Insulation moulding and method for its manufacture

A method for manufacturing an insulation moulding comprising

• filling a cavity between an inner and an outer wall of an open-box-shaped mould with a polyurethane reaction mixture and
• allowing the polyurethane reaction mixture to cure to a polyurethane comprising polymer C,
• wherein the inner and outer wall being arranged a fixed distance from one another and each wall comprising a bottom face and a plurality of side faces, wherein the fixed distance between the inner and outer wall can be the same or different for each face,
• wherein the polyurethane reaction mixture is fed through an inlet opening positioned in a middle area of the bottom face of the outer wall,
• wherein before filling the cavity, the mould is turned with the bottom face of the outer wall downwards so that the polyurethane reaction mixture is foaming upwards to fill the cavity,
• wherein the polyurethane reaction mixture comprises an isocyanate component B, which is reacted with an emulsion comprising
• (I) an isocyanate-reactive composition A, comprising a polyol mixture A1 comprising at least three polyols A1a, A1b and A1c as a continuous phase and
• (II) at least one physical blowing agent T as a disperse phase, wherein:
• (i) Ala is a polyether polyol having a hydroxyl value from 15 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 6.0, obtained by addition of an epoxy to at least one starter compound selected from the group consisting of carbohydrates, difunctional alcohols, and higher-functional alcohols;
• (ii) A1b is a polyether polyol having a hydroxyl value from 100 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 5.0, obtained by addition of an epoxy to an aromatic amine;
• (iii) A1c is a polyester polyether polyol having a hydroxyl value from 100 mg KOH/g to 450 mg KOH/g and an OH functionality from 1.5 to 3.5, obtained by addition of an epoxy to an esterification product of an aromatic dicarboxylic acid derivative and a difunctional and/or higher-functional alcohol.