Hcfo-containing polyurethane foam-forming compositions, related foams and methods for their production

A polyurethane foam-forming composition comprising:

• (a) polyol blend comprising:
• (1) 30% to 98% by weight, based on total weight of the polyol blend, of a first hydroxyl-initiated polyether polyol having a functionality of 1.5 to less than 4.0 and an OH number of 200 to 600 mg KOH/g;
• (2) 1 to 40% by weight, based on total weight of the polyol blend, of a second hydroxyl-initiated polyether polyol having a functionality of 4.0 to 8 and an OH number of 300 to 600 mg KOH/g;
• and
• (3) 1 to 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,
• herein the polyol blend has a content of —C2H4O— units of 2 to 8% by weight, based on the total weight of the polyol blend.
• (b) a blowing agent composition comprising:
• (1) a physical blowing agent;
• and
• (2) water, in which
• (i) the water is present in an amount of at least 1% by weight, based on the total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate,
• (ii) the physical blowing agent comprises a hydrochlorofluoroolefin that is present in an amount of 5 to 25% by weight, based on total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate, and in an amount of at least 80% by weight, based on total weight of the physical blowing agent present in the blowing agent composition, and
• (iii) the physical blowing agent and the water are present in a relative ratio, by weight, of at least 4:1;
• and
• (c) a polyisocyanate is present in an amount sufficient to provide an isocyanate index of 0.9 to 1.5.

A method of producing a polyurethane foam comprising reacting, at an isocyanate index of 0.9 to 1.5, a polyurethane foam-forming composition comprising:

• (a) a polyol blend comprising:
• (1) 30% to 98% by weight, based on total weight of the polyol blend, of a first hydroxyl-initiated polyether polyol having a functionality of 1.5 to less than 4.0 and an OH number of 200 to 600 mg KOH/g;
• (2) 1 to 40% by weight, based on total weight of the polyol blend, of a second hydroxyl-initiated polyether polyol having a functionality of 4.0 to 8 and an OH number of 300 to 600 mg KOH/g;
• and
• (3) 1 to 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,
• wherein the polyol blend has a content of —C2H4O— units of 2 to 8% by weight, based on the total weight of the polyol blend.
• (b) a blowing agent composition comprising:
• (1) a physical blowing agent;
• and
• (2) water, in which
• (i) the water is present in an amount of at least 1% by weight, based on the total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate,
• (ii) the physical blowing agent comprises a hydrochlorofluoroolefin that is present in an amount of 5 to 25% by weight, based on total weight of the polyurethane foam-forming composition except for the weight of the polyisocyanate, and in an amount of at least 80% by weight, based on total weight of the physical blowing agent present in the blowing agent composition;
• and
• (iii) the physical blowing agent and the water are present in a relative ratio, by weight, of at least 4:1;
• and
• (c) a polyisocyanate.