 1 wt.% to about 30 wt.%.
• the blowing agent composition may also include one or more additional blowing agents other than trans-l-chloro-3,3,3-trifluoropropene or methyl formate.
• additional blowing agents may be selected from water, organic acids that produce C0 2 and/or CO , hydrocarbons; ethers, halogenated ethers; esters, alcohols, aldehydes, ketones, pentafluorobutane;
• HCFC-124 1,1-dichloro-l-fluoroethane
• HCFC- 141b 1,1,1,2-tetrafluoroethane
• HFC-134a 1,1,2,2-tetrafluoroethane
• 1-chloro 1,1-difluoroethane HCFC-142b
• HFC-365mfc 1,1,1,2,3,3,3- heptafluoropropane
• HFC-227ea trichlorofluoromethane (CFC-11); dichlorodifluoromethane (CFC-12); dichlorofluoromethane (HCFC-22); 1,1,1,3,3,3-hexafluoropropane (HFC-236fa); 1,1,1, 2,3, 3 -hexafluoropropane (HFC-2
• Additional agents for use in the premix may include, but are not limited to, a silicone surfactant, a non-silicone surfactant, a metal catalyst, an amine catalyst, a flame retardant, and combinations thereof.
• FIG. 1 illustrates initial thermal conductivity of foams with various blends of 1233zd (Solstice LB A) and methyl formate - tested from about 20°F to about 110 °F.
• FIG. 2 illustrates thermal conductivity of foams with various blends of 1233zd (Solstice LB A) and methyl formate after 28 days of aging - tested from about 20°F to about 110 °F.
• FIG. 3 illustrates comparative compressive strengths of foams with various 1233zd (Solctice LBA)/methyl formate blends.
• FIG. 4 illustrates dimensional stability of foams with various 1233zd (Solstice LBA)/methyl formate blends after 28 days of aging.
• the present compositions can generally be in the form of blowing agent compositions, foamable compositions, or the resulting foams.
• the present invention requires at least one fluoroalkene compound as described herein and optionally but preferably one or more additional components, as described in more detail below.
• the present invention is directed to blowing agent compositions which may comprise, in addition to either 1234ze(E) or 1233zd(E)at least one additional fluoroalkene containing from 2 to 6, preferably 3 to 5 carbon atoms, more preferably 3 to 4 carbon atoms, and in certain embodiments most preferably three carbon atoms, and at least one carbon-carbon double bond.
• the fluoroalkene compounds of the present invention are sometimes referred to herein for the purpose of convenience as hydrofluoro-olefins or "HFOs" if they contain at least one hydrogen. Although it is contemplated that the HFOs of the present invention may contain two carbon— carbon double bonds, such compounds at the present time are not considered to be preferred.
• HFOs which also contain at least one chlorine atom, the designation HFCO is sometimes used herein
• HFO or HFCO compounds comprise one or more compounds in accordance with Formula I below:
• each R is independently CI, F, Br, I or H
• R' is (CR 2 ) n Y
• n is 0, 1, 2 or 3, preferably 0 or 1, it being generally preferred however that either Br is not present in the compound or when Br is present in the compound there is no hydrogen in the compound.
• Y is CF 3
• n is 0 or 1 (most preferably 0) and at least one of the remaining Rs is F or CI, and preferably no R is Br, or when Br is present there is no hydrogen in the compound. It is preferred in certain cases that no R in Formula I is Br.
• the compounds of the above identified Formula I are generally effective and exhibit utility in blowing agent compositions in accordance with the teachings contained herein.
• applicants have surprisingly and unexpectedly found that certain of the compounds having a structure in accordance with the formula described above, as discussed in greater detail below, exhibit a highly desirable low level of toxicity compared to other of such compounds.
• certain of the compounds of Formula I have highly desirable physical properties and/or thermal conductivity/insulation under a wide array of conditions, as compared to other of such compounds and/or existing blowing agents.
• the compound of the present invention comprises a C 3 or C 4 HFCO or HFO, preferably a C 3 HFCO or HFO, and more preferably a compound in accordance with Formula I in which Y is CF 3 , n is 0, at least one R on the unsaturated terminal carbon is H, and at least one of the remaining Rs is F or CI.
• HFCO- 1233 is one example of such a preferred HCFO compound
• tetrafluoropropenes, particularly HFO- 1234 is one example of such a preferred HFO compound.
• HFCO-1233 is used herein to refer to all trifluoromonochloropropenes. Among the trifluoromonochloropropenes are included both cis- and trans- 1,1,1 -trifluo- 3,chlororopropene (HFCO-1233zd or 1233zd).
• HFCO-1233zd or “1233zd” is used herein generically to refer to l,l,l-trifluo-3,chloro-propene, independent of whether it is the cis- or trans-form.
• cis HFCO-1233zd and “transHFCO-1233zd” are used herein to describe the cis- and trans-forms of l,l,l-trifluo,3-chlororopropene, respectively.
• HFCO-1233zd therefore includes within its scope cis HFCO-1233zd (also referred to as 1233zd(Z)), transHFCO-1233zd (also referred to as 1233(E)), and all combinations and mixtures of these.
• HFO-1234 includes HFO-1234yf, (cis)HFO-1234ze and (trans)HFO-1234ze, with HFO-1234ze being generally preferred and trans HFO-1234ze being highly preferred in certain embodiments. Although the properties of (cis)HFO-1234ze and (trans)HFO-1234ze differ in at least some respects, it is contemplated that each of these compounds is adaptable for use, either alone or together with other compounds including its stereo isomer, in connection with each of the applications, methods and systems described herein.
• (trans)HFO- 1234ze may be preferred for use in certain systems because of its relatively low boiling point (- 19° C), while (cis)HFO-1234ze, with a boiling point of +9° C, may be preferred in other applications.
• cis- and trans- isomers will be acceptable and/or preferred in many embodiments.
• the terms "HFO-1234ze” and 1,3,3,3-tetrafluoropropene refer to both stereo isomers, and the use of this term is intended to indicate that each of the cis-and trans- forms applies and/or is useful for the stated purpose unless otherwise indicated.
• compositions of the present invention have a Global Warming Potential (GWP) of not greater than about 1000, more preferably not greater than about 500, and even more preferably not greater than about 150.
• GWP of the present compositions is not greater than about 100 and even more preferably not greater than about 75.
• GWP is measured relative to that of carbon dioxide and over a 100 year time horizon, as defined in "The Scientific Assessment of Ozone Depletion, 2002, a report of the World Meteorological Association's Global Ozone Research and Monitoring Project,” which is incorporated herein by reference.
• the present compositions also preferably have an Ozone Depletion Potential (ODP) of not greater than 0.05, more preferably not greater than 0.02 and even more preferably about zero.
• ODP Ozone Depletion Potential
• “ODP” is as defined in "The Scientific Assessment of Ozone Depletion, 2002, A report of the World Meteorological Association's Global Ozone Research and Monitoring Project,” which is incorporated herein by reference.
• polyurethane foam is used extensively as the core insulation material in several types of articles.
• some of the most commonly used blowing agents for polyurethane foams included HFC-245fa, HFC- 134a and hydrocarbons.
• Such compounds are commonly used in the majority of the polyurethane foam markets in developing countries.
• LGWP low global warming potential
• one advantage of the present invention is that the resulting foam product including the blowing agent of the present invention, alone or in combination with one or more commonly used other co-blowing agents, has improved characteristics of the foam, and surprisingly, resulted in improved flammability and thermal conductivity across a wide array of temperature conditions and as the foam ages.
• the 1233zd/1234ze methyl formate blowing agents of the present invention in preferred embodiments are capable of achieving comparable physical properties (e.g. free rise density, core density, etc.) to foams formed with existing blowing agents, which makes them suitable drop-in replacements within existing foam formulations.
• Foams formed in accordance preferred aspects of the present invention are also demonstrated herein to surprisingly and unexpectedly excellent thermal insulation properties, initially and after 3 months of aging, than foams formed with 245fa, C5 hydrocarbons, or methyl formate alone. They are also surprisingly demonstrated to have superior flammability properties than methyl formate alone and 141b. Accordingly, foams formed in accordance with the present invention exhibit a myriad of improved properties over foams formed with several existing blowing agents.
• the preferred blowing agent of the present invention has been surprisingly found to result in improved flammability and thermal stability, initially and particularly after foam aging, as compared to foams produced using methyl formate alone.
• 1233zd blended with 50 mol or less of methyl formate in certain embodiments from greater than about 25 mol % to about 50 mol % methyl formate, and in further embodiments from about 30 mol % to about 50 mol % methyl formate, surprisingly and unexpectedly exhibited similar thermal conductivity to 1233zd, alone, and/or a K-value of less than 0.14 when measured at temperatures below 55 °F and a K-value of less than 0.13 when measured at temperatures below 40 °F or 20 °F.
• cold storage applications for use with such blending blowing agents include, but are not limited to, walk-in coolers and freezers, commercial refrigeration, industrial coolers and freezers, iso-containers or any container used for transporting cold materials, or any similar application where it is desirable to cool or maintain the temperature of an article below room temperature.
• 1233zd/methyl formate blends in accordance with the present invention have also been found to unexpectedly impart superior physical properties to the resulting foams.
• 1233zd/ methyl formate blends were found to maintain similar dimensional stability as foams using 1233zd alone. This is particularly true in embodiments where methyl formate is provided in an amount less than about 75 mol % and in certain embodiments wherein methyl formate is provided in an amount at or below 50 mol .
• the present invention relates to the use of 1233zd or 1234ze, but in certain preferred aspects to HCFO-1233zd(E), as a blowing agent in polyol premix and in foams, particularly in premixes and foams useful as a panel foam.
• co-blowing agents which may be added according to the needs of a particular application include, but are not limited to, water, organic acids that produce C0 2 and/or CO , hydrocarbons; ethers, halogenated ethers; esters, alcohols, aldehydes, ketones, pentafluorobutane; pentafluoropropane; hexafluoropropane; heptafluoropropane; trans-1,2 dichloroethylene; methylal, l-chloro-l,2,2,2-tetrafluoroethane (HCFC-124); 1,1-dichloro-l- fluoroethane (HCFC-141b); 1 , 1 , 1 ,2-tetrafluoroethane (HFC-134a); 1,1,2,2-tetrafluoroethane (HFC-134); 1-chloro 1,1-difluoroethane (HCFC)
• the blowing agent of the present invention component is preferably present in the polyol premix composition in an amount of from about 1 wt.% to about 30 wt.%, preferably from about 3 wt.% to about 25 wt.%, and more preferably from about 5 wt.% to about 25 wt.%, by weight of the polyol premix composition.
• Such amounts result in a foam cell structure containing a gas that comprises in major proportion by weight, and in certain preferred embodiments consists essentially of, and in other preferred embodiments consists of, a combination of 1233zd(E) and methyl formate according to the present invention..
• the content of the gas in the resulting foam cell structure is dependent upon the component amounts of blowing agents used in the blend, and the relative percentage of the 1233zd(e) and methyl formate components in the blowing agent will preferably correspond substantially to the relative percentage in the gas contained in the cells upon initial formation of the foam.
• the polyol component which may include mixtures of polyols, can be any polyol which reacts in a known fashion with an isocyanate in preparing a polyurethane or polyisocyanurate foam.
• Useful polyols comprise one or more of a sucrose containing polyol; phenol, a phenol formaldehyde containing polyol; a glucose containing polyol; a sorbitol containing polyol; a methyl glucoside containing polyol; an aromatic polyester polyol; glycerol; ethylene glycol; diethylene glycol; propylene glycol; graft copolymers of polyether polyols with a vinyl polymer; a copolymer of a polyether polyol with a polyurea; one or more of (a) condensed with one or more of (b): (a) glycerine, ethylene glycol, diethylene glycol, trimethylolpropane, ethylene diamine, pen
• the polyol component is preferably present in the polyol premix composition in an amount of from about 60 wt.% to about 95 wt.%, preferably from about 65 wt.% to about 95 wt.%, and more preferably from about 70 wt.% to about 90 wt.%, by weight of the polyol premix composition.
• the polyol premix composition may also contain at least one silicone-containing surfactant.
• the silicone-containing surfactant is used to aid in the formation of foam from the mixture, as well as to control the size of the bubbles of the foam so that a foam of a desired cell structure is obtained.
• a foam with small bubbles or cells therein of uniform size is desired since it has the most desirable physical properties such as compressive strength and thermal conductivity. Also, it is critical to have a foam with stable cells which do not collapse prior to forming or during foam rise.
• Silicone surfactants for use in the preparation of polyurethane or polyisocyanurate foams are available under a number of trade names known to those skilled in this art. Such materials have been found to be applicable over a wide range of formulations allowing uniform cell formation and maximum gas entrapment to achieve very low density foam structures.
• the preferred silicone surfactant comprises a polysiloxane polyoxyalkylene block co-polymer.
• silicone surfactants useful for this invention are Momentive's L-5130, L-5180, L- 5340, L-5440, L-6100, L-6900, L-6980 and L-6988; Air Products DC- 193, DC-197, DC-5582 , and DC-5598; and B-8404, B-8407, B-8409 and B-8462 from Goldschmidt AG of Essen, Germany. Others are disclosed in U.S. patents 2,834,748; 2,917,480; 2,846,458 and 4,147,847, the contents of which are incorporated herein by reference.
• the silicone surfactant component is usually present in the polyol premix composition in an amount of from about 0.5 wt.
• the polyol premix composition may optionally contain a non-silicone surfactant, such as a non-silicone, non-ionic surfactant.
• a non-silicone surfactant such as a non-silicone, non-ionic surfactant.
• a non-silicone surfactant such as a non-silicone, non-ionic surfactant.
• Such may include oxyethylated alkylphenols, oxyethylated fatty alcohols, paraffin oils, castor oil esters, ricinoleic acid esters, turkey red oil, groundnut oil, paraffins, and fatty alcohols.
• a preferred, but non-limiting, non-silicone non-ionic surfactant is LK-443 which is commercially available from Air Products Corporation.
• non-silicone, non-ionic surfactant used, it is present in the polyol premix composition in an amount of from about 0.05 wt.% to about 3.0 wt.%, preferably from about 0.05 wt.% to about 2.5 wt.%, and more preferably from about 0.1 wt.% to about 2.0 wt. %, by weight of the polyol premix composition.
• the polyol premix composition may also include one or more catalysts, in particular amine catalysts and/or metal catalysts.
• Amine catalysts may include, but are not limited to, primary amine, secondary amine or tertiary amine.
• Useful tertiary amine catalysts non- exclusively include N,N,N',N",N"-pentamethyldiethyltriamine, N,N-dicyclohexylmethylamine; ⁇ , ⁇ -ethyldiisopropylamine; ⁇ , ⁇ -dimethylcyclohexylamine; ⁇ , ⁇ -dimethylisopropylamine; N- methyl-N-isopropylbenzylamine; N-methyl-N-cyclopentylbenzylamine; N-isopropyl-N-sec- butyl-trifluoroethylamine; N,N-diethyl-(a -phenylethyl)amine, N,N,N-tri-n-
• Useful secondary amine catalysts non-exclusively include dicyclohexylamine; t-butylisopropylamine ; di-t-butylamine; cyclohexyl-t-butylamine; di-sec- butylamine, dicyclopentylamine; di-(a -trifluoromethylethyl)amine; di-(a -phenylethyl)amine; or combinations thereof.
• Useful primary amine catalysts non-exclusively include: triphenylmethylamine and 1,1-diethyl- n-propylamine.
• Suitable amines includes morpholines, imidazoles, ether containing compounds, and the like. These include
• an amine catalyst When used, it is present in the polyol premix composition in an amount of from about 0.05 wt.% to about 3.0 wt.%, preferably from about 0.05 wt.% to about 2.5 wt.%, and more preferably from about 0.1 wt.% to about 2.0 wt. %, by weight of the polyol premix composition.
• Catalysts may also include one or a combination of metal catalysts, such as, but not limited to organometallic catalysts.
• organometallic catalyst refers to and is intended to cover in its broad sense both to preformed organometalic complexes and to compositions (including physical combinations, mixtures and/or blends) comprising metal carboxylates and/or amidines.
• the catalyst of the present invention comprises: (a) one or more metal selected from the group consisting of zinc, lithium, sodium, magnesium, barium, potassium, calcium, bismuth, cadmium, aluminum, zirconium, tin, or hafnium, titanium, lanthanum, vanadium, niobium, tantalum, tellurium, molybdenum, tungsten, cesium; (b) in a complex and/or composition with an amidine compound; and/or (c) in a complex and/or composition with an aliphatic compound, aromatic compound and/or polymeric carboxylate.
• Acyclic amidines and guanidines can alternatively be used.
• One preferred catalyst complex/composition comprises zinc (II), a methyl, ethyl, or propyl hexannoate, and a imidazole (preferably an lower alkylimidazole such as methylimidazole.
• Such catalysts may include Zn(l-methylimidazole)2(2-ethylhexannoate)2, together with, di-ethylene glycol, preferably as a solvent for the catalyst.
• Zn(l-methylimidazole)2(2-ethylhexannoate)2 together with, di-ethylene glycol, preferably as a solvent for the catalyst.
• one exemplified catalyst includes, but is not limited to, a catalyst sold under the trade designation K-Kat XK-614 by King Industries of Norwalk, Connecticut.
• Other catalysts include those sold under the trade designation Dabco K 15 and/or Dabco MB 20 by Air Products, Inc.
• such a catalyst(s) is present in the polyol premix composition in an amount of from about 0.5 wt. to about 10 wt. , or preferably from about 1.0 wt.% to about 8.0 wt.% by weight of the polyol premix composition.
• polyurethane or polyisocyanurate foams are prepared by combining an isocyanate, the polyol premix composition, and other materials such as optional flame retardants, water, colorants, or other additives.
• foams can be rigid, flexible, or semi-rigid, and can have a closed cell structure, an open cell structure or a mixture of open and closed cells.
• the foam formulation is pre-blended into two components.
• the isocyanate and optionally other isocyanate compatible raw materials including but not limited to blowing agents and certain silicone surfactants, comprise the first component, commonly referred to as the "A" component.
• the polyol mixture composition, including surfactant, catalysts, blowing agents, and optional other ingredients comprise the second component, commonly referred to as the "B" component.
• the "B" component may not contain all the above listed components, for example some formulations omit the flame retardant if flame retardancy is not a required foam property.
• polyurethane or polyisocyanurate foams are readily prepared by bringing together the A and B side components either by hand mix for small preparations and, preferably, machine mix techniques to form blocks, slabs, laminates, pour-in-place panels and other items, spray applied foams, froths, and the like.
• other ingredients such as fire retardants, colorants, auxiliary blowing agents, water, and even other polyols can be added as a stream to the mix head or reaction site. Most conveniently, however, they are all, with the exception of water, incorporated into one B component as described above.
• a foamable composition suitable for forming a polyurethane or polyisocyanurate foam may be formed by reacting an organic polyisocyanate and the polyol premix composition described above.
• Any organic polyisocyanate can be employed in polyurethane or polyisocyanurate foam synthesis inclusive of aliphatic and aromatic polyisocyanates.
• Suitable organic polyisocyanates include aliphatic, cycloaliphatic, araliphatic, aromatic, and heterocyclic isocyanates which are well known in the field of polyurethane chemistry. These are described in, for example, U.S.
• Preferred as a class are the aromatic polyisocyanates.
• organic polyisocyanates correspond to the formula:
• R is a polyvalent organic radical which is either aliphatic, aralkyl, aromatic or mixtures thereof, and z is an integer which corresponds to the valence of R and is at least two.
• organic polyisocyanates contemplated herein includes, for example, the aromatic diisocyanates such as 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, mixtures of 2,4- and 2,6-toluene diisocyanate, crude toluene diisocyanate, methylene diphenyl diisocyanate, crude methylene diphenyl diisocyanate and the like; the aromatic triisocyanates such as 4,4',4"- triphenylmethane triisocyanate, 2,4,6-toluene triisocyanates; the aromatic tetraisocyanates such as 4,4'-dimethyldiphenylmethane-2,2'5,5-'tetraisocyanate
• organic polyisocyanates include polymethylene polyphenylisocyanate, hydrogenated methylene diphenylisocyanate, m- phenylene diisocyanate, naphthylene-l,5-diisocyanate, l-methoxyphenylene-2,4-diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'-biphenyl diisocyanate, 3,3'-dimethyl-4,4'- biphenyl diisocyanate, and 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate;
• Typical aliphatic polyisocyanates are alkylene diisocyanates such as trimethylene diisocyanate, tetramethylene diisocyanate, and hexamethylene diisocyanate, isophorene diisocyanate, 4, 4'- methylenebis(cyclohexyl is
• Preferred polyisocyanates are the polymethylene polyphenyl isocyanates, Particularly the mixtures containing from about 30 to about 85 percent by weight of methylenebis(phenyl isocyanate) with the remainder of the mixture comprising the polymethylene polyphenyl polyisocyanates of functionality higher than 2.
• These polyisocyanates are prepared by conventional methods known in the art.
• the polyisocyanate and the polyol are employed in amounts which will yield an NCO/OH stoichiometric ratio in a range of from about 0.9 to about 5.0.
• the NCO/OH equivalent ratio is, preferably, about 1.0 or more and about 3.0 or less, with the ideal range being from about 1.1 to about 2.5.
• Especially suitable organic polyisocyanate include polymethylene polyphenyl isocyanate, methylenebis(phenyl isocyanate), toluene diisocyanates, or combinations thereof.
• trimerization catalysts are used for the purpose of converting the blends in conjunction with excess A component to polyisocyanurate- polyurethane foams.
• the trimerization catalysts employed can be any catalyst known to one skilled in the art, including, but not limited to, glycine salts, tertiary amine trimerization catalysts, quaternary ammonium carboxylates, and alkali metal carboxylic acid salts and mixtures of the various types of catalysts.
• Preferred species within the classes are potassium acetate, potassium octoate, and N-(2-hydroxy-5-nonylphenol)methyl-N-methylglycinate.
• Optional flame retardants can also be incorporated, preferably in amount of not more than about 20 percent by weight of the reactants.
• Optional flame retardants include tris(2- chloroethyl)phosphate, tris(2-chloropropyl)phosphate, tris(2,3-dibromopropyl)phosphate, tris(l,3-dichloropropyl)phosphate, tri(2-chloroisopropyl)phosphate, tricresyl phosphate, tri(2,2- dichloroisopropyl)phosphate, diethyl N,N-bis(2-hydroxyethyl) aminomethylphosphonate, dimethyl methylphosphonate, tri(2,3-dibromopropyl)phosphate, tri(l,3- dichloropropyl)phosphate, and tetra-kis-(2-chloroethyl)ethylene diphosphate, triethylphosphate, diammonium phosphate, various halogenated aromatic compounds,
• Other optional ingredients can include from 0 to about 7 percent water, which chemically reacts with the isocyanate to produce carbon dioxide.
• This carbon dioxide acts as an auxiliary blowing agent.
• the water cannot be added to the polyol blend but, if used, can be added as a separate chemical stream.
• Formic acid is also used to produce carbon dioxide by reacting with the isocyanate and is optionally added to the "B" component.
• Dispersing agents and cell stabilizers can be incorporated into the present blends.
• Conventional fillers for use herein include, for example, aluminum silicate, calcium silicate, magnesium silicate, calcium carbonate, barium sulfate, calcium sulfate, glass fibers, carbon black and silica.
• the filler, if used, is normally present in an amount by weight ranging from about 5 parts to 100 parts per 100 parts of polyol.
• a pigment which can be used herein can be any conventional pigment such as titanium dioxide, zinc oxide, iron oxide, antimony oxide, chrome green, chrome yellow, iron blue siennas, molybdate oranges and organic pigments such as para reds, benzidine yellow, toluidine red, toners and phthalocyanines.
• the polyurethane or polyisocyanurate foams produced can vary in density from about 0.5 pounds per cubic foot to about 60 pounds per cubic foot, preferably from about 1.0 to 20.0 pounds per cubic foot, and most preferably from about 1.5 to 6.0 pounds per cubic foot.
• the density obtained is a function of how much of the blowing agent or blowing agent mixture disclosed in this invention plus the amount of auxiliary blowing agent, such as water or other co- blowing agents is present in the A and / or B components, or alternatively added at the time the foam is prepared.
• These foams can be rigid, flexible, or semi-rigid foams, and can have a closed cell structure, an open cell structure or a mixture of open and closed cells. These foams are used in a variety of well known applications, including but not limited to thermal insulation, cushioning, flotation, packaging, adhesives, void filling, crafts and decorative, and shock absorption.
• the foams of the present invention may be used to insulate buildings (e.g. building envelope) or any construction where energy management and/or insulation from temperature fluctuations on its exterior side are desirable.
• buildings e.g. building envelope
• Such structures include any standard structure known in the art including, but not limited to those, manufactured from clay, wood, stone, metals, plastics, cement, or the like, including, but not limited to homes, office buildings, or other structures residential, commercial, or otherwise were energy efficiency and insulation may be desirable.
• a two or more part foamable composition in accordance with the foregoing embodiments may be provided.
• the components of a two part system commonly referred to as the A-side and the B-side may be delivered through separate lines into a mixing head, such as a high pressure impingement-type mixer or a low pressure mechanical type mixer.
• a mixing head such as a high pressure impingement-type mixer or a low pressure mechanical type mixer.
• the components are provided through separate lines into a mixing head, such as a high pressure impingement-type mixer or a low pressure mechanical type mix head.
• the streams of the first, second and optionally additional component streams intersect in the mix head and mix with each other either by direct impingement of the high pressure component streams or by mechanical mixing of the low pressure component streams.
• the blowing agent does not vaporize. However, as the mixture exits the mix head and enters into atmospheric pressure, the blowing agent vaporizes as reaction of the polyisocyanate and polyol (to form the polyurethane or polyisocyanurate) occurs. Crosslinking and molecular weight captures the bubbles generated by the evolution of the gas before they can coalesce and escape and forms cells that provide the insulative function.
• foams in certain embodiments, may be produced in a discontinuous or a continuous process.
• a discontinuous process individual panel or other pars are produced in a mold or other suitable device.
• the foamable mixture is dispensed onto a moving conveyor and allowed to rise between the upper and lower facers of the panel.
• Typical facers include aluminum foil, roofing felt, aluminum, steel, particle board, plywood, FRP or other similar materials.
• the foams of the present invention may be used to insulate a building envelope such as a house, commercial building, or the like.
• the foams of the present invention may serve as a roofing insulation for flat or pitched roofs, as walls, ceilings, and floors in residential, commercial, governmental, and industrial buildings.
• the foam panels may be used to insulate and provide structure to cold storage buildings, walk in coolers and freezers, insulated transportation container, such as rail cars, trucks, and iso containers, and the like.
• the GWP of 1233zd(E) of ⁇ 7 is more than two orders of magnitude lower than that of currently utilized HFCs, and is more than one order of magnitude lower than the present limitations in the EU F-Gas Regulation.
• 1234ze(E) has properties similar to 134a.
• the GWP of 1234ze(E) of ⁇ 6 is more than two orders of magnitude lower than 134a and is within the EU F-Gas Regulation limit.
• Table 3 A and Table 3B list the properties of 1233zd(E) compared to some nonflammable blowing agents, such as 245fa and 141b, and various flammable blowing agents, such as methyl formate and hydrocarbons.
• the 1233zd(E) exhibits certain physical properties, such as boiling point and flammability, similar to those of 245fa and superior to those of methyl formate or hydrocarbons.
• the global warming potential (GWP) of 1233zd(E) of less than 5 is the lowest among all blowing agents compared.
• the GWP of 1233zd(E) is more than two orders of magnitude lower than that of the currently utilized 245fa, and is more than one order of magnitude lower than the present limitations in the EU F-Gas Regulation.
• a generic polyurethane foam formulation with 1233zd(E) and components that can be easily sourced in the US is listed in Table 5.
• This generic formulation was developed to yield a free rise density of about 1.9 lb/ft . With approximately 20% overpack.
• the density of the prepared foams ranged from 2.2 lb/ft 3 to 2.3 lb/ft 3.
• the amount of each of the blowing agent blends were calculated such that the total moles of blowing agent in the formulation were constant. This experiment is considered as a "drop-in" replacement study to determine the blowing agent blends' feasibility.
• the formulation was not optimized for any particular blowing agent that was used in this study.
• the free rise density and core density of the polyurethane foams prepared with methyl formate or 1233zd(E)/methyl formate blowing agent blends are within a 10% range of each other, as shown in Table 6. With the insignificant difference in density, comparisons of their physical, thermal properties are considered as fair and valid.
• Foams with 1233zd(E) offer the lowest initial and aged thermal conductivity, i.e. the best insulation value, when compared to that of 1233zd(E)/methyl formate blends or that of methyl formate alone.
• Foams with 1233zd(E)/methyl formate blends and methyl formate demonstrate a linear relationship between thermal conductivity and temperature, which is probably related to the boiling point of the blowing agent or blowing agent blends.
• Blending of up to 50 mol of methyl formate with 1233zd(E), such as 75/25mol 1233zd(E)/methyl and 50/50mol of 1233zd(E)/methyl demonstrates an insignificant impact on thermal conductivity at all evaluated temperatures. After the foam is aged, 1233zd(E) provides the best thermal retention, as shown in Figure 2.
• Table 8 summarizes physical properties, such as dimensional stability and compressive strength, of foam with various ratios of 1233zd(E)/methyl formate blends. Foams were evaluated after 28 days aging at -29°C, 90°C and 70°C/95 relative humidity as per ASTM D-2126-09. Furthermore, the compressive strength of foams was tested at both parallel and perpendicular directions as per ASTM D-1621-10.
• foams with 1233zd(E)/methyl formate blends demonstrate no significant difference in compressive strength, which ranged between 15psi to 20psi and 20psi to 25psi for perpendicular and parallel directions respectively.
• Dimensional stability of foams with methyl formate is a major drawback of the blowing agent.
• the dimensional stability of foams at both hot temperature environments i.e. 90°C and 70°C/95 R.H, improved significantly, more than three times better, with the addition of 1233zd(E).
• foam with 1233zd(E) has the best flame retardancy when compared to those with any of the 1233zd(E)/hydrocarbon blends and 1233zd(E)/methyl formate blends evaluated.
• foams with hydrocarbons unlike that with cyclopentane, those with isopentane and n-pentane have failed the B2 evaluation requirements.
• adding 1233zd(E) improves the flame retardancy of foams with isopentane, n-pentane or cyclopentane.
• foams with methyl formate passed the evaluation, a similar foam flammability improvement was not observed when 1233zd(E) was blended with methyl formate.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• General Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Polyurethanes Or Polyureas (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Related Child Applications (2)

Publications (1)

Family

ID=48572218

Family Applications (2)

Family Applications After (1)

Country Status (8)

Cited By (2)

Families Citing this family (29)

Citations (5)

Family Cites Families (34)

• 2012
  • 2012-09-21 JP JP2014545067A patent/JP2015500362A/ja active Pending
  • 2012-09-21 WO PCT/CN2012/081754 patent/WO2013082964A1/en not_active Ceased
  • 2012-09-21 WO PCT/CN2012/081740 patent/WO2013082963A1/en not_active Ceased
  • 2012-09-21 US US14/360,704 patent/US20150322225A1/en not_active Abandoned
  • 2012-09-21 MX MX2014006655A patent/MX350555B/es active IP Right Grant
  • 2012-09-21 EP EP23207970.7A patent/EP4310120A3/en active Pending
  • 2012-09-21 CN CN201280069212.4A patent/CN104271650B/zh active Active
  • 2012-09-21 EP EP12855052.2A patent/EP2788415A4/en not_active Withdrawn
  • 2012-09-21 US US14/362,495 patent/US20140312261A1/en not_active Abandoned
  • 2012-09-21 CA CA2856746A patent/CA2856746C/en not_active Expired - Fee Related
  • 2012-09-21 KR KR1020147015416A patent/KR20140105739A/ko not_active Ceased
  • 2012-12-10 US US13/710,416 patent/US20130149452A1/en not_active Abandoned
• 2017
  • 2017-06-16 JP JP2017118336A patent/JP2017197768A/ja active Pending
• 2018
  • 2018-07-02 US US16/025,633 patent/US20180312651A1/en not_active Abandoned

Patent Citations (5)

Also Published As

Similar Documents

Legal Events