Process for making low density spray polyurethane foam for insulation, sound abatement, and air sealing of building enclosures
AssigneeSES Foam, LLC
InventorsJose Luna, Charles Valentine
Life of this patent
Estimating the term…
Abstract
This disclosure provides for new low density, open cell polyurethane (PUR) foams, which can be prepared using a combination of precursors and conditions, for example, an off-ratio A-side:B-side volume ratio (v:v) which includes a higher volume of A-side than the volume of B-side, an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0, and an Isocyanate Index of from about 20 percent to about 40 percent. Using the processes and precursors disclosed herein, polyurethane foams having a density of from about 0.25 lb/ft3 to about 0.45 lb/ft3 can be obtained.
Claims43
A low density polyurethane (PUR) foam, the foam comprising the contact product of:
- (a) a first reaction composition (A-side) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0;
- and
- (b) a second reaction composition (B-side) comprising:
- a polyether polyol characterized by a Hydroxyl Number (mg KOH/g) of from about 20 to about 45;
- a polyurethane producing catalyst in a concentration of from 5 wt % to 12 wt % in the second reaction composition (B-side);
- a flame retardant;
- a surfactant;
- and
- water;
- wherein the first reaction composition (A-side) and the second reaction composition (B-side) are contacted in amounts to provide [1] an A-side:B-side volume ratio (v:v) of from 1.2:1 to 2:1, and [2] an Isocyanate Index of 20 to 40 (expressed as a percentage);
- and
- the low density PUR foam has a density from about 0.25 lb/ft3 to about 0.45 lb/ft3.
A process for making a low density polyurethane (PUR) foam, the process comprising the steps of contacting:
- (a) a first reaction composition (A-side) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0;
- and
- (b) a second reaction composition (B-side) comprising:
- a polyether polyol characterized by a Hydroxyl Number (mg KOH/g) of from about 20 to about 45;
- a polyurethane producing catalyst in a concentration of from 5 wt % to 12 wt % in the second reaction composition (B-side);
- a flame retardant;
- a surfactant;
- and
- water;
- wherein the first reaction composition (A-side) and the second reaction composition (B-side) are contacted in amounts to provide [1] an A-side:B-side volume ratio (v:v) of from 1.2:1 to 2:1, and [2] an Isocyanate Index of 20 to 40 (expressed as a percentage);
- and
- the low density PUR foam has a density from about 0.25 lb/ft3 to about 0.45 lb/ft3.
Dependencies are inferred from the claim text.