Methods of preparing ultra-low density spray polyurethane foam and uses thereof

Abstract

Open-cell spray polyurethane foams having low densities and high yields, methods for the manufacture thereof, and methods of use thereof are disclosed. A isocyanate mixture and a resin mixture comprising a polyol, an emulsifier, a flame retardant, a catalyst, a surfactant, and a blowing agent may be simultaneously applied to a substrate with a spraying system. If the isocyanate and resin mixtures are sprayed while the spraying system is in an environment having an ambient temperature ranging from 80 to 90 degrees Fahrenheit and a relative humidity of 30% or less, the resulting foam may have a density of 5 pounds per cubic foot or less and a yield of at least 15,000 board feet per 50 gallons. Such foams may also have various desirable physical characteristics similar to conventional closed-cell spray polyurethane foams, making these foams ideal for insulating buildings.

Dependencies are inferred from the claim text.