# US 11,999,833 B2 · Process for producing isocyanate-based foam construction boards

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- Number: US 11,999,833 B2
- Document ID: US11999833B2
- Status: Granted
- Kind: B2
- Application number: 17/511,123
- Filed: 2021-10-26
- Published: 2022-02-17
- Granted: 2024-06-04
- Earliest claimed: 2015-12-08
- Assignees: Holcim Technology Ltd
- Applicants: Holcim Technology Ltd.
- Inventors: John Letts; Chunhua Yao; Michael Hubbard
- Web page: https://patentgrep.com/patent/US11999833B2

## CPC

- C08J 9/0023: {containing oxygen}
- B32B 5/20: foamed in situ
- B32B 37/15: with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- C08G 18/14: {Manufacture of cellular products}
- C08G 18/42: Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08J 9/141: {Hydrocarbons}
- C08J 9/142: {Compounds containing oxygen but no halogen atom}
- C08J 9/149: {Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143}
- B32B 2266/0278: Polyurethane
- B32B 2266/08: Closed cell foam
- B32B 2419/00: Buildings or parts thereof
- C08J 2201/022: 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
- C08J 2203/12: Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
- C08J 2203/14: Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J 2203/182: of physical blowing agents, e.g. acetone and butane
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2205/10: Rigid foams
- C08J 2207/00: Foams characterised by their intended use
- C08J 2375/06: from polyesters
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

## Abstract

A process for producing a polyurethane or polyisocyanurate construction board, the process comprising (i) providing an A-side reactant stream that includes an isocyanate-containing compound; (ii) providing a B-side reactant stream that includes a polyol, where the B-side reactant stream includes a blowing agent that includes a pentane and a blowing agent additive that has a Hansen Solubility Parameter (δt) that is greater than 17 MPa−0.5; and (iii) mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture.

## Claims

### Claim 1

A process for producing a polyurethane or polyisocyanurate foam construction board, the process comprising:
(i) providing an A-side reactant stream that includes a polymeric MDI;
(ii) providing a B-side reactant stream that includes an aromatic polyester polyol, from about 1.0 to about 5.0 parts by weight surfactant, from about 5 to about 30 parts by weight of a flame retardant, up to 1.0 parts by weight of added water, one or more catalysts to initiate the reaction between the polymeric MDI and the aromatic polyester polyol and to promote a trimerization reaction to form polyisocyanurate groups, and from about 12 to about 40 parts by weight of a physical blowing agent mixture that includes an isopentane, n-pentane, and methyl formate, where the amounts are based on 100 parts by weight of the aromatic polyester polyol, and where the physical blowing agent mixture includes from about 7 to about 35 mole % of the methyl formate based on the total moles of physical blowing agent mixture; and
(iii) mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture, to thereby produce a closed-cell foam having a density of from about 1.5 to about 1.8 lbs/ft3, and an index of at least 210.

### Claim 2 (depends on 1)

The process of claim 1, further comprising exposing the reaction mixture to heat.

### Claim 3 (depends on 2)

The process of claim 2, where the reaction mixture is deposited onto a facer and the reaction mixture is processed within a laminator.

### Claim 4 (depends on 1)

The process of claim 1, where the process produces a construction board having an index of at least 220.

### Claim 5 (depends on 1)

The process of claim 1, where the physical blowing agent mixture includes from about 10 to about 30 mole % of the methyl formate based on the total moles of physical blowing agent mixture.

### Claim 6 (depends on 1)

The process of claim 1, where the B-side reactant stream includes less than 0.8 parts by weight water per 100 parts by weight polyol.

### Claim 7 (depends on 1)

The process of claim 1, where the flame retardant is selected from the group consisting of tri(monochloropropyl) phosphate and tri-2-chloroethyl phosphate.

### Claim 8

A process for producing a polyurethane or polyisocyanurate construction board, the process comprising:
(i) combining a polyester polyol, an isocyanate, and a physical blowing agent mixture, said physical blowing agent mixture including an isopentane, n-pentane, and methyl formate, and less than 0.6 parts by weight water per 100 parts by weight polyol to form a foam-forming mixture, where the ratio of polyol to isocyanate provides a closed-cell foam having an Index of at least 210, and where the amount of isopentane, n-pentane, and methyl formate, and any water present provide a closed-cell foam having a density of 1.0 to 2.5 lbs/ft3, and where the isopentane, n-pentane, and methyl formate form a blowing agent mixture, and where the physical blowing agent mixture includes from about 7 to about 35 mole % methyl formate based on the total moles of blowing agent mixture;
(ii) depositing the foam-forming mixture on a facer; and
(iii) heating the foam-forming mixture to form a closed-cell foam.