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US 11,767,407 B1Granted
HCFO-containing polyurethane foam-forming compositions, related foams and methods for their production
AssigneeCovestro LLC
InventorBrandon Parks
Life of this patent
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Abstract
Polyurethane foam-forming compositions, methods of producing polyurethane foams, polyurethane foams produced from such compositions made by such methods, as well as isocyanate-reactive compositions. The polyurethane foam-forming compositions include a polyol blend, a blowing agent composition, and a polyisocyanate. The polyol blend includes an aromatic amine-initiated polyether polyol, a saccharide-initiated polyether polyol, and an aromatic polyester polyol and has a content of —C2H4O— units of 3 to 6% by weight, based on the total weight of the polyurethane foam-forming composition. The blowing agent composition includes a hydrochlorofluoroolefin and water.
Claims23
A polyurethane foam-forming composition comprising:
- (a) a polyol blend comprising:
- (1) at least 30% by weight, based on total weight of the polyol blend, of an aromatic amine-initiated polyether polyol having a functionality of at least 2.5 and an OH number of 200 to 600 mg KOH/g;
- (2) at least 30% by weight, based on total weight of the polyol blend, of a saccharide-initiated polyether polyol having a functionality of 4 to 6 and an OH number of 200 to 600 g/KOH gram;
- and
- (3) 1 to 25% by weight, based on total weight of the polyol blend, of an aromatic polyester polyol having a functionality of 1.5 to 3 and an OH number of 150 to 410 mg KOH/g,
- wherein the polyol blend has a content of —C2H4O— units of 3 to 6% by weight, based on the total weight of the polyurethane foam-forming composition;
- (b) a polyisocyanate present in an amount sufficient to provide an isocyanate index of 1.01 to less than 1.15;
- and
- (c) a blowing agent composition comprising:
- (1) a physical blowing agent;
- and
- (2) water present in an amount of at least 1.70% by weight, based on the total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate,
- wherein:
- (i) the physical blowing agent comprises a hydrochlorofluoroolefin that is present in an amount of 5% to 15% by weight, based on total weight of the polyurethane foam-forming composition, and in an amount of at least 90% by weight, based on total weight of physical blowing agent in the blowing agent composition, and
- (ii) the physical blowing agent composition and the water are present in a relative ratio, by weight, of 5:1 to 50:1.
12 more elements
A method of producing a polyurethane foam, comprising reacting, at an isocyanate index of 1.01 to less than 1.15, a polyurethane foam-forming composition comprising a polyol blend, a polyisocyanate, and a blowing agent composition, wherein:
- (a) the polyol blend comprises:
- (1) at least 30% by weight, based on total weight of the polyol blend, of an aromatic amine-initiated polyether polyol having a functionality of at least 2.5 and an OH number of 200 to 600 mg KOH/g;
- (2) at least 30% by weight, based on total weight of the polyol blend, of a saccharide-initiated polyether polyol having a functionality of 4 to 6 and an OH number of 200 to 600 g/KOH gram;
- and
- (3) 1 to 25% by weight, based on total weight of the polyol blend, of an aromatic polyester polyol having a functionality of 1.5 to 3 and an OH number of 150 to 410 mg KOH/g,
- wherein the polyol blend has a content of —C2H4O— units of 3 to 6% by weight, based on the total weight of the polyurethane foam-forming composition;
- and
- (b) the blowing agent composition comprises:
- (1) a physical blowing agent;
- and
- (2) water present in an amount of at least 1.70% by weight, based on the total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate,
- wherein:
- (i) the physical blowing agent comprises a hydrochlorofluoroolefin that is present in an amount of 5% to 15% by weight, based on total weight of the polyurethane foam-forming composition and in an amount of at least 20% by weight, based on total weight of physical blowing agent in the blowing agent composition, and
- (ii) the physical blowing agent composition and the water are present in a relative ratio, by weight, of 5:1 to 50:1.
11 more elements
An isocyanate-reactive composition, comprising:
- (a) polyol blend comprising:
- (1) at least 30% by weight, based on total weight of the polyol blend, of an aromatic amine-initiated polyether polyol having a functionality of at least 2.5 and an OH number of 200 to 600 mg KOH/g;
- (2) at least 30% by weight, based on total weight of the polyol blend, of a saccharide-initiated polyether polyol having a functionality of 4 to 6 and an OH number of 200 to 600 g/KOH gram;
- and
- (3) 1 to 25% by weight, based on total weight of the polyol blend, of an aromatic polyester polyol having a functionality of 1.5 to 3 and an OH number of 150 to 410 mg KOH/g,
- wherein the polyol blend has a content of —C2H4O— units of 5 to 15% by weight, based on the total weight of the isocyanate-reactive composition;
- and
- (b) a blowing agent composition comprising:
- (1) a physical blowing agent and
- (2) water present in an amount of at least 1.70% by weight, based on the total weight of the isocyanate-reactive composition,
- wherein:
- (i) the physical blowing agent comprises a hydrochlorofluoroolefin that is present in an amount of 10% to 30% by weight, based on total weight of the isocyanate-reactive composition and in an amount of at least 90% by weight, based on total weight of physical blowing agent in the blowing agent composition, and
- (ii) the physical blowing agent composition and the water are present in a relative ratio, by weight, of 5:1 to 50:1.
10 more elements
Dependencies are inferred from the claim text.