# US 11,299,882 B2 · Foam insulation with improved low temperature properties using polyol additives > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,299,882 B2 - Document ID: US11299882B2 - Status: Granted - Kind: B2 - Application number: 16/207,735 - Filed: 2018-12-03 - Published: 2020-06-04 - Granted: 2022-04-12 - Earliest claimed: 2018-12-03 - Assignees: Johns Manville - Applicants: Johns Manville - Inventors: Malay Nandi; Lance Wang; Jawed Asrar - Web page: https://patentgrep.com/patent/US11299882B2 ## CPC - E04B 1/7608: {comprising a prefabricated insulating layer, disposed between two other layers or panels} - E04D 11/02: Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition (gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17) - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/245: {another layer next to it being a foam layer} - E04D 3/351: {at least one of the layers being composed of insulating material, e.g. fibre or foam material} - E04D 13/1643: {the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs} - F16L 59/029: {layered} - B32B 2250/02: 2 layers - B32B 2262/101: Glass fibres - B32B 2266/0214: Materials belonging to B32B27/00 - B32B 2266/0278: Polyurethane - B32B 2266/06: Open cell foam - B32B 2307/304: Insulating - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/72: Density - B32B 2307/7265: Non-permeable - B32B 2307/732: Dimensional properties - B32B 2419/00: Buildings or parts thereof - B32B 2419/06: Roofs, roof membranes - E04B 2001/742: {Use of special materials; Materials having special structures or shape} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL ## Abstract A polyisocyanurate foam insulation product is produced from an isocyanate component and a polyol-containing component including a blowing agent. The polyol-containing component comprises one or more polyols, a fire retardant, and a hydroxyl-containing low-molecular-weight additive effective to increase the R-value per inch of the insulation product as measured at 40° F., as compared with an otherwise-identical formulation lacking the hydroxyl-containing low-molecular-weight additive. The polyisocyanurate foam insulation product may have an R-value per inch of at least 6.0 when measured at 40° F. and may have an R-value per inch of at least 5.5 when measured at 25° F. Suitable hydroxyl-containing low-molecular-weight additives may include triethanolamine, trimethylolpropane, N-methyldiethanolamine, 1,4 butanediol, or another suitable multi-functional alcohol or combination of multi-functional alcohols. ## Claims ### Claim 1 A polyisocyanurate foam insulation product produced from: an isocyanate component; and a polyol-containing component including a blowing agent, one or more polyester polyols, a fire retardant, and one or more hydroxyl-containing low-molecular-weight additives selected from a group consisting of: triethanolamine (TEA), trimethylolpropane (TMP), diethyl bis(2-hydroxyethyl)aminomethylphosphonate (DEHAMP), N-methyldiethanolamine (MDEA), 1,4 butanediol (BD), isobutanol, diethylethanolamine (DEEA), and a multi-functional alcohol, wherein: the one or more hydroxyl-containing low-molecular weight additives is present in an amount of between 10 parts and 20 parts per 100 parts of the one or more polyester polyols; the polyisocyanurate foam insulation product has an R-value per inch of at least 6.0 when measured at 40° F.; the polyisocyanurate foam insulation product has a cell size of less than 200 microns; the polyol-containing component does not include any polyol that is not a polyester polyol or the one or more hydroxyl-containing low-molecular-weight additives; and the polyisocyanurate foam insulation product is an insulation board having at least one facer, the facer comprising fiberglass, foil, or paper. ### Claim 2 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives is effective to increase the R-value per inch of the insulation product as measured at 40° F., as compared with an otherwise-identical formulation lacking the one or more hydroxyl-containing low-molecular-weight additives. ### Claim 3 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 6.5 when measured at 40° F. ### Claim 4 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 5.5 when measured at 25° F. ### Claim 5 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product has an R-value per inch of at least 6.0 when measured at 25° F. ### Claim 6 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives has a molecular weight of between 50 and 500. ### Claim 7 (depends on 6) The polyisocyanurate foam insulation product of claim 6, wherein the one or more hydroxyl-containing low-molecular-weight additives has a molecular weight of between 50 and 300. ### Claim 8 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives is a multi-functional alcohol. ### Claim 9 (depends on 8) The polyisocyanurate foam insulation product of claim 8, wherein the multi-functional alcohol is selected from the group consisting of aliphatic, cycloaliphatic, aromatic, heterocyclic, and polyhydric alcohols and combinations thereof. ### Claim 10 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises triethanolamine (TEA). ### Claim 11 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises trimethylolpropane (TMP). ### Claim 12 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises diethyl bis(2-hydroxyethyl)aminomethylphosphonate (DEHAMP). ### Claim 13 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises N-methyldiethanolamine (MDEA). ### Claim 14 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises 1,4 butanediol (BD). ### Claim 15 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises isobutanol. ### Claim 16 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises diethylethanolamine (DEEA). ### Claim 17 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises triethanolamine (TEA) and trimethylolpropane (TMP). ### Claim 18 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises triethanolamine (TEA) and sorbitol. ### Claim 19 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the fire retardant is non-halogenated. ### Claim 20 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the fire retardant comprises at least one fire retardant selected from the group of fire retardants consisting of diethyl hydroxymethyl phosphonate (DEHMP), and tris(2-chloroisopropyl)phosphate (TCPP). ### Claim 21 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the fire retardant comprises one or more compounds selected from the group of compounds consisting of an organo-phosphate, an organo-phosphite, and an organo-phosphonate. ### Claim 22 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product is a rigid foam having a density of between 1.45 and 25 lbs/ft3. ### Claim 23 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product has a cell size of less than 150 microns. ### Claim 24 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyisocyanurate foam insulation product has a cell size of less than 120 microns. ### Claim 25 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component has, before the addition of the blowing agent, a viscosity of less than 3000 centipoise (cps). ### Claim 26 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component has, before the addition of the blowing agent, a viscosity of less than 2800 centipoise (cps). ### Claim 27 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component has, before the addition of the blowing agent, a viscosity of less than 2500 centipoise (cps). ### Claim 28 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component has, before the addition of the blowing agent, a viscosity of less than 2000 centipoise (cps). ### Claim 29 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein at least one of the one or more polyester polyols has a hydroxyl number between 25 and 500. ### Claim 30 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the blowing agent comprises a mixture of n-pentane and isopentane. ### Claim 31 (depends on 30) The polyisocyanurate foam insulation product of claim 30, wherein the blowing agent comprises water in an amount between 0.1 and 1.0 weight percent of the polyol-containing component. ### Claim 32 (depends on 1) The polyisocyanurate foam insulation product of claim 1, further comprising a catalyst and a surfactant. ### Claim 33 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component comprises a polyol having a functionality of greater than 2.0. ### Claim 34 (depends on 33) The polyisocyanurate foam insulation product of claim 33, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises triethanolamine (TEA). ### Claim 35 (depends on 33) The polyisocyanurate foam insulation product of claim 33, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises one or more additives selected from the group consisting of trimethylolpropane (TMP), diethyl bis(2-hydroxyethyl)aminomethylphosphonate (DEHAMP), N-methyldiethanolamine (MDEA), 1,4 butanediol (BD), isobutanol, and diethylethanolamine (DEEA). ### Claim 36 (depends on 33) The polyisocyanurate foam insulation product of claim 33, wherein the one or more hydroxyl-containing low-molecular-weight additives comprises triethanolamine (TEA), and the hydroxyl-containing low-molecular-weight additive comprises trimethylolpropane (TMP) or sorbitol. ### Claim 37 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component comprises a polyol having a functionality of at least 2.45. ### Claim 38 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component comprises a polyol having a functionality of between 2.0 and 2.45. ### Claim 39 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component comprises two polyols, at least one of which has a functionality of greater than 2.0. ### Claim 40 (depends on 1) The polyisocyanurate foam insulation product of claim 1, wherein the polyol-containing component comprises two polyols, both of which have functionalities of at least 2.0.