# US 2019/0375878 A1 · Hydrocarbon Blown Polyurethane Foam Formulation Giving Desirable Thermal Insulation Properties

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- Number: US 2019/0375878 A1
- Document ID: US20190375878A1
- Status: Published application
- Kind: A1
- Application number: 16/546,364
- Filed: 2019-08-21
- Published: 2019-12-12
- Earliest claimed: 2012-07-31
- Assignees: Huntsman International LLC
- Applicants: Huntsman International LLC
- Inventors: Sachchida N. Singh; Kristof Dedecker; Sheila Dubs; Paul Coleman
- Web page: https://patentgrep.com/patent/US20190375878A1

## CPC

- C08G 18/14: {Manufacture of cellular products}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 18/06: with compounds having active hydrogen
- C08G 18/092: {oligomerisation to isocyanurate groups}
- C08G 18/163: {covered by C08G18/18 and C08G18/22}
- C08G 18/1808: {having alkylene polyamine groups}
- C08G 18/1816: {having carbocyclic groups}
- C08G 18/1825: {having hydroxy or primary amino groups}
- C08G 18/1833: {having ether, acetal, or orthoester groups}
- C08G 18/1875: {containing ammonium salts or mixtures of secondary of tertiary amines and acids}
- C08G 18/2018: {having one nitrogen atom in the ring}
- C08G 18/2027: {having two nitrogen atoms in the ring}
- C08G 18/2063: {having two nitrogen atoms in the condensed ring system}
- C08G 18/2081: {containing at least two non-condensed heterocyclic rings}
- C08G 18/225: {of alkali or alkaline earth metals}
- C08G 18/4829: {Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C08G 18/5033: {containing carbocyclic groups (C08G18/5024 takes precedence)}
- C08J 9/141: {Hydrocarbons}
- C08G 18/161: {containing two or more components to be covered by at least two of the groups C08G18/166, C08G18/18 or C08G18/22}
- C08G 18/4208: {containing aromatic groups}
- C08G 18/4211: {derived from aromatic dicarboxylic acids and dialcohols}
- C08G 18/4216: {from mixtures or combinations of aromatic dicarboxylic acids and aliphatic dicarboxylic acids and dialcohols}
- C08G 18/4219: {from aromatic dicarboxylic acids and dialcohols in combination with polycarboxylic acids and/or polyhydroxy compounds which are at least trifunctional}
- C08G 18/4222: {derived from aromatic polyhydroxy compounds and polycarboxylic acids}
- C08G 18/4227: {derived from aromatic polycarboxylic acids containing at least two aromatic rings and polyhydroxy compounds}
- C08G 2110/0025: rigid
- C08G 2110/005: < 50kg/m3
- C08G 2115/02: to isocyanurate groups
- C08J 2203/14: Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J 2203/182: of physical blowing agents, e.g. acetone and butane
- C08J 2375/04: Polyurethanes
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- 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)

## Abstract

Polyurethane/polyisocyanurate foam insulation described herein is derived from a composition that contains an organic polyisocyanate, an isocyanate reactive material containing at least about 20% by weight, based on the total weight of the composition, of an aromatic polyester polyol, a hydrocarbon blowing agent, a first catalyst selected from the group consisting of a carboxylate salt of an alkali metal, a carboxylate salt of an alkaline earth metal, a carboxylate salt of a quaternary ammonium, and combinations thereof, and a second catalyst comprising a non-reactive tertiary amine, wherein a molar ratio of the first catalyst to the second catalyst is less than about 1.25, the composition gels quickly, and the composition has an isocyanate index greater than about 175. Such an insulating foam has a ratio of thermal conductivity at 75° F. to thermal conductivity at 25° F. between about 0.98 and about 1.10.

## Claims

### Claim 1

A method of forming an insulating member, comprising:
forming a composition, comprising:
an organic polyisocyanate;
at least about 20% by weight of an aromatic polyester polyol based on the total weight of the composition;
a hydrocarbon blowing agent;
a first catalyst comprising a salt selected from the group consisting of a carboxylate salt of an alkali metal, a carboxylate salt of an alkaline earth metal, a carboxylate salt of a quaternary ammonium, and combinations thereof;
a tertiary amine selected from the group consisting of a trialkylamine, an alkyl amine, an alkylaryl amine, an aliphatic polyamine, diazabicyclooctane, 1,4-ethylene piperidine, N-methylimidazole, 1,2-dimethylimidazole, 1,8-diazabicyclo(5,4,0)undecene-7, an ether amine, a saturated heterocyclic amine, and a combination thereof;
wherein a molar ratio of the first catalyst to the tertiary amine is less than about 1.0 or less, wherein the tertiary amine is present in an amount of at least 4.0 millimoles per 100 grams of the composition to 9.46 millimoles per 100 grams of the composition, and the composition has an isocyanate index of about 200 to 500; and
dispensing the composition onto a substantially flat moving surface.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first catalyst is selected from the group consisting of potassium formate, potassium acetate, potassium propionate, potassium butanoate, potassium pentanoate, potassium hexanoate, potassium neohexanoate, potassium heptanoate, potassium octoate, potassium neooctoate, potassium 2-ethylhexanoate, potassium decanoate, potassium butyrate, potassium isobutyrate, sodium octoate, lithium octoate, trimethyl(2-hydroxypropyl)ammonium formate, and trimethyl(2-hydroxypropyl)ammonium 2-ethylhexanoate.

### Claim 3 (depends on 1)

The method of claim 1, wherein the organic polyisocyanate is a polymeric polymethylene polyphenylene polyisocyanate having an isocyanate functionality greater than about 2.0.

### Claim 4 (depends on 3)

The method of claim 3, wherein the organic polyisocyanate has a diphenyl methane diisocyanate content between about 15% and about 42% by weight based on the total weight of the organic polyisocyanate.

### Claim 5 (depends on 1)

The method claim 1, wherein the hydrocarbon blowing agent comprises a hydrocarbon selected from the group consisting of isopentane, n-pentane, and cyclopentane.

### Claim 6 (depends on 1)

The method of claim 1, wherein the hydrocarbon blowing agent comprises a blend of isopentane and n-pentane in a ratio of isopentane to n-pentane between about 80:20 and 20:80 parts by weight.

### Claim 7 (depends on 1)

The method of claim 1, wherein the tertiary amine is present in an amount of at least about 4.5 millimoles per 100 grams of the composition to 9.46 millimoles per 100 grams of the composition.

### Claim 8 (depends on 1)

The method of claim 1, wherein the composition further comprises a polyol selected from the group consisting of a polyether polyol and an aliphatic polyester polyol, wherein the polyether polyol or the aliphatic polyester polyol has an equivalent weight between about 40 and about 4000 and a functionality of about 2 to about 8.

### Claim 9

A method of forming an insulating member, comprising:
forming a composition, comprising:
an organic polyisocyanate;
at least about 20% by weight of an aromatic polyester polyol;
a hydrocarbon blowing agent comprising a C4-C6 hydrocarbon;
a first catalyst comprising a salt selected from the group consisting of a carboxylate salt of an alkali metal, a carboxylate salt of an alkaline earth metal, a carboxylate salt of a quaternary ammonium, and combinations thereof;
a tertiary amine selected from the group consisting of a trialkylamine, an alkyl amine, an alkylaryl amine, an aliphatic polyamine, diazabicyclooctane, 1,4-ethylene piperidine, N-methylimidazole, 1,2-dimethylimidazole, 1,8-diazabicyclo(5,4,0)undecene-7, an etheramine, a saturated heterocyclic amine, and a combination thereof;
wherein a molar ratio of the first catalyst to the tertiary amine is less than about 1.5 or less, wherein the tertiary amine is present in an amount of at least 3.0 millimoles per 100 grams of the composition; and
dispensing the composition onto a substantially flat moving surface.

### Claim 10 (depends on 9)

The method of claim 9, wherein the first catalyst is selected from the group consisting of potassium formate, potassium acetate, potassium propionate, potassium butanoate, potassium pentanoate, potassium hexanoate, potassium neohexanoate, potassium heptanoate, potassium octoate, potassium neooctoate, potassium 2-ethylhexanoate, potassium decanoate, potassium butyrate, potassium isobutyrate, sodium octoate, lithium octoate, trimethyl(2-hydroxypropyl)ammonium formate, and trimethyl(2-hydroxypropyl)ammonium 2-ethylhexanoate.

### Claim 11 (depends on 9)

The method of claim 9, wherein the organic polyisocyanate is a polymeric polymethylene polyphenylene polyisocyanate having an isocyanate functionality greater than about 2.0.

### Claim 12 (depends on 11)

The method of claim 11, wherein the organic polyisocyanate has a diphenyl methane diisocyanate content between about 15% and about 42% by weight based on the total weight of the organic polyisocyanate.

### Claim 13 (depends on 9)

The method claim 9, wherein the hydrocarbon blowing agent comprises a hydrocarbon selected from the group consisting of isopentane, n-pentane, and cyclopentane.

### Claim 14 (depends on 9)

The method of claim 9, wherein the hydrocarbon blowing agent comprises a blend of isopentane and n-pentane in a ratio of isopentane to n-pentane between about 80:20 and 20:80 parts by weight.

### Claim 15 (depends on 9)

The method of claim 9, wherein the tertiary amine is present in an amount of at least about 4.5 millimoles per 100 grams of the composition to 9.46 millimoles per 100 grams of the composition.

### Claim 16 (depends on 9)

The method of claim 9, wherein the composition further comprises a polyol selected from the group consisting of a polyether polyol and an aliphatic polyester polyol, wherein the polyether polyol or the aliphatic polyester polyol has an equivalent weight between about 40 and about 4000 and a functionality of about 2 to about 8.