US20150028247A1 - Rigid foam and associated article and method - Google Patents
Rigid foam and associated article and method Download PDFInfo
- Publication number
- US20150028247A1 US20150028247A1 US13/948,416 US201313948416A US2015028247A1 US 20150028247 A1 US20150028247 A1 US 20150028247A1 US 201313948416 A US201313948416 A US 201313948416A US 2015028247 A1 US2015028247 A1 US 2015028247A1
- Authority
- US
- United States
- Prior art keywords
- polyurethane
- polyisocyanurate foam
- phenylene ether
- particulate poly
- diisocyanate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 0 *O[Si](*)([8*])[8*] Chemical compound *O[Si](*)([8*])[8*] 0.000 description 2
- SNPOZKMCSJMKKV-UHFFFAOYSA-N COC1=C(C)C(C)=C(C)C(C)=C1C Chemical compound COC1=C(C)C(C)=C(C)C(C)=C1C SNPOZKMCSJMKKV-UHFFFAOYSA-N 0.000 description 1
- QPOOSIBQVRSWEP-UHFFFAOYSA-N COC1=C(O)C=CC(CCC[Si](C)(C)O[Si](C)(C)CCCC2=CC=C(O)C(CO)=C2)=C1 Chemical compound COC1=C(O)C=CC(CCC[Si](C)(C)O[Si](C)(C)CCCC2=CC=C(O)C(CO)=C2)=C1 QPOOSIBQVRSWEP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0014—Use of organic additives
- C08J9/0023—Use of organic additives containing oxygen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/08—Processes
- C08G18/14—Manufacture of cellular products
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
- C08G18/3203—Polyhydroxy compounds
- C08G18/3206—Polyhydroxy compounds aliphatic
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
- C08G18/3203—Polyhydroxy compounds
- C08G18/3218—Polyhydroxy compounds containing cyclic groups having at least one oxygen atom in the ring
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
- C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
- C08G18/6633—Compounds of group C08G18/42
- C08G18/6637—Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38
- C08G18/664—Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
- C08G18/72—Polyisocyanates or polyisothiocyanates
- C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
- C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
- C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
- C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/02—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by the reacting monomers or modifying agents during the preparation or modification of macromolecules
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/143—Halogen containing compounds
- C08J9/144—Halogen containing compounds containing carbon, halogen and hydrogen only
- C08J9/146—Halogen containing compounds containing carbon, halogen and hydrogen only only fluorine as halogen atoms
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/143—Halogen containing compounds
- C08J9/147—Halogen containing compounds containing carbon and halogen atoms only
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K21/00—Fireproofing materials
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K21/00—Fireproofing materials
- C09K21/14—Macromolecular materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0025—Foam properties rigid
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0041—Foam properties having specified density
- C08G2110/005—< 50kg/m3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G2110/00—Foam properties
- C08G2110/0083—Foam properties prepared using water as the sole blowing agent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J2203/142—Halogenated saturated hydrocarbons, e.g. H3C-CF3
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/16—Unsaturated hydrocarbons
- C08J2203/162—Halogenated unsaturated hydrocarbons, e.g. H2C=CF2
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2205/00—Foams characterised by their properties
- C08J2205/10—Rigid foams
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2471/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
- C08J2471/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2471/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
- C08J2471/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
- C08J2471/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
- C08J2471/12—Polyphenylene oxides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2483/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon only; Derivatives of such polymers
- C08J2483/10—Block- or graft-copolymers containing polysiloxane sequences
- C08J2483/12—Block- or graft-copolymers containing polysiloxane sequences containing polyether sequences
Definitions
- Polyurethanes are prepared from compounds with at least two hydroxyl groups and compounds with at least two isocyanate groups. See, e.g., D. Randall and S. Lee, “The Polyurethanes Book”, New York: John Wiley & Sons, 2003; and K. Uhlig, “Discovering Polyurethanes”, New York: Hanser Gardner, 1999.
- the isocyanate groups of the isocyanate compound react with the hydroxyl groups of the hydroxyl compound to form urethane linkages.
- the hydroxyl compound is a low molecular weight polyether or polyester.
- the isocyanate compound can be aliphatic or aromatic, and in the preparation of linear polyurethanes is typically difunctional (i.e., it is a diisocyanate).
- isocyanate compounds with greater functionality are used in preparing thermoset polyurethanes.
- the family of polyurethane resins is very complex because of the enormous variation in the compositional features of the hydroxyl compounds and isocyanate compounds. This variety results in a large numbers of polymer structures and performance profiles. Indeed, polyurethanes can be rigid solids, soft and elastomeric, or a have a foam (cellular) structure.
- Rigid polyurethane and polyisocyanurate foams are particularly effective thermal insulators. Most applications are as insulating materials in construction. However, the inherent ability of polyurethane and polyisocyanurate foams to burn creates a need for reduced flammability. See, e.g., S. V. Levchik, E. D. Weil, “Thermal decomposition, combustion and fire-retardancy of polyurethanes—a review of the recent literature”, Polymer International, volume 53, pages 1585-1610 (2004). Polyurethane and polyisocyanurate foams also exhibit high moisture absorption, with the absorbed moisture acting as a plasticizer that detracts from the physical properties of the foams.
- One embodiment is a polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03.
- Another embodiment is an article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03.
- Another embodiment is a method of forming a polyurethane or polyisocyanurate foam, the method comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether).
- the present inventor has determined that rigid polyurethane and polyisocyanurate foams exhibiting improved resistance to burning and/or reduced moisture absorption are obtained by incorporating particulate poly(phenylene ether) into the foams.
- One embodiment is a polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03.
- the polyurethane or polyisocyanurate foam comprises a particulate poly(phenylene ether).
- Poly(phenylene ether)s include those comprising repeating structural units having the formula
- each occurrence of Z 1 is independently halogen, unsubstituted or substituted C 1 -C 12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C 1 -C 12 hydrocarbylthio, C 1 -C 12 hydrocarbyloxy, or C 2 -C 12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z 2 is independently hydrogen, halogen, unsubstituted or substituted C 1 -C 12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C 1 -C 12 hydrocarbylthio, C 1 -C 12 hydrocarbyloxy, or C 2 -C 12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms.
- hydrocarbyl refers to a residue that contains only carbon and hydrogen.
- the residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties.
- the hydrocarbyl residue when described as substituted, it may, optionally, contain heteroatoms over and above the carbon and hydrogen members of the substituent residue.
- the hydrocarbyl residue when specifically described as substituted, can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue.
- Z 1 can be a di-n-butylaminomethyl group formed by reaction of a terminal 3,5-dimethyl-1,4-phenyl group with the di-n-butylamine component of an oxidative polymerization catalyst.
- the poly(phenylene ether) can comprise molecules having aminoalkyl-containing end group(s), typically located in a position ortho to the hydroxyl group. Also frequently present are tetramethyldiphenoquinone (TMDQ) end groups, typically obtained from 2,6-dimethylphenol-containing reaction mixtures in which tetramethyldiphenoquinone by-product is present.
- TMDQ tetramethyldiphenoquinone
- the poly(phenylene ether) can be in the form of a homopolymer, a copolymer, a graft copolymer, an ionomer, or a block copolymer, as well as combinations thereof.
- the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer.
- poly(phenylene ether)-polysiloxane block copolymer refers to a block copolymer comprising at least one poly(phenylene ether) block and at least one polysiloxane block.
- the poly(phenylene ether)-polysiloxane block copolymer is prepared by an oxidative copolymerization method.
- the poly(phenylene ether)-polysiloxane block copolymer is the product of a process comprising oxidatively copolymerizing a monomer mixture comprising a monohydric phenol and a hydroxyaryl-terminated polysiloxane.
- the monomer mixture comprises 70 to 99 parts by weight of the monohydric phenol and 1 to 30 parts by weight of the hydroxyaryl-terminated polysiloxane, based on the total weight of the monohydric phenol and the hydroxyaryl-terminated polysiloxane.
- the hydroxyaryl-diterminated polysiloxane can comprise a plurality of repeating units having the structure
- each occurrence of R 8 is independently hydrogen, C 1 -C 12 hydrocarbyl or C 1 -C 12 halohydrocarbyl; and two terminal units having the structure
- each occurrence of R 9 is independently hydrogen, C 1 -C 12 hydrocarbyl or C 1 -C 12 halohydrocarbyl.
- each occurrence of R 8 and R 9 is methyl, and Y is methoxyl.
- the monohydric phenol comprises 2,6-dimethylphenol, 2,3,6-trimethylphenol, or a combination thereof, and the hydroxyaryl-terminated polysiloxane has the structure
- n is, on average, 5 to 100, specifically 30 to 60.
- the oxidative copolymerization method produces poly(phenylene ether)-polysiloxane block copolymer as the desired product and poly(phenylene ether) (without an incorporated polysiloxane block) as a by-product. It is not necessary to separate the poly(phenylene ether) from the poly(phenylene ether)-polysiloxane block copolymer.
- the poly(phenylene ether)-polysiloxane block copolymer can thus be utilized as a “reaction product” that includes both the poly(phenylene ether) and the poly(phenylene ether)-polysiloxane block copolymer.
- the poly(phenylene ether) has an intrinsic viscosity of 0.25 to 1 deciliter per gram measured by Ubbelohde viscometer at 25° C. in chloroform. Within this range, the poly(phenylene ether) intrinsic viscosity can be 0.3 to 0.65 deciliter per gram, more specifically 0.35 to 0.5 deciliter per gram, even more specifically 0.4 to 0.5 deciliter per gram.
- the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof.
- the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer.
- the poly(phenylene ether)-polysiloxane block copolymer can, for example, contribute 0.05 to 2 weight percent, specifically 0.1 to 1 weight percent, more specifically 0.2 to 0.8 weight percent, of siloxane groups to the composition as a whole.
- the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers. Within this range, the mean particle size can be 1 to 20 micrometers, specifically 2 to 8 micrometers. In some embodiments, 90 percent of the particle volume distribution of the particulate poly(phenylene ether) is less than or equal to 23 micrometers, specifically less than or equal to 17 micrometers, more specifically 1 to 8 micrometers. In some embodiments, fifty percent of the particle volume distribution of the particulate poly(phenylene ether) is than or equal to 15 micrometers, specifically less than or equal to 10 micrometers, more specifically less than or equal to 6 micrometers.
- ten percent of the particle volume distribution of the particulate poly(phenylene ether) is less than or equal to 9 micrometers, specifically less than or equal to 6 micrometers, more specifically less than or equal to 4 micrometers. In some embodiments, less than 10 percent, specifically less than 1 percent, and more specifically less than 0.1 percent, of the particle volume distribution is less than or equal to 38 nanometers. In some embodiments, the particles of the particulate poly(phenylene ether) have a mean aspect ratio of 1:1 to 2:1. Equipment to determine particle size and shape characteristics is commercially available as, for example, the CAMSIZERTM and CAMSIZERTM XT Dynamic Image Analysis Systems from Retsch Technology, and the QICPICTM Particle Size and Shape Analyzer from Sympatec.
- Particulate poly(phenylene ether) can be obtained according to methods readily available to the skilled artisan, for example by jet milling, ball milling, pulverizing, air milling, or grinding commercial grade poly(phenylene ether).
- “Classification” is defined as the sorting of a distribution of particles to achieve a desired degree of particle size uniformity.
- a classifier is often used together with milling for the continuous extraction of fine particles from the material being milled.
- the classifier can be, for example, a screen of certain mesh size on the walls of the grinding chamber. Once the milled particles reach sizes small enough to pass through the screen, they are removed. Larger particles retained by the screen remain in the milling chamber for additional milling and size reduction.
- Air classification is another method of removing the finer particles from milling.
- Air classifiers include static classifiers (cyclones), dynamic classifiers (single-stage, multi-stage), cross-flow classifiers, and counter-flow classifiers (elutriators).
- a flow of air is used to convey the particles from the mill to the classifier, where the fine particles are further conveyed to a collector.
- the coarse particles, being too heavy to be carried by the air stream, are returned to the mill for further milling and size reduction.
- air classification is more efficient, while in smaller operations a screen can be used.
- the polyurethane or polyisocyanurate foam comprises the particulate poly(phenylene ether) in an amount of 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam (which is equivalent to the total weight of the reaction mixture from which the foam is prepared).
- the amount of particulate poly(phenylene ether) can be 3 to 40 weight percent, specifically 5 to 30 weight percent.
- the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03. Within this range, the core density can be 0.03 to 0.2 grams/centimeter 3 , specifically 0.03 to 0.06 grams/centimeter 3 .
- polyurethane and polyisocyanurate foams Both are prepared from polyisocyanates and polyols. Reaction mixtures used to prepare polyurethane and polyisocyanurate foams are characterized by an isocyanate index, which is calculated according to the equation
- Isocyanate ⁇ ⁇ Index Moles NCO Moles OH + Moles HOH + Moles NH ⁇ 100
- Moles NCO is the moles of isocyanate groups in the reaction mixture
- Moles OH is the moles of OH groups in the reaction mixture from sources other than water (including OH groups from alcohols and carboxylic acid)
- Moles HOH is the moles of OH groups in the reaction mixture from water
- Moles NH is the moles of NH groups in the reaction mixture.
- the products of reaction mixtures having an isocyanate index of 100 to 125, specifically 105 to 125, are typically characterized as polyurethanes, while the products of reaction mixtures having an isocyanate index of 180 to 350 are typically characterized as polyisocyanurates.
- Formation of isocyanurate groups is favored not only by high isocyanate indices, but also by use of catalysts for isocyanurate formation, such as N-hydroxyalkyl quaternary ammonium carboxylates.
- the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam, wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule.
- the polyol can comprise, on average, at least two hydroxyl groups per molecule and often comprises three or more hydroxyl groups per molecule.
- Polyols useful in the method include polyether polyols prepared by reacting an initiator containing 2 to 8 hydroxyl groups per molecule, specifically 3 to 8 hydroxyl groups per molecule, with an alkoxylating agent such as ethylene oxide, propylene oxide, or butylene oxide.
- polyols include ethoxylated saccharides, propoxylated saccharides, butoxylated saccharides, ethoxylated glycerins, propoxylated glycerins, butoxylated glycerins, ethoxylated diethanolamines, propoxylated diethanolamines, butoxylated diethanolamines, ethoxylated triethanolamines, propoxylated triethanolamines, butoxylated triethanolamines, ethoxylated trimethylolpropanes, propoxylated trimethylolpropanes, butoxylated trimethylolpropanes, ethoxylated erythritols, propoxylated erythritols, butoxylated erythritols, ethoxylated pentaerythritols, propoxylated pentaerythritols, butoxylated pentaerythritols, and combinations
- the polyol is selected from propoxylated saccharides, propoxylated glycerins, propoxylated diethanolamines, propoxylated triethanolamines, propoxylated trimethylolpropanes, propoxylated erythritols, propoxylated pentaerythritols, and combinations thereof.
- Polyols further include aliphatic polyester diols, aromatic polyester polyols, and combinations thereof.
- the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof.
- Isocyanate compounds useful in the method include, for example, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3-diisocyanate, and cyclohexane-1,4-diisocyanate, 1-isocyanato-2-isocyanatomethyl cyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, bis(4-isocyanatocyclohexyl)methane, 2,4′-dicyclohexyl-methane diisocyanate, 1,3-bis(isocyanatomethyl)-cyclohexane, 1,4-bis-(isocyanatomethyl)-cyclohexane, bis(4-isocyanato
- Blowing agents useful in the method including physical blowing agents, chemical blowing agents, and combinations thereof.
- Physical blowing agents can be, for example, C 3 -C 5 hydrofluoroalkanes and C 3 -C 5 hydrofluoroalkenes.
- the hydrofluoroalkane and hydrofluoroalkene blowing agents can also contain one or more hydrogen atoms and/or halogen atoms other than fluorine.
- the hydrofluoroalkane and hydrofluoroalkene blowing agents have a boiling point of 10 to 40° C. at 1 atmosphere.
- Specific physical blowing agents include 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane, pentafluoroethane, 1,1,1,3,3-pentafluoropropane, 1,1,1,3,3-pentafluorobutane, 2-bromopentafluoropropene, 1-bromopentafluoropropene, 3-bromopentafluoropropene, 3,4,4,5,5,5-heptafluoro-1-pentene, 3-bromo-1,1,3,3-tetrafluoropropene, 2-bromo-1,3,3,3-tetrafluoropropene, 1-bromo-2,3,3,3-tetrafluoropropene, 1,1,2,3,3,4,4-heptafluorobut-1-ene, 2-bromo-3,3,3-trifluoropropene, E-1-bromo-3,3,3-trifluoropropene-1, (Z)-1,
- Chemical blowing agents include water and carboxylic acids that reaction with isocyanate groups to liberate carbon dioxide.
- chemical blowing agents and specifically water, can be used in an amount of 0.2 to 5 weight percent, based on the total weight of the reaction mixture. Within this range, the chemical blowing agent amount can be 0.2 to 3 weight percent.
- the reaction mixture can include additives such as, for example, catalysts, surfactants, fire retardants, smoke suppressants, fillers and/or reinforcements other than the particulate poly(phenylene ether), antioxidants, UV stabilizers, antistatic agents, infrared radiation absorbers, viscosity reducing agents, pigments, dyes, mold release agents, antifungal agents, biocides, and combinations thereof.
- additives such as, for example, catalysts, surfactants, fire retardants, smoke suppressants, fillers and/or reinforcements other than the particulate poly(phenylene ether), antioxidants, UV stabilizers, antistatic agents, infrared radiation absorbers, viscosity reducing agents, pigments, dyes, mold release agents, antifungal agents, biocides, and combinations thereof.
- Catalysts include urethane catalysts, isocyanurate catalysts, and combinations thereof.
- Suitable catalysts include tertiary amine catalysts such as dimethylcyclohexylamine, benzyldimethylamine, N,N,N′,N′′,N′′-pentamethyldiethylenetriamine, 2,4,6-tris-(dimethylaminomethyl)-phenol, triethylenediamine, N,N-dimethyl ethanolamine, and combinations thereof, organometallic compounds such as potassium octoate (2-ethyl hexanoate), potassium acetate, dibutyltin dilaurate, dibutlytin diacetate, and combinations thereof; quaternary ammonium salts such as 2-hydroxpropyl trimethylammonium formate; N-substituted triazines such as N,N′,N′′-dimethylaminopropylhexahydrotriazine; and combinations thereof.
- Suitable surfactants include, for example, polyorganosiloxanes, polyorganosiloxane polyether copolymers, phenol alkoxylates (such as ethoxylated phenol), alkylphenol alkoxylates (such as ethoxylated nonylphenol), and combinations thereof.
- the surfactants can function as emulsifiers and/or foam stabilizers.
- the particulate poly(phenylene ether) contributes to the flame retardancy of the foam. Flame retardancy is also promoted by the use of aromatic polyester polyols, when employed, and isocyanurate groups, when formed. One or more additional flame retardants can, optionally, be included in the reaction mixture.
- Such additional flame retardants include, for example, organophosphorous compounds such as organic phosphates (including trialkyl phosphates such as triethyl phosphate and tris(2-chloropropyl)phosphate, and triaryl phosphates such as triphenyl phosphate and diphenyl cresyl phosphate), phosphites (including trialkyl phosphites, triaryl phosphites, and mixed alkyl-aryl phosphites), phosphonates (including diethyl ethyl phosphonate, dimethyl methyl phosphonate), polyphosphates (including melamine polyphosphate, ammonium polyphosphates), polyphosphites, polyphosphonates, phosphinates (including aluminum tris(diethyl phosphinate); halogenated fire retardants such as tetrabromophthalate esters and chlorinated paraffins; metal hydroxides such as magnesium hydroxide, aluminum hydroxide, cobalt
- the flame retatrdant can be a reactive type flame-retardant (including polyols which contain phosphorus groups, 10-(2,5-dihydroxyphenyl)-10H-9-oxa-10-phospha-phenanthrene-10-oxide, phosphorus-containing lactone-modified polyesters, ethylene glycol bis(diphenyl phosphate), neopentylglycol bis(diphenyl phosphate), amine- and hydroxyl-functionalized siloxane oligomers). These flame retardants can be used alone or in conjunction with other flame retardants.
- additives are typically used in a total amount of 0.01 to 30 weight percent, based on the total weight of the reaction mixture. Within this range, the total additive amount can be 0.02 to 10 weight percent.
- the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03;
- the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether);
- the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers;
- the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers;
- the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether);
- the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(pheny)
- the polyurethane or polyisocyanurate foam is particularly useful as a thermal insulation material.
- one embodiment is an article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03. All of the variations of the foam described above apply as well to the foam as a component of the article.
- thermo insulation material examples include domestic appliances (such as domestic and commercial refrigerators and freezers, and hot water tanks); building materials (such as wall and roofing panels, cut-to-size pieces from slab stock, and spray-in-place foam for insulation and sealing); thermally insulated tanks and containers, pipelines, heating pipes, cooling pipes, and cold stores; and thermally insulated refrigerated vehicles for road and rail including containers.
- domestic appliances such as domestic and commercial refrigerators and freezers, and hot water tanks
- building materials such as wall and roofing panels, cut-to-size pieces from slab stock, and spray-in-place foam for insulation and sealing
- thermally insulated tanks and containers pipelines, heating pipes, cooling pipes, and cold stores
- thermally insulated refrigerated vehicles for road and rail including containers.
- One embodiment is a method of forming a polyurethane or polyisocyanurate foam, the method comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether).
- Polyols, isocyanate compounds, and blowing agents are described above in the context of the product-by-process embodiments of the foam. All variations of the foam and the process described above apply as well to the present method of forming a polyurethane or polyisocyanurate foam.
- the polyol, the isocyanate compound, and water, if any, are present in amounts sufficient to provide an isocyanate index of 180 to 350.
- the polyol component and the isocyanate component which have been temperature controlled and provided with additives, are thoroughly mixed together.
- the reaction starts after a short period of time and progresses with heat development.
- the reaction mixture is continually expanded by the blowing gases released, until the reaction product reaches the solid state as a result of progressive cross-linkage, the foam structure being retained.
- the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03;
- the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether);
- the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers;
- the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers;
- the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether);
- the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and
- the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate
- the invention includes at least the following embodiments.
- a polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03.
- polyurethane or polyisocyanurate foam of embodiment 1 or 2 wherein the polyurethane or polyisocyanurate foam is a polyurethane foam that is the product of a process characterized by an isocyanate index of 105 to 125.
- polyurethane or polyisocyanurate foam of embodiment 1 or 2 wherein the polyurethane or polyisocyanurate foam is a polyisocyanurate foam that is the product of a process characterized by an isocyanate index of 180 to 350.
- polyurethane or polyisocyanurate foam of any of embodiments 1-7 comprising 5 to 30 weight percent of the particulate poly(phenylene ether).
- polyurethane or polyisocyanurate foam of any of embodiments 1-8 wherein the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule.
- polyol comprises an ethoxylated saccharide, a propoxylated saccharide, a butoxylated saccharide, an ethoxylated glycerin, a propoxylated glycerin, a butoxylated glycerin, an ethoxylated diethanolamine, a propoxylated diethanolamine, a butoxylated diethanolamine, an ethoxylated triethanolamine, a propoxylated triethanolamine, a butoxylated triethanolamine, an ethoxylated trimethylolpropane, a propoxylated trimethylolpropane, a butoxylated trimethylolpropane, an ethoxylated erythritol, a propoxylated erythritol, a butoxylated erythritol, an ethoxylated pentaerythritol
- polyurethane or polyisocyanurate foam of embodiment 14 wherein the polyurethane or polyisocyanurate foam is a polyisocyanurate foam that is the product of a process characterized by an isocyanate index of 180 to 350.
- An article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03.
- a method of forming a polyurethane or polyisocyanurate foam comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether).
- the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter 3 determined at 23° C. using ASTM D 1622-03; wherein the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether); wherein the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers; wherein the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers; wherein the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether); wherein the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and wherein the isocyanate compound comprises an oligomeric diphenylmethan
- TERATE TM 4026 An aromatic polyester polyol having an OH number of 200 milligrams/gram, a viscosity of 2500 centipoise at 25° C., a number average molecular weight of about 560 grams/mole, and about 2 hydroxyl groups per molecule; available as TERATE TM 4026 from Invista.
- RUBINATE TM M An oligomeric diphenylmethane diisocyanate having 31.0 weight percent isocyanate groups and an average of 2.7 isocyanate groups per molecule; available as RUBINATE TM M from Huntsman.
- NIAX TM A-1 70 weight percent bis(dimethylaminoethyl)ether in dipropylene glycol; available as NIAX TM A-1 from Momentive.
- DABCO TM TMR-4 An N-hydroxyalkyl quaternary ammonium carboxylate (catalyst for formation of isocyanurate groups) having an OH number of 687 milligrams OH/gram and a viscosity of 34 centipoise at 25° C.; available as DABCO TM TMR-4 from Air Products.
- POLYCAT TM 8 N,N-dimethylcyclohexylamine; available as POLYCAT TM 8 from Air Products.
- DABCO TM DC193 A polysiloxane surfactant; available as DABCO TM DC193 from Air Products.
- Particulate poly(2,6-dimethyl-1,4-phenylene ether) was obtained by jet milling commercial grade poly(phenylene ether) powder obtained as PPOTM 640 resin from Sabic Innovative Plastics. Compressed nitrogen gas was introduced into the nozzles of a jet mill to create a supersonic grinding stream. Particle-on-particle impact collisions in this grinding stream resulted in substantial particle size reductions. Large particles were held in the grinding area by centrifugal force while centripetal force drove finer particles toward the center of the discharge. A sieve of a specific upper size limit was then used in-line to recover particles with a precise size distribution and having diameters below the nominal sieve openings. Larger particles were recycled to the reduction size chamber for further grinding.
- the particulate poly(2,6-dimethyl-1,4-phenylene ether) was classified by passing the jet-milled particles through a screen with 6 micrometer openings.
- the particle size and shape characterization in Table 1 was determined using a CAMSIZERTM XT from Retsch Technology GmbH operating in air dispersion mode.
- Rigid foams were prepared using a high-torque mixer (CRAFTSMAN Ten Inch Drill Press, Model No. 137.219000) at 3,100 rotations per minute. Polyol components and isocyanate components of the foam systems were mixed for 10 seconds. The resulting mixture was transferred into an open cake box before the cream time and allowed to free-rise. Foaming profile, including cream time, gel time, rise time, and tack-free time was determined on all foams.
- CRAFTSMAN Ten Inch Drill Press Model No. 137.219000
- Table 2 summarizes examples in which the particulate poly(phenylene ether) was added only to the polyol component of the polyurethane formulation.
- the property results show that similar core densities were obtained for each foam, but, relative to Comparative Example A, inventive Examples 1-3 exhibited higher compressive strength values.
- the particulate poly(phenylene ether) was added through both the polyol component and the isocyanate component of the foam systems.
- Compositions, processes, and properties are summarized in Table 3. The property results show that, relative to Comparative Example B, inventive Examples 4-6 with particulate poly(phenylene ether) exhibited reduced flammability and reduced water absorption.
- Examples of polyisocyanurate foam systems are summarized in Table 4.
- the particulate poly(phenylene ether) was added through the both polyol component and isocyanate component of the foam systems.
- the property results show that, relative to Comparative Example C, inventive Examples 7-9 with particulate poly(phenylene ether) exhibited reduced flammability and reduced water absorption.
Abstract
Description
- Polyurethanes are prepared from compounds with at least two hydroxyl groups and compounds with at least two isocyanate groups. See, e.g., D. Randall and S. Lee, “The Polyurethanes Book”, New York: John Wiley & Sons, 2003; and K. Uhlig, “Discovering Polyurethanes”, New York: Hanser Gardner, 1999. The isocyanate groups of the isocyanate compound react with the hydroxyl groups of the hydroxyl compound to form urethane linkages. In many cases, the hydroxyl compound is a low molecular weight polyether or polyester. The isocyanate compound can be aliphatic or aromatic, and in the preparation of linear polyurethanes is typically difunctional (i.e., it is a diisocyanate). However isocyanate compounds with greater functionality are used in preparing thermoset polyurethanes. The family of polyurethane resins is very complex because of the enormous variation in the compositional features of the hydroxyl compounds and isocyanate compounds. This variety results in a large numbers of polymer structures and performance profiles. Indeed, polyurethanes can be rigid solids, soft and elastomeric, or a have a foam (cellular) structure.
- Rigid polyurethane and polyisocyanurate foams are particularly effective thermal insulators. Most applications are as insulating materials in construction. However, the inherent ability of polyurethane and polyisocyanurate foams to burn creates a need for reduced flammability. See, e.g., S. V. Levchik, E. D. Weil, “Thermal decomposition, combustion and fire-retardancy of polyurethanes—a review of the recent literature”, Polymer International, volume 53, pages 1585-1610 (2004). Polyurethane and polyisocyanurate foams also exhibit high moisture absorption, with the absorbed moisture acting as a plasticizer that detracts from the physical properties of the foams.
- There is therefore a need for polyurethane and polyisocyanurate foams exhibiting improved resistance to burning and/or reduced moisture absorption.
- One embodiment is a polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- Another embodiment is an article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- Another embodiment is a method of forming a polyurethane or polyisocyanurate foam, the method comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether).
- These and other embodiments are described in detail below.
- The present inventor has determined that rigid polyurethane and polyisocyanurate foams exhibiting improved resistance to burning and/or reduced moisture absorption are obtained by incorporating particulate poly(phenylene ether) into the foams.
- One embodiment is a polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- The polyurethane or polyisocyanurate foam comprises a particulate poly(phenylene ether). Poly(phenylene ether)s include those comprising repeating structural units having the formula
- wherein each occurrence of Z1 is independently halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and each occurrence of Z2 is independently hydrogen, halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms. As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically described as substituted, the hydrocarbyl residue can also contain one or more carbonyl groups, amino groups, hydroxyl groups, or the like, or it can contain heteroatoms within the backbone of the hydrocarbyl residue. As one example, Z1 can be a di-n-butylaminomethyl group formed by reaction of a terminal 3,5-dimethyl-1,4-phenyl group with the di-n-butylamine component of an oxidative polymerization catalyst.
- The poly(phenylene ether) can comprise molecules having aminoalkyl-containing end group(s), typically located in a position ortho to the hydroxyl group. Also frequently present are tetramethyldiphenoquinone (TMDQ) end groups, typically obtained from 2,6-dimethylphenol-containing reaction mixtures in which tetramethyldiphenoquinone by-product is present. The poly(phenylene ether) can be in the form of a homopolymer, a copolymer, a graft copolymer, an ionomer, or a block copolymer, as well as combinations thereof.
- In some embodiments, the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer. As used herein, the term “poly(phenylene ether)-polysiloxane block copolymer” refers to a block copolymer comprising at least one poly(phenylene ether) block and at least one polysiloxane block.
- In some embodiments, the poly(phenylene ether)-polysiloxane block copolymer is prepared by an oxidative copolymerization method. In this method, the poly(phenylene ether)-polysiloxane block copolymer is the product of a process comprising oxidatively copolymerizing a monomer mixture comprising a monohydric phenol and a hydroxyaryl-terminated polysiloxane. In some embodiments, the monomer mixture comprises 70 to 99 parts by weight of the monohydric phenol and 1 to 30 parts by weight of the hydroxyaryl-terminated polysiloxane, based on the total weight of the monohydric phenol and the hydroxyaryl-terminated polysiloxane. The hydroxyaryl-diterminated polysiloxane can comprise a plurality of repeating units having the structure
- wherein each occurrence of R8 is independently hydrogen, C1-C12 hydrocarbyl or C1-C12 halohydrocarbyl; and two terminal units having the structure
- wherein Y is hydrogen, C1-C12 hydrocarbyl, C1-C12 hydrocarbyloxy, or halogen, and wherein each occurrence of R9 is independently hydrogen, C1-C12 hydrocarbyl or C1-C12 halohydrocarbyl. In a very specific embodiment, each occurrence of R8 and R9 is methyl, and Y is methoxyl.
- In some embodiments, the monohydric phenol comprises 2,6-dimethylphenol, 2,3,6-trimethylphenol, or a combination thereof, and the hydroxyaryl-terminated polysiloxane has the structure
- wherein n is, on average, 5 to 100, specifically 30 to 60.
- The oxidative copolymerization method produces poly(phenylene ether)-polysiloxane block copolymer as the desired product and poly(phenylene ether) (without an incorporated polysiloxane block) as a by-product. It is not necessary to separate the poly(phenylene ether) from the poly(phenylene ether)-polysiloxane block copolymer. The poly(phenylene ether)-polysiloxane block copolymer can thus be utilized as a “reaction product” that includes both the poly(phenylene ether) and the poly(phenylene ether)-polysiloxane block copolymer. Certain isolation procedures, such as precipitation from isopropanol, make it possible to assure that the reaction product is essentially free of residual hydroxyaryl-terminated polysiloxane starting material. In other words, these isolation procedures assure that the polysiloxane content of the reaction product is essentially all in the form of poly(phenylene ether)-polysiloxane block copolymer. Detailed methods for forming poly(phenylene ether)-polysiloxane block copolymers are described in U.S. Pat. No. 8,017,697 to Carrillo et al., and U.S. Patent Application Publication No. US 2012/0329961 A1 of Carrillo et al.
- In some embodiments, the poly(phenylene ether) has an intrinsic viscosity of 0.25 to 1 deciliter per gram measured by Ubbelohde viscometer at 25° C. in chloroform. Within this range, the poly(phenylene ether) intrinsic viscosity can be 0.3 to 0.65 deciliter per gram, more specifically 0.35 to 0.5 deciliter per gram, even more specifically 0.4 to 0.5 deciliter per gram.
- In some embodiments, the poly(phenylene ether) comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and combinations thereof.
- In some embodiments, the poly(phenylene ether) comprises a poly(phenylene ether)-polysiloxane block copolymer. In these embodiments, the poly(phenylene ether)-polysiloxane block copolymer can, for example, contribute 0.05 to 2 weight percent, specifically 0.1 to 1 weight percent, more specifically 0.2 to 0.8 weight percent, of siloxane groups to the composition as a whole.
- The particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers. Within this range, the mean particle size can be 1 to 20 micrometers, specifically 2 to 8 micrometers. In some embodiments, 90 percent of the particle volume distribution of the particulate poly(phenylene ether) is less than or equal to 23 micrometers, specifically less than or equal to 17 micrometers, more specifically 1 to 8 micrometers. In some embodiments, fifty percent of the particle volume distribution of the particulate poly(phenylene ether) is than or equal to 15 micrometers, specifically less than or equal to 10 micrometers, more specifically less than or equal to 6 micrometers. In some embodiments, ten percent of the particle volume distribution of the particulate poly(phenylene ether) is less than or equal to 9 micrometers, specifically less than or equal to 6 micrometers, more specifically less than or equal to 4 micrometers. In some embodiments, less than 10 percent, specifically less than 1 percent, and more specifically less than 0.1 percent, of the particle volume distribution is less than or equal to 38 nanometers. In some embodiments, the particles of the particulate poly(phenylene ether) have a mean aspect ratio of 1:1 to 2:1. Equipment to determine particle size and shape characteristics is commercially available as, for example, the CAMSIZER™ and CAMSIZER™ XT Dynamic Image Analysis Systems from Retsch Technology, and the QICPIC™ Particle Size and Shape Analyzer from Sympatec.
- Particulate poly(phenylene ether) can be obtained according to methods readily available to the skilled artisan, for example by jet milling, ball milling, pulverizing, air milling, or grinding commercial grade poly(phenylene ether). “Classification” is defined as the sorting of a distribution of particles to achieve a desired degree of particle size uniformity. A classifier is often used together with milling for the continuous extraction of fine particles from the material being milled. The classifier can be, for example, a screen of certain mesh size on the walls of the grinding chamber. Once the milled particles reach sizes small enough to pass through the screen, they are removed. Larger particles retained by the screen remain in the milling chamber for additional milling and size reduction.
- Air classification is another method of removing the finer particles from milling. Air classifiers include static classifiers (cyclones), dynamic classifiers (single-stage, multi-stage), cross-flow classifiers, and counter-flow classifiers (elutriators). In general, a flow of air is used to convey the particles from the mill to the classifier, where the fine particles are further conveyed to a collector. The coarse particles, being too heavy to be carried by the air stream, are returned to the mill for further milling and size reduction. In larger operations, air classification is more efficient, while in smaller operations a screen can be used.
- The polyurethane or polyisocyanurate foam comprises the particulate poly(phenylene ether) in an amount of 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam (which is equivalent to the total weight of the reaction mixture from which the foam is prepared). Within this range, the amount of particulate poly(phenylene ether) can be 3 to 40 weight percent, specifically 5 to 30 weight percent.
- The polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03. Within this range, the core density can be 0.03 to 0.2 grams/centimeter3, specifically 0.03 to 0.06 grams/centimeter3.
- Those skilled in the art understand that there is a continuum between polyurethane and polyisocyanurate foams. Both are prepared from polyisocyanates and polyols. Reaction mixtures used to prepare polyurethane and polyisocyanurate foams are characterized by an isocyanate index, which is calculated according to the equation
-
- wherein MolesNCO is the moles of isocyanate groups in the reaction mixture, MolesOH is the moles of OH groups in the reaction mixture from sources other than water (including OH groups from alcohols and carboxylic acid), MolesHOH is the moles of OH groups in the reaction mixture from water, and MolesNH is the moles of NH groups in the reaction mixture. When the reaction mixture molar ratio of isocyanate groups to hydroxyl groups is 1:1 and no water or NH groups are present in the reaction mixture, the isocyanate index is 100, and a “pure” polyurethane is formed. The products of reaction mixtures having an isocyanate index of 100 to 125, specifically 105 to 125, are typically characterized as polyurethanes, while the products of reaction mixtures having an isocyanate index of 180 to 350 are typically characterized as polyisocyanurates. Formation of isocyanurate groups is favored not only by high isocyanate indices, but also by use of catalysts for isocyanurate formation, such as N-hydroxyalkyl quaternary ammonium carboxylates.
- In some embodiments, the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam, wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule. The polyol can comprise, on average, at least two hydroxyl groups per molecule and often comprises three or more hydroxyl groups per molecule.
- Polyols useful in the method include polyether polyols prepared by reacting an initiator containing 2 to 8 hydroxyl groups per molecule, specifically 3 to 8 hydroxyl groups per molecule, with an alkoxylating agent such as ethylene oxide, propylene oxide, or butylene oxide. Specific examples of polyols include ethoxylated saccharides, propoxylated saccharides, butoxylated saccharides, ethoxylated glycerins, propoxylated glycerins, butoxylated glycerins, ethoxylated diethanolamines, propoxylated diethanolamines, butoxylated diethanolamines, ethoxylated triethanolamines, propoxylated triethanolamines, butoxylated triethanolamines, ethoxylated trimethylolpropanes, propoxylated trimethylolpropanes, butoxylated trimethylolpropanes, ethoxylated erythritols, propoxylated erythritols, butoxylated erythritols, ethoxylated pentaerythritols, propoxylated pentaerythritols, butoxylated pentaerythritols, and combinations thereof. In some embodiments, the polyol is selected from propoxylated saccharides, propoxylated glycerins, propoxylated diethanolamines, propoxylated triethanolamines, propoxylated trimethylolpropanes, propoxylated erythritols, propoxylated pentaerythritols, and combinations thereof. Polyols further include aliphatic polyester diols, aromatic polyester polyols, and combinations thereof. In some embodiments, the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof.
- Isocyanate compounds useful in the method include, for example, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3-diisocyanate, and cyclohexane-1,4-diisocyanate, 1-isocyanato-2-isocyanatomethyl cyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, bis(4-isocyanatocyclohexyl)methane, 2,4′-dicyclohexyl-methane diisocyanate, 1,3-bis(isocyanatomethyl)-cyclohexane, 1,4-bis-(isocyanatomethyl)-cyclohexane, bis(4-isocyanato-3-methyl-cyclohexyl)methane, alpha,alpha,alpha′,alpha′-tetramethyl-1,3-xylylene diisocyanate, alpha,alpha,alpha′,alpha′-tetramethyl-1,4-xylylene diisocyanate, 1-isocyanato-1-methyl-4(3)-isocyanatomethyl cyclohexane, 2,4-hexahydrotoluene diisocyanate, 2,6-hexahydrotoluene diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4-diphenylmethane diisocyanate, 4,4′-diphenylmethane diisocyanate, 1,5-diisocyanato naphthalene, an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule, and combinations thereof. In some embodiments, the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- Blowing agents useful in the method including physical blowing agents, chemical blowing agents, and combinations thereof. Physical blowing agents can be, for example, C3-C5 hydrofluoroalkanes and C3-C5 hydrofluoroalkenes. The hydrofluoroalkane and hydrofluoroalkene blowing agents can also contain one or more hydrogen atoms and/or halogen atoms other than fluorine. In some embodiments, the hydrofluoroalkane and hydrofluoroalkene blowing agents have a boiling point of 10 to 40° C. at 1 atmosphere. Specific physical blowing agents include 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane, pentafluoroethane, 1,1,1,3,3-pentafluoropropane, 1,1,1,3,3-pentafluorobutane, 2-bromopentafluoropropene, 1-bromopentafluoropropene, 3-bromopentafluoropropene, 3,4,4,5,5,5-heptafluoro-1-pentene, 3-bromo-1,1,3,3-tetrafluoropropene, 2-bromo-1,3,3,3-tetrafluoropropene, 1-bromo-2,3,3,3-tetrafluoropropene, 1,1,2,3,3,4,4-heptafluorobut-1-ene, 2-bromo-3,3,3-trifluoropropene, E-1-bromo-3,3,3-trifluoropropene-1, (Z)-1,1,1,4,4,4-hexafluoro-2-butene, 3,3,3-trifluoro-2-(trifluoromethyl)propene, 1-chloro-3,3,3-trifluoropropene, 2-chloro-3,3,3-trifluoropropene, 1,1,1-trifluoro-2-butene, and combinations thereof. The physical blowing agent, when used, may be present at 2 to 20 weight percent, based on the total weight of the reaction mixture. Within this range, the physical blowing agent amount can be 2.5 to 15 weight percent.
- Chemical blowing agents include water and carboxylic acids that reaction with isocyanate groups to liberate carbon dioxide. When present, chemical blowing agents, and specifically water, can be used in an amount of 0.2 to 5 weight percent, based on the total weight of the reaction mixture. Within this range, the chemical blowing agent amount can be 0.2 to 3 weight percent.
- In addition to the polyol, the isocyanate compound, and the blowing agent, the reaction mixture can include additives such as, for example, catalysts, surfactants, fire retardants, smoke suppressants, fillers and/or reinforcements other than the particulate poly(phenylene ether), antioxidants, UV stabilizers, antistatic agents, infrared radiation absorbers, viscosity reducing agents, pigments, dyes, mold release agents, antifungal agents, biocides, and combinations thereof.
- Catalysts include urethane catalysts, isocyanurate catalysts, and combinations thereof. Suitable catalysts include tertiary amine catalysts such as dimethylcyclohexylamine, benzyldimethylamine, N,N,N′,N″,N″-pentamethyldiethylenetriamine, 2,4,6-tris-(dimethylaminomethyl)-phenol, triethylenediamine, N,N-dimethyl ethanolamine, and combinations thereof, organometallic compounds such as potassium octoate (2-ethyl hexanoate), potassium acetate, dibutyltin dilaurate, dibutlytin diacetate, and combinations thereof; quaternary ammonium salts such as 2-hydroxpropyl trimethylammonium formate; N-substituted triazines such as N,N′,N″-dimethylaminopropylhexahydrotriazine; and combinations thereof.
- Suitable surfactants include, for example, polyorganosiloxanes, polyorganosiloxane polyether copolymers, phenol alkoxylates (such as ethoxylated phenol), alkylphenol alkoxylates (such as ethoxylated nonylphenol), and combinations thereof. The surfactants can function as emulsifiers and/or foam stabilizers.
- The particulate poly(phenylene ether) contributes to the flame retardancy of the foam. Flame retardancy is also promoted by the use of aromatic polyester polyols, when employed, and isocyanurate groups, when formed. One or more additional flame retardants can, optionally, be included in the reaction mixture. Such additional flame retardants include, for example, organophosphorous compounds such as organic phosphates (including trialkyl phosphates such as triethyl phosphate and tris(2-chloropropyl)phosphate, and triaryl phosphates such as triphenyl phosphate and diphenyl cresyl phosphate), phosphites (including trialkyl phosphites, triaryl phosphites, and mixed alkyl-aryl phosphites), phosphonates (including diethyl ethyl phosphonate, dimethyl methyl phosphonate), polyphosphates (including melamine polyphosphate, ammonium polyphosphates), polyphosphites, polyphosphonates, phosphinates (including aluminum tris(diethyl phosphinate); halogenated fire retardants such as tetrabromophthalate esters and chlorinated paraffins; metal hydroxides such as magnesium hydroxide, aluminum hydroxide, cobalt hydroxide, and hydrates of the foregoing metal hydroxide; and combinations thereof. The flame retatrdant can be a reactive type flame-retardant (including polyols which contain phosphorus groups, 10-(2,5-dihydroxyphenyl)-10H-9-oxa-10-phospha-phenanthrene-10-oxide, phosphorus-containing lactone-modified polyesters, ethylene glycol bis(diphenyl phosphate), neopentylglycol bis(diphenyl phosphate), amine- and hydroxyl-functionalized siloxane oligomers). These flame retardants can be used alone or in conjunction with other flame retardants.
- When present, additives are typically used in a total amount of 0.01 to 30 weight percent, based on the total weight of the reaction mixture. Within this range, the total additive amount can be 0.02 to 10 weight percent.
- In a very specific embodiment of the polyurethane or polyisocyanurate foam, the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter3 determined at 23° C. using ASTM D 1622-03; the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether); the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers; the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers; the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether); the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam, wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; the polyol comprises a wherein the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- The polyurethane or polyisocyanurate foam is particularly useful as a thermal insulation material. Thus, one embodiment is an article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03. All of the variations of the foam described above apply as well to the foam as a component of the article. Specific examples of articles that can utilize the polyurethane or polyisocyanurate foam as a thermal insulation material include domestic appliances (such as domestic and commercial refrigerators and freezers, and hot water tanks); building materials (such as wall and roofing panels, cut-to-size pieces from slab stock, and spray-in-place foam for insulation and sealing); thermally insulated tanks and containers, pipelines, heating pipes, cooling pipes, and cold stores; and thermally insulated refrigerated vehicles for road and rail including containers.
- One embodiment is a method of forming a polyurethane or polyisocyanurate foam, the method comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether). Polyols, isocyanate compounds, and blowing agents are described above in the context of the product-by-process embodiments of the foam. All variations of the foam and the process described above apply as well to the present method of forming a polyurethane or polyisocyanurate foam.
- In some embodiments of the method, the polyol, the isocyanate compound, and water, if any, are present in amounts sufficient to provide an isocyanate index of 180 to 350.
- To prepare the polyurethane or polyisocyanurate foam, the polyol component and the isocyanate component, which have been temperature controlled and provided with additives, are thoroughly mixed together. The reaction starts after a short period of time and progresses with heat development. The reaction mixture is continually expanded by the blowing gases released, until the reaction product reaches the solid state as a result of progressive cross-linkage, the foam structure being retained.
- The following stages are characteristic of the reaction and foaming process.
-
- The mix time indicates the time needed for mixing the reactants.
- The cream time is the time which elapses from the start of mixing of the reactants to the first definite appearance of foam expansion. In many cases this can be seen clearly by a color change as the reaction mixture begins to rise. With slow reacting mixtures this requires practiced observation.
- The gel time is the interval of time between mixing the reactants and the formation of a non-flowing, semi-solid, jelly-like system. It is the time when the foam has developed enough gel strength to be dimensionally stable. After the gel time, the speed at which the foam rises slows down.
- The rise time is the time from the start of mixing until the end of the optically perceptible rise. Hence it is the time until foam expansion ceases. The surface of the foam is still tacky when the rise process is complete.
- The tack-free time is the time elapsing from the start of mixing to the moment when the foam surface has cured sufficiently that its surface is no longer tacky or sticky. The moment of freedom from tack can be determined by repeatedly testing the foam surface with a wooden rod.
- In a specific embodiment of the method, the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter3 determined at 23° C. using ASTM D 1622-03; the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether); the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers; the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers; the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether); the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying within the disclosed range.
- The invention includes at least the following embodiments.
- A polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- The polyurethane or polyisocyanurate foam of embodiment 1, having a core density of 0.03 to 0.06 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- The polyurethane or polyisocyanurate foam of embodiment 1 or 2, wherein the polyurethane or polyisocyanurate foam is a polyurethane foam that is the product of a process characterized by an isocyanate index of 105 to 125.
- The polyurethane or polyisocyanurate foam of embodiment 1 or 2, wherein the polyurethane or polyisocyanurate foam is a polyisocyanurate foam that is the product of a process characterized by an isocyanate index of 180 to 350.
- The polyurethane or polyisocyanurate foam of any of embodiments 1-4, wherein the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether).
- The polyurethane or polyisocyanurate foam of any of embodiments 1-5, wherein the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers.
- The polyurethane or polyisocyanurate foam of any of embodiments 1-6, wherein the particulate poly(phenylene ether) has a particle size distribution wherein 90 volume percent of the particle size distribution is in the range of 1 to 8 micrometers.
- The polyurethane or polyisocyanurate foam of any of embodiments 1-7, comprising 5 to 30 weight percent of the particulate poly(phenylene ether).
- The polyurethane or polyisocyanurate foam of any of embodiments 1-8, wherein the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule.
- The polyurethane or polyisocyanurate foam of embodiment 9, wherein the polyol comprises an ethoxylated saccharide, a propoxylated saccharide, a butoxylated saccharide, an ethoxylated glycerin, a propoxylated glycerin, a butoxylated glycerin, an ethoxylated diethanolamine, a propoxylated diethanolamine, a butoxylated diethanolamine, an ethoxylated triethanolamine, a propoxylated triethanolamine, a butoxylated triethanolamine, an ethoxylated trimethylolpropane, a propoxylated trimethylolpropane, a butoxylated trimethylolpropane, an ethoxylated erythritol, a propoxylated erythritol, a butoxylated erythritol, an ethoxylated pentaerythritol, a propoxylated pentaerythritol, a butoxylated pentaerythritol, an aliphatic polyester diol, an aromatic polyester polyol, or a combination thereof
- The polyurethane or polyisocyanurate foam of embodiment 9, wherein the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof
- The polyurethane or polyisocyanurate foam of any of embodiments 9-11, wherein the isocyanate compound comprises 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3-diisocyanate, and cyclohexane-1,4-diisocyanate, 1-isocyanato-2-isocyanatomethyl cyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane, bis(4-isocyanatocyclohexyl)methane, 2,4′-dicyclohexyl-methane diisocyanate, 1,3-bis(isocyanatomethyl)-cyclohexane, 1,4-bis-(isocyanatomethyl)-cyclohexane, bis(4-isocyanato-3-methyl-cyclohexyl)methane, alpha,alpha,alpha′,alpha′-tetramethyl-1,3-xylylene diisocyanate, alpha,alpha,alpha′,alpha′-tetramethyl-1,4-xylylene diisocyanate, 1-isocyanato-1-methyl-4(3)-isocyanatomethyl cyclohexane, 2,4-hexahydrotoluene diisocyanate, 2,6-hexahydrotoluene diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 2,4-diphenylmethane diisocyanate, 4,4′-diphenylmethane diisocyanate, 1,5-diisocyanato naphthalene, an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule, or a combination thereof
- The polyurethane or polyisocyanurate foam of any of embodiments 9-11, wherein the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- The polyurethane or polyisocyanurate foam of embodiment 1, wherein the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter3 determined at 23° C. using ASTM D 1622-03; wherein the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether); wherein the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers; wherein the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers; wherein the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether); wherein the polyurethane or polyisocyanurate foam is a product of a method comprising reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form the polyurethane or polyisocyanurate foam, wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the polyol comprises a wherein the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and wherein the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- The polyurethane or polyisocyanurate foam of embodiment 14, wherein the polyurethane or polyisocyanurate foam is a polyurethane foam that is the product of a process characterized by an isocyanate index of 105 to 125.
- The polyurethane or polyisocyanurate foam of embodiment 14, wherein the polyurethane or polyisocyanurate foam is a polyisocyanurate foam that is the product of a process characterized by an isocyanate index of 180 to 350.
- An article comprising thermal insulation comprising polyurethane or polyisocyanurate foam comprising 1 to 50 weight percent, based on the total weight of the polyurethane or polyisocyanurate foam, of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers; wherein the polyurethane or polyisocyanurate foam has a core density of 0.03 to 0.7 grams/centimeter3 determined at 23° C. using ASTM D 1622-03.
- A method of forming a polyurethane or polyisocyanurate foam, the method comprising: reacting a polyol and an isocyanate compound in the presence of a blowing agent and a particulate poly(phenylene ether) to form a polyurethane or polyisocyanurate foam; wherein the isocyanate compound comprises, on average, at least two isocyanate groups per molecule; wherein the particulate poly(phenylene ether) has a mean particle size of 1 to 40 micrometers; and wherein the polyurethane or polyisocyanurate foam comprises 1 to 50 weight percent of the particulate poly(phenylene ether).
- The method of embodiment 16, wherein the polyol, the isocyanate compound, and water, if any, are present in amounts sufficient to provide an isocyanate index of 180 to 350.
- The method of embodiment 16, wherein the polyurethane or polyisocyanurate foam has a core density of 0.02 to 0.06 grams/centimeter3 determined at 23° C. using ASTM D 1622-03; wherein the particulate poly(phenylene ether) is a particulate poly(2,6-dimethyl-1,4-phenylene ether); wherein the particulate poly(phenylene ether) has a mean particle size of 2 to 8 micrometers; wherein the particulate poly(phenylene ether) has a particle size distribution wherein 90 percent of the particle volume distribution is in the range of 1 to 8 micrometers; wherein the polyurethane or polyisocyanurate foam comprises 5 to 30 weight percent of the particulate poly(phenylene ether); wherein the polyol comprises a propoxylated sucrose, a propoxylated glycerin, an aromatic polyester diol, or a combination thereof; and wherein the isocyanate compound comprises an oligomeric diphenylmethane diisocyanate having an average of greater than 2 and less than or equal to 4 isocyanate groups per molecule.
- The invention is further illustrated by the following non-limiting examples.
- Raw materials used in the working examples are summarized in Table 1.
-
TABLE 1 Reagent Description POLY-G ™ 74-376 A mixture of propoxylated sucrose (CAS Reg. No. 9049-71-2) and propoxylated glycerin (CAS Reg. No. 25791-96-2), the mixture having an OH number of 368 milligrams KOH/gram and a viscosity of 2700 centipoise at 25° C.; available as POLY-G ™ 74-376 from Arch Chemicals, Inc. TERATE ™ 4026 An aromatic polyester polyol having an OH number of 200 milligrams/gram, a viscosity of 2500 centipoise at 25° C., a number average molecular weight of about 560 grams/mole, and about 2 hydroxyl groups per molecule; available as TERATE ™ 4026 from Invista. RUBINATE ™ M An oligomeric diphenylmethane diisocyanate having 31.0 weight percent isocyanate groups and an average of 2.7 isocyanate groups per molecule; available as RUBINATE ™ M from Huntsman. DABCO ™ 33LV 33 weight percent triethylenediamine in dipropylene glycol; available as DABCO ™ 33LV from Air Products. NIAX ™ A-1 70 weight percent bis(dimethylaminoethyl)ether in dipropylene glycol; available as NIAX ™ A-1 from Momentive. DABCO ™ TMR-4 An N-hydroxyalkyl quaternary ammonium carboxylate (catalyst for formation of isocyanurate groups) having an OH number of 687 milligrams OH/gram and a viscosity of 34 centipoise at 25° C.; available as DABCO ™ TMR-4 from Air Products. POLYCAT ™ 8 N,N-dimethylcyclohexylamine; available as POLYCAT ™ 8 from Air Products. DABCO ™ DC193 A polysiloxane surfactant; available as DABCO ™ DC193 from Air Products. ENOVATE ™ 3000 1,1,1,3,3-pentafluropropane (HFC-245fa); available as ENOVATE ™ 3000 from Honeywell Particulate PPE Poly(2,6-dimethyl-1,4-phenylene ether) particles having a mean particle size of 6.1 micrometers, 10 volume percent of particles less than 4.0 micrometers, 10 volume percent of particles greater than 8.1 micrometers, and a mean aspect ratio of 1.41:1. - Particulate poly(2,6-dimethyl-1,4-phenylene ether) was obtained by jet milling commercial grade poly(phenylene ether) powder obtained as PPO™ 640 resin from Sabic Innovative Plastics. Compressed nitrogen gas was introduced into the nozzles of a jet mill to create a supersonic grinding stream. Particle-on-particle impact collisions in this grinding stream resulted in substantial particle size reductions. Large particles were held in the grinding area by centrifugal force while centripetal force drove finer particles toward the center of the discharge. A sieve of a specific upper size limit was then used in-line to recover particles with a precise size distribution and having diameters below the nominal sieve openings. Larger particles were recycled to the reduction size chamber for further grinding. The particulate poly(2,6-dimethyl-1,4-phenylene ether) was classified by passing the jet-milled particles through a screen with 6 micrometer openings. The particle size and shape characterization in Table 1 was determined using a CAMSIZER™ XT from Retsch Technology GmbH operating in air dispersion mode.
- Rigid foams were prepared using a high-torque mixer (CRAFTSMAN Ten Inch Drill Press, Model No. 137.219000) at 3,100 rotations per minute. Polyol components and isocyanate components of the foam systems were mixed for 10 seconds. The resulting mixture was transferred into an open cake box before the cream time and allowed to free-rise. Foaming profile, including cream time, gel time, rise time, and tack-free time was determined on all foams.
- All foams were cut and tested after aging at ambient conditions for one week. The following methods were used for testing of rigid foams. Core density values, expressed in grams/centimeter3, were determined at 23° C. using ASTM D 1622-03 and a sample size of 5.08 centimeters×5.08 centimeters×2.54 centimeters (2 inches×2 inches×1 inch). Compressive strength values, expressed in megapascals, were determined at 23° C. using ASTM D 1621-00 and a sample size of 5.08 centimeters×5.08 centimeters×2.54 centimeters (2 inches×2 inches×1 inch) and a head speed of 2.5 millimeters/minute. Values of burning rate in a horizontal position, expressed in millimeters/minute, were determined according to ASTM D635-03 using a sample size of 15.24 centimeters×5.08 centimeters×1.27 centimeters (6 inches×2 inches×0.5 inch). Water absorption values, expressed in percent, were determined according to ASTM D 2842-01 using a sample size of 5.08 centimeters×5.08 centimeters×2.54 centimeters (2 inches×2 inches×1 inch), and immersion in water for 96 and 168 hours at 25° C. and 1 atmosphere.
- Table 2 summarizes examples in which the particulate poly(phenylene ether) was added only to the polyol component of the polyurethane formulation. The property results show that similar core densities were obtained for each foam, but, relative to Comparative Example A, inventive Examples 1-3 exhibited higher compressive strength values.
-
TABLE 2 C. Ex. A Ex. 1 Ex. 2 Ex. 3 COMPOSITION Polyol Component POLY-G ™ 74-376 100 90 80 70 Particulate PPE 0 10 20 30 Water 4.5 4.5 4.5 4.5 DABCO ™ DC193 2.5 2.5 2.5 2.5 DABCO ™ 33LV 0.6 0.6 0.6 0.6 Isocyanate Component RUBINATE ™ M 173.62 163.85 154.07 144.3 PROCESS Isocyanate Index 110 110 110 110 PPE content (wt %) 0 3.68 7.64 11.91 Reaction Profile of Free-rise No. of foaming 2 1 1 1 experiments Mix time (sec) 10 10 10 10 Cream time (sec) 68 68 50 45 Gel time (sec) 290 145 133 120 Rise time (sec) 820 380 360 290 Tack-free time (sec) 1230 990 690 540 PROPERTIES Core density (g/cc) 0.04101 0.04149 0.04197 0.04261 Compressive Strength 0.1296 0.1859 0.1826 0.1882 at Yield (MPa) - In order to maximize the amount of the particulate poly(phenylene ether) in the polyurethane foam system, the particulate poly(phenylene ether) was added through both the polyol component and the isocyanate component of the foam systems. Compositions, processes, and properties are summarized in Table 3. The property results show that, relative to Comparative Example B, inventive Examples 4-6 with particulate poly(phenylene ether) exhibited reduced flammability and reduced water absorption.
-
TABLE 3 C. Ex. B Ex. 4 Ex. 5 Ex. 6 COMPOSITION Polyol Component POLY-G ™ 74-376 100 85 80 75 Particulate PPE 0 44.9 61.2 78.2 Water 4.5 4.5 4.5 4.5 DABCO ™ DC193 2 2 2 2 DABCO ™ 33LV 1.8 1.8 1.8 1.8 NIAX ™ A-1 0.1 0.1 0.1 0.1 Isocyanate Component RUBINATE ™ M 175.29 160.63 155.74 150.85 PROCESS PPE content (wt %) 0 15 20 25 Mode of particulate PPE addition: Polyol Component (pbw) 0 27.76 26.12 24.5 Isocyanate Component 0 17.14 35.08 53.7 (pbw) Isocyanate Index 110 110 110 110 Reaction Profile of Free-rise No. of foaming 4 3 3 3 experiments Mix time (sec) 7 7 7 7 Cream time (sec) 13 13 13 12 Gel time (sec) 63 58 51 48 Rise time (sec) 95 98 93 85 Tack-free time (sec) 105 115 110 100 PROPERTIES Core density (g/cc) 0.03396 0.03829 0.04133 0.04037 Compressive Strength 0.1646 0.2206 0.2023 0.1287 at Yield (MPa) Flammability - 31.06 24.4 23.9 21.35 Burn Rate (cm/min) Water Absorption at 25° C. % change after 96 hours 230 — — 126 % change after 168 hours 239 — — 153 - Examples of polyisocyanurate foam systems are summarized in Table 4. The particulate poly(phenylene ether) was added through the both polyol component and isocyanate component of the foam systems. The property results show that, relative to Comparative Example C, inventive Examples 7-9 with particulate poly(phenylene ether) exhibited reduced flammability and reduced water absorption.
-
TABLE 4 C. Ex. C Ex. 7 Ex. 8 Ex. 9 COMPOSITION Polyol Component POLY-G ™ 74-376 50 45 42.5 40 TERATE ™ 4026 50 45 42.5 40 Particulate PPE 0 33.25 38.25 68 Water 1 1 1 1 DABCO ™ DC193 1.4 1.4 1.4 1.4 POLYCAT ™ 8 0.4 0.4 0.4 0.4 DABCO ™ TMR-4 2.1 2.1 2.1 2.1 ENOVATE ™ 3000 25 25 30 30 Isocyanate Component RUBINATE ™ M 192.23 177.1 169.6 162.05 PROCESS PPE content (wt %) 0 10 15 20 Mode of particulate PPE addition: Polyol Component (pbw) 0 27 25.5 24 Isocyanate Component 0 6.25 13.5 44 (pbw) Isocyanate Index 220 220 220 220 Reaction Profile of Free-rise No. of foaming 3 2 2 2 experiments Mix time (sec) 7 7 7 7 Cream time (sec) 15 14 13 13 Gel time (sec) 70 58 53 47 Rise time (sec) 149 156 157 138 Tack-free time (sec) 260 256 235 255 PROPERTIES Core density (g/cc) 0.03268 0.03380 0.03252 0.03460 Compressive Strength 0.1648 0.1336 0.1166 0.1055 at Yield (MPa) Flammability - 33.1 27.18 28.87 21.61 Burn Rate (cm/min) Water Absorption at 25° C. % change after 96 hours 237 — — 153 % change after 168 hours 239 — — 173
Claims (18)
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/948,416 US20150028247A1 (en) | 2013-07-23 | 2013-07-23 | Rigid foam and associated article and method |
EP14828964.8A EP3036288B1 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
JP2016515976A JP6158431B2 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and related articles and methods |
US14/900,428 US9493621B2 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
CN201480039997.XA CN105377988A (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
CN201910204954.7A CN110041690A (en) | 2013-07-23 | 2014-06-24 | Rigid foam and correlated product and method |
KR1020167002816A KR101669073B1 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
PCT/US2014/043773 WO2015012989A1 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/948,416 US20150028247A1 (en) | 2013-07-23 | 2013-07-23 | Rigid foam and associated article and method |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/900,428 Continuation US9493621B2 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
Publications (1)
Publication Number | Publication Date |
---|---|
US20150028247A1 true US20150028247A1 (en) | 2015-01-29 |
Family
ID=52389703
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/948,416 Abandoned US20150028247A1 (en) | 2013-07-23 | 2013-07-23 | Rigid foam and associated article and method |
US14/900,428 Active US9493621B2 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/900,428 Active US9493621B2 (en) | 2013-07-23 | 2014-06-24 | Rigid foam and associated article and method |
Country Status (6)
Country | Link |
---|---|
US (2) | US20150028247A1 (en) |
EP (1) | EP3036288B1 (en) |
JP (1) | JP6158431B2 (en) |
KR (1) | KR101669073B1 (en) |
CN (2) | CN105377988A (en) |
WO (1) | WO2015012989A1 (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2016532726A (en) * | 2013-10-03 | 2016-10-20 | サビック グローバル テクノロジーズ ベスローテン フェンノートシャップ | Flexible polyurethane foam and related methods and articles |
US9493621B2 (en) | 2013-07-23 | 2016-11-15 | Sabic Global Technologies B.V. | Rigid foam and associated article and method |
IT201600077120A1 (en) * | 2016-07-22 | 2018-01-22 | Doors & More S R L | HIGH DENSITY COMPACT POLYESOCYANURATE |
WO2018015938A1 (en) * | 2016-07-22 | 2018-01-25 | Doors & More S.R.L. | High fire-resistant polyisocyanurate, and use thereof to manufacture fire door or window frames and/or profiles therefor |
IT201700020006A1 (en) * | 2017-02-22 | 2018-08-22 | Doors & More S R L | USE OF POLYESOCYANURATE FOR EXAMPLE FOR THE CONSTRUCTION OF SECURITY WINDOWS OR COMPARTMENTS |
IT201700020013A1 (en) * | 2017-02-22 | 2018-08-22 | Doors & More S R L | USE OF COMPACT POLYISOCYANURATE FOR THE CONSTRUCTION OF PROFILES FOR SECURITY FRAMES |
US10333234B2 (en) | 2017-08-14 | 2019-06-25 | Shore Acres Enterprises Inc. | Corrosion-protective jacket for electrode |
EP3433093B1 (en) | 2016-07-20 | 2019-09-04 | Brugg Rohr Ag Holding | Thermally insulated medium pipes having hfo-containing cell gas |
US10665364B2 (en) | 2013-08-16 | 2020-05-26 | Shore Acres Enterprises Inc. | Corrosion protection of buried metallic conductors |
WO2021165149A1 (en) * | 2020-02-19 | 2021-08-26 | Evonik Operations Gmbh | Polyurethane insulating foams and production thereof |
US11121482B2 (en) | 2017-10-04 | 2021-09-14 | Shore Acres Enterprises Inc. | Electrically-conductive corrosion-protective covering |
US11421392B2 (en) | 2019-12-18 | 2022-08-23 | Shore Acres Enterprises Inc. | Metallic structure with water impermeable and electrically conductive cementitous surround |
US20230049261A1 (en) * | 2021-07-28 | 2023-02-16 | Momentive Performance Materials Inc. | Flexible foams comprising additives for improving hardness |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104892885A (en) * | 2015-05-25 | 2015-09-09 | 遵义市凤华电器有限责任公司 | Flame-retardant rigid polyurethane for foaming layer of refrigerator |
US20190367667A1 (en) * | 2017-02-22 | 2019-12-05 | Mitsui Chemicals Inc. | Polyurethane elastomer foam material, polyurethane elastomer foam, and method for producing polyurethane elastomer foam |
TWI686527B (en) * | 2018-06-29 | 2020-03-01 | 遠東新世紀股份有限公司 | Lightweight tile |
KR102159783B1 (en) * | 2018-08-31 | 2020-09-23 | (주)다담상사 | The wall structure using low temperature storage and the low temperature storage comprising thereof |
CN112644225A (en) * | 2020-12-29 | 2021-04-13 | 永佳工业车辆(苏州)有限公司 | Cart caster with steering positioning brake mechanism and manufacturing method thereof |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6121338A (en) * | 1997-09-25 | 2000-09-19 | Imperial Chemical Industries Plc | Process for rigid polyurethane foams |
US20040092616A1 (en) * | 2000-11-09 | 2004-05-13 | Ernesto Occhiello | Process for producing rigid polyurethane foams and finished articles obtained therefrom |
Family Cites Families (144)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2768994A (en) | 1952-08-30 | 1956-10-30 | Du Pont | Polyoxymethylenes |
US2998409A (en) | 1954-04-16 | 1961-08-29 | Du Pont | Polyoxymethylene carboxylates of improved thermal stability |
US3027352A (en) | 1958-02-28 | 1962-03-27 | Celanese Corp | Copolymers |
BE635349A (en) | 1962-07-24 | |||
NL141540B (en) | 1965-01-06 | 1974-03-15 | Gen Electric | PROCESS FOR PREPARING A POLYSTYRENE CONTAINING POLYMER MIXTURE WHICH CAN BE PROCESSED INTO PRODUCTS WITH HIGH BENDING AND TENSILE STRENGTHS, AS WELL AS SUCH PRODUCTS. |
US3383340A (en) | 1965-05-12 | 1968-05-14 | Gen Electric | Reinforcing fillers for rubber |
US3513114A (en) | 1966-01-07 | 1970-05-19 | Monsanto Co | Intumescent coating compositions |
US3836829A (en) | 1969-12-29 | 1974-09-17 | Gen Electric | Polyolefin film containing therein widely dispersed fine particles of a dielectric liquid soluble material |
CA927538A (en) | 1970-03-09 | 1973-05-29 | M. Summers Robert | Rubber modified polyphenylene ether and process |
US3847867A (en) | 1971-01-20 | 1974-11-12 | Gen Electric | Polyetherimides |
US3972902A (en) | 1971-01-20 | 1976-08-03 | General Electric Company | 4,4'-Isopropylidene-bis(3- and 4-phenyleneoxyphthalic anhydride) |
US3850885A (en) | 1973-11-23 | 1974-11-26 | Gen Electric | Method for making polyetherimides |
DE2359699B2 (en) | 1973-11-30 | 1978-09-21 | Hoechst Ag, 6000 Frankfurt | Inflatable, flame-retardant coating compounds |
US3855178A (en) | 1973-12-03 | 1974-12-17 | Gen Electric | Method for making polyetherimides |
US3852242A (en) | 1973-12-03 | 1974-12-03 | Gen Electric | Method for making polyetherimide |
US3873477A (en) | 1973-12-17 | 1975-03-25 | Stepan Chemical Co | Metallic salts of tetrazoles used as blowing and intumescent agents for thermoplastic polymers |
US3955987A (en) | 1974-04-19 | 1976-05-11 | Monsanto Research Corporation | Intumescent compositions and substrates coated therewith |
FR2284638A1 (en) | 1974-09-10 | 1976-04-09 | Ugine Kuhlmann | Stable dispersions of thermoplastic particles in polyhydroxy cpds - by dehydrating homogeneous mixt of polyol and thermoplastic latex |
JPS5165159A (en) | 1974-12-04 | 1976-06-05 | Sumitomo Electric Industries | GANYUHORIASETA ARUSOSEIBUTSU |
US3983093A (en) | 1975-05-19 | 1976-09-28 | General Electric Company | Novel polyetherimides |
US4216261A (en) | 1978-12-06 | 1980-08-05 | The United States Of America As Represented By The Secretary Of The Army | Semi-durable, water repellant, fire resistant intumescent process |
US4341694A (en) | 1981-07-06 | 1982-07-27 | Borg-Warner Corporation | Intumescent flame retardant compositions |
US4336184A (en) | 1981-08-12 | 1982-06-22 | Borg-Warner Chemicals, Inc. | Intumescent flame retardant thermoplastic polyphenylene ether compositions |
US4455410A (en) | 1982-03-18 | 1984-06-19 | General Electric Company | Polyetherimide-polysulfide blends |
US4443591A (en) | 1983-01-21 | 1984-04-17 | General Electric Company | Method for making polyetherimide |
EP0119416A1 (en) | 1983-02-18 | 1984-09-26 | General Electric Company | Thermoplastic molding compostions having improved dust suppression |
US4623558A (en) | 1985-05-29 | 1986-11-18 | W. R. Grace & Co. | Reactive plastisol dispersion |
US5304593A (en) | 1986-09-30 | 1994-04-19 | Sumitomo Chemical Co., Ltd. | Blends of dispersing phase of polyphenylene ether, a crystalline thermoplastic matrix resin and a mutual compatiblizer |
US4801625A (en) | 1987-08-27 | 1989-01-31 | Akzo America Inc. | Bicyclic phosphate ether, ester, and carbonate intumescent flame retardant compositions |
JPH0198645A (en) * | 1987-10-13 | 1989-04-17 | Nippon Petrochem Co Ltd | Thermoplastic resin composition and its production |
EP0309025B1 (en) | 1987-09-09 | 1995-05-17 | Asahi Kasei Kogyo Kabushiki Kaisha | A cured polyphenylene ether resin and a curable polyphenylene ether resin |
JPH01222951A (en) | 1988-03-02 | 1989-09-06 | Toray Ind Inc | Laminated film |
US5326817A (en) | 1988-03-23 | 1994-07-05 | Nippon Petrochemicals Co. Ltd. | Blend of polyphenylene ether, polycarbonate or polyoxymethylene resins and multi-phase thermoplastic resins |
CA2048079A1 (en) | 1988-07-15 | 1993-01-30 | Shahid P. Qureshi | Fiber-reinforced composites toughened with resin particles |
US5087657A (en) | 1989-02-23 | 1992-02-11 | Amoco Corporation | Fiber-reinforced composites toughened with resin particles |
US5010117A (en) | 1989-06-16 | 1991-04-23 | Dow Chemical Company | Flexible polyurethane foams prepared using low unsaturation polyether polyols |
US5147710A (en) | 1989-10-27 | 1992-09-15 | General Electric Company | Flame retardant low density foam articles |
JPH03197538A (en) | 1989-12-27 | 1991-08-28 | Idemitsu Petrochem Co Ltd | Polyolefinic resin composition |
JP2591838B2 (en) | 1990-02-13 | 1997-03-19 | 東ソー株式会社 | Polyphenylene sulfide resin composition |
US5032622A (en) | 1990-07-02 | 1991-07-16 | The Dow Chemical Company | Densifiable and re-expandable polyurethane foam |
JPH04159366A (en) | 1990-10-23 | 1992-06-02 | Asahi Chem Ind Co Ltd | Resin composition containing pps |
JP2519767Y2 (en) | 1991-02-08 | 1996-12-11 | 三菱自動車工業株式会社 | Air bag device |
US5169887A (en) | 1991-02-25 | 1992-12-08 | General Electric Company | Method for enhancing the flame retardance of polyphenylene ethers |
JP2598742B2 (en) | 1993-03-09 | 1997-04-09 | チッソ株式会社 | Melamine-coated ammonium polyphosphate and method for producing the same |
US5424344A (en) | 1994-01-05 | 1995-06-13 | E. I. Dupont De Nemours And Company | Flame retardant polyamide compositions |
EP0835908B1 (en) | 1995-06-29 | 2004-03-10 | Asahi Kasei Kabushiki Kaisha | Resin composition and resin composition for secondary battery jar |
JPH09104094A (en) | 1995-10-12 | 1997-04-22 | Matsushita Electric Works Ltd | Manufacture of laminated sheet |
US5723515A (en) | 1995-12-29 | 1998-03-03 | No Fire Technologies, Inc. | Intumescent fire-retardant composition for high temperature and long duration protection |
DE19613979A1 (en) | 1996-04-09 | 1997-10-16 | Hoechst Ag | Mixtures of thermoplastics and oxidized polyarylene sulfides |
TW550278B (en) * | 1996-11-12 | 2003-09-01 | Gen Electric | A curable polyphenylene ether-thermosetting resin composition |
US5834565A (en) * | 1996-11-12 | 1998-11-10 | General Electric Company | Curable polyphenylene ether-thermosetting resin composition and process |
JPH10298438A (en) * | 1997-04-28 | 1998-11-10 | Asahi Chem Ind Co Ltd | Thermoplastic resin composition containing liquid additive |
US6096817A (en) | 1997-06-26 | 2000-08-01 | E. I. Du Pont De Nemours And Company | Mixtures of polyimides and elastomers |
WO1999061519A1 (en) | 1998-05-22 | 1999-12-02 | Solvay Fluor Und Derivate Gmbh | The production of polyurethane foams and foamed thermoplastic synthetic materials |
US6063875A (en) | 1998-06-11 | 2000-05-16 | General Electric Company | Carboxy-functionalized polyphenylene ethers and blends containing them |
DE19853025A1 (en) * | 1998-11-18 | 2000-05-25 | Basf Ag | Isocyanate based rigid foam, useful for the production of insulating material is prepared from an aromatic polyether polyol and a mixture of isocyanate reactive and unreactive phosphonate compounds |
EP1169389A1 (en) | 1999-04-02 | 2002-01-09 | General Electric Company | Compositions of an interpolymer and polyphenylene ether resin |
US6096821A (en) | 1999-04-02 | 2000-08-01 | General Electric Company | Polyphenylene ether resin concentrates |
JP2001019839A (en) | 1999-07-09 | 2001-01-23 | Asahi Chem Ind Co Ltd | Curable resin composition |
AU6086700A (en) | 1999-07-19 | 2001-02-05 | W.R. Grace & Co.-Conn. | Thermally protective intumescent compositions |
JP2001098166A (en) | 1999-08-03 | 2001-04-10 | Lewin Menachem | Flame retardant polymeric composition |
EP1242523B1 (en) | 1999-08-06 | 2005-10-19 | Pabu Services, Inc. | Intumescent polymer compositions |
CA2293005A1 (en) | 1999-09-29 | 2001-03-29 | E.I. Du Pont De Nemours And Company | Polyoxymethylene resin compositions having improved molding characteristics |
US6576718B1 (en) | 1999-10-05 | 2003-06-10 | General Electric Company | Powder coating of thermosetting resin(s) and poly(phenylene ethers(s)) |
US6352782B2 (en) | 1999-12-01 | 2002-03-05 | General Electric Company | Poly(phenylene ether)-polyvinyl thermosetting resin |
CN1209397C (en) | 2000-02-16 | 2005-07-06 | 三洋化成工业株式会社 | Resin dispersions having uniform particle diameters, resin particles and processes for producing both |
US6508910B2 (en) | 2000-05-18 | 2003-01-21 | Hexcel Corporation | Self-adhesive prepreg face sheet for sandwich panels |
US6756430B2 (en) | 2000-06-13 | 2004-06-29 | Mitsui Chemicals, Inc. | Flame-retarding thermoplastic resin composition |
JP5101782B2 (en) | 2000-08-09 | 2012-12-19 | ルブリゾール アドバンスト マテリアルズ,インコーポレイティド | Low molecular weight engineering thermoplastic polyurethanes and blends thereof |
ATE380837T1 (en) | 2001-04-27 | 2007-12-15 | Stichting Dutch Polymer Inst | POLYETHER MULTIBLOCK COPOLYMER |
EP1404766A1 (en) | 2001-06-01 | 2004-04-07 | W. & J. Leigh & Co. | Coating compositions |
US7022777B2 (en) | 2001-06-28 | 2006-04-04 | General Electric | Moldable poly(arylene ether) thermosetting compositions, methods, and articles |
JP2003128909A (en) | 2001-10-23 | 2003-05-08 | Asahi Kasei Corp | Flame-retardant thermosetting resin composition |
US6809129B2 (en) | 2002-01-23 | 2004-10-26 | Delphi Technologies, Inc. | Elastomeric intumescent material |
US6706793B2 (en) | 2002-01-23 | 2004-03-16 | Delphi Technologies, Inc. | Intumescent fire retardant composition and method of manufacture thereof |
JP4007828B2 (en) | 2002-03-08 | 2007-11-14 | 旭化成ケミカルズ株式会社 | Method for producing low molecular weight polyphenylene ether |
US7091266B2 (en) | 2002-05-28 | 2006-08-15 | Asahi Kasei Kabushiki Kaisha | Flame retardant composition |
DE10241374B3 (en) | 2002-09-06 | 2004-02-19 | Clariant Gmbh | Flame retardant powder based on organophosphorous compound, used in thermoplastic or thermosetting polymer molding composition or intumescent coating, contains dust-reducing metal or ammonium dialkyl (di)phosphinate |
US20050171266A1 (en) | 2003-06-10 | 2005-08-04 | Matthijssen Johannes G. | Filled compositions and a method of making |
US7041780B2 (en) | 2003-08-26 | 2006-05-09 | General Electric | Methods of preparing a polymeric material composite |
JP2005105009A (en) | 2003-09-26 | 2005-04-21 | Asahi Kasei Chemicals Corp | Flame-retardant curable resin composition |
US7022765B2 (en) | 2004-01-09 | 2006-04-04 | General Electric | Method for the preparation of a poly(arylene ether)-polyolefin composition, and composition prepared thereby |
US7151158B2 (en) | 2004-01-30 | 2006-12-19 | General Electric Company | Method of preparing a poly(arylene ether), apparatus therefor, and poly(arylene ether) prepared thereby |
US20050170238A1 (en) | 2004-02-04 | 2005-08-04 | Abu-Isa Ismat A. | Fire shielding battery case |
US20070228343A1 (en) | 2004-05-13 | 2007-10-04 | Michael Roth | Flame Retardants |
KR101014183B1 (en) | 2004-07-21 | 2011-02-14 | 삼성전자주식회사 | Back light assembly and liquid crystal display having the same |
JP4093216B2 (en) | 2004-08-24 | 2008-06-04 | 松下電工株式会社 | Prepreg and method for producing prepreg |
US8889815B2 (en) | 2004-09-01 | 2014-11-18 | Ppg Industries Ohio, Inc. | Reinforced polyurethanes and poly(ureaurethane)s, methods of making the same and articles prepared therefrom |
DE102004050479A1 (en) | 2004-10-15 | 2006-04-27 | Chemische Fabrik Budenheim Kg | Molding composition for the production of flame-retardant articles, pigment therefor and its use |
DE102004050478A1 (en) | 2004-10-15 | 2006-04-27 | Chemische Fabrik Budenheim Kg | Molding composition for the production of flame-retardant articles, pigment therefor and its use |
GB0428009D0 (en) | 2004-12-21 | 2005-01-26 | W & J Leigh & Co | Intumescent coating compositions |
US20060292375A1 (en) | 2005-06-28 | 2006-12-28 | Martin Cary J | Resin compositions with high thermoplatic loading |
US7378455B2 (en) | 2005-06-30 | 2008-05-27 | General Electric Company | Molding composition and method, and molded article |
US7429800B2 (en) | 2005-06-30 | 2008-09-30 | Sabic Innovative Plastics Ip B.V. | Molding composition and method, and molded article |
US9315612B2 (en) * | 2005-07-27 | 2016-04-19 | Certainteed Corporation | Composite material including rigid foam with inorganic fillers |
US7825176B2 (en) | 2005-08-31 | 2010-11-02 | Sabic Innovative Plastics Ip B.V. | High flow polyester composition |
US20070066739A1 (en) | 2005-09-16 | 2007-03-22 | General Electric Company | Coated articles of manufacture made of high Tg polymer blends |
US20070093602A1 (en) * | 2005-10-24 | 2007-04-26 | Bayer Materialscience Llc | Solid polyurethane compositions, infrastucture repair and geo-stabilization processes |
EP2471836A1 (en) | 2005-10-28 | 2012-07-04 | SABIC Innovative Plastics IP B.V. | Method for the Preparation of a Poly(Arylene Ether), and Related Compositions |
WO2007055147A1 (en) | 2005-11-10 | 2007-05-18 | Asahi Kasei Chemicals Corporation | Resin composition excellent in flame retardance |
US8026303B2 (en) | 2006-01-06 | 2011-09-27 | Icl-Ip America Inc. | Halogen-free flame retardant compositions, thermoplastic compositions comprising the same and methods of producing the compositions |
JP2008050526A (en) | 2006-08-28 | 2008-03-06 | Matsushita Electric Works Ltd | Resin composition, prepreg and laminated board using the same |
GB0619401D0 (en) | 2006-10-02 | 2006-11-08 | Hexcel Composites Ltd | Composite materials with improved performance |
US7718721B2 (en) | 2006-11-13 | 2010-05-18 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether)/polyolefin composition, method, and article |
DE102006058414A1 (en) | 2006-12-12 | 2008-06-19 | Clariant International Limited | New carboxyethyl(alkyl)phosphinic acid-alkylester salts useful e.g. as flame resistant for clear varnishes and intumescent coating, as binder for molding sands, and in flame-resistant thermoplastic polymer molding materials |
US7585906B2 (en) | 2007-02-28 | 2009-09-08 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether) composition, method, and article |
US7576150B2 (en) | 2007-02-28 | 2009-08-18 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether) composition, method, and article |
GB2448514B (en) | 2007-04-18 | 2010-11-17 | Univ Sheffield Hallam | Steel component with intumescent coating |
WO2009003124A1 (en) | 2007-06-26 | 2008-12-31 | Seeqpod, Inc. | Media discovery and playlist generation |
DE102007034458A1 (en) | 2007-07-20 | 2009-01-22 | Evonik Röhm Gmbh | Resin system for intumescent coating with improved metal adhesion |
US8025158B2 (en) | 2008-02-21 | 2011-09-27 | Sabic Innovative Plastics Ip B.V. | High molecular weight poly(2,6-dimethyl-1,4-phenylene ether) and process therefor |
CN101980860B (en) | 2008-04-04 | 2014-01-29 | 纳幕尔杜邦公司 | Composite panels having improved fluid impermeability |
US8017697B2 (en) | 2008-06-24 | 2011-09-13 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether)-polysiloxane composition and method |
US8039535B2 (en) | 2008-07-03 | 2011-10-18 | Cheil Industries Inc. | Flame retardant and impact modifier, method for preparing the same, and thermoplastic resin composition including the same |
US7847032B2 (en) | 2008-12-10 | 2010-12-07 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether) composition and extruded articles derived therefrom |
US7829614B2 (en) | 2008-12-30 | 2010-11-09 | Sabic Innovative Plastics Ip B.V. | Reinforced polyester compositions, methods of manufacture, and articles thereof |
US9558867B2 (en) | 2009-04-29 | 2017-01-31 | Polyone Corporation | Flame retardant thermoplastic elastomers |
US9567426B2 (en) | 2009-05-29 | 2017-02-14 | Cytec Technology Corp. | Engineered crosslinked thermoplastic particles for interlaminar toughening |
US20110028609A1 (en) | 2009-08-03 | 2011-02-03 | E. I. Du Pont De Nemours And Company | Making Renewable Polyoxymethylene Compositions |
US8470923B2 (en) | 2010-04-21 | 2013-06-25 | Hexcel Corporation | Composite material for structural applications |
DE102010018680A1 (en) | 2010-04-29 | 2011-11-03 | Clariant International Limited | Flame retardant stabilizer combination for thermoplastic and thermosetting polymers |
DE102010018681A1 (en) | 2010-04-29 | 2011-11-03 | Clariant International Ltd. | Flame retardant stabilizer combination for thermoplastic and thermosetting polymers |
DE102010048025A1 (en) | 2010-10-09 | 2012-04-12 | Clariant International Ltd. | Flame retardant stabilizer combination for thermoplastic polymers |
CN101983987B (en) | 2010-11-02 | 2013-01-23 | 蓝星化工新材料股份有限公司 | Polydiphenyl ether particles and granulation method thereof |
DE102011011928A1 (en) | 2011-02-22 | 2012-08-23 | Clariant International Ltd. | Flame retardant stabilizer combination for thermoplastic polymers |
US8779081B2 (en) | 2011-03-15 | 2014-07-15 | Sabic Global Technologies B.V. | Process for formation of poly(arylene ethers) with lower fine particle content |
US20120301703A1 (en) | 2011-05-27 | 2012-11-29 | Joseph Labock | Labock fire resistant paint |
US8686288B2 (en) | 2011-05-31 | 2014-04-01 | Tesla Motors, Inc. | Power electronics interconnection for electric motor drives |
US20120305238A1 (en) | 2011-05-31 | 2012-12-06 | Baker Hughes Incorporated | High Temperature Crosslinked Polysulfones Used for Downhole Devices |
CN102219978A (en) | 2011-06-07 | 2011-10-19 | 东莞创盟电子有限公司 | Halogen-free flame retardant polyolefin elastomer composition used for cover material of wires and cables |
US8669332B2 (en) | 2011-06-27 | 2014-03-11 | Sabic Innovative Plastics Ip B.V. | Poly(arylene ether)-polysiloxane composition and method |
ES2714250T3 (en) * | 2011-09-29 | 2019-05-27 | Dow Global Technologies Llc | Use of trialkyl phosphate as a smoke suppressor in polyurethane foam |
SE1100784A1 (en) | 2011-10-21 | 2013-01-08 | Perstorp Ab | New phosphate compound |
CN102492231B (en) | 2011-12-02 | 2015-03-25 | 太原理工大学 | Halogen-free flame-retarding polystyrene composite material and preparation method thereof |
CN103998498A (en) * | 2011-12-19 | 2014-08-20 | 陶氏环球技术有限责任公司 | Thermoset polyurethane foam containing brominated polymeric flame retardant |
CN102702562A (en) | 2012-05-24 | 2012-10-03 | 中国科学院宁波材料技术与工程研究所 | Preparation method for thermoplastic polyimide foaming particle and formed body thereof |
CN102731955B (en) | 2012-06-14 | 2014-01-22 | 苏州德尔泰高聚物有限公司 | Halogen-free flame retardant high-temperature elastomer plug material and its preparation method |
US8912261B2 (en) | 2012-06-22 | 2014-12-16 | Sabic Global Technologies B.V. | Process for making particulate-free poly(phenylene ether) compositions and photovoltaic backsheet materials derived therefrom |
US9611385B2 (en) | 2012-06-29 | 2017-04-04 | Sabic Global Technologies B.V. | Ultrafine poly(phenylene ether) particles and compositions derived therefrom |
US8703848B1 (en) | 2012-10-09 | 2014-04-22 | Sabic Innovative Plastics | Blends of micronized polyphenylene ether and thermoplastic polyurethanes blend |
US20150004402A1 (en) | 2013-06-28 | 2015-01-01 | Sabic Innovative Plastics Ip B.V. | Intumescent coating composition comprising particulate poly(phenylene ether) |
US20150028247A1 (en) | 2013-07-23 | 2015-01-29 | Sabic Innovative Plastics Ip B.V. | Rigid foam and associated article and method |
US9447227B2 (en) * | 2013-10-03 | 2016-09-20 | Sabic Global Technologies B.V. | Flexible polyurethane foam and associated method and article |
US20150191594A1 (en) | 2014-01-03 | 2015-07-09 | Sabic Innovative Plastics, Ip B.V. | Non-dusting poly(phenylene ether) particles |
-
2013
- 2013-07-23 US US13/948,416 patent/US20150028247A1/en not_active Abandoned
-
2014
- 2014-06-24 JP JP2016515976A patent/JP6158431B2/en not_active Expired - Fee Related
- 2014-06-24 WO PCT/US2014/043773 patent/WO2015012989A1/en active Application Filing
- 2014-06-24 EP EP14828964.8A patent/EP3036288B1/en active Active
- 2014-06-24 US US14/900,428 patent/US9493621B2/en active Active
- 2014-06-24 KR KR1020167002816A patent/KR101669073B1/en active IP Right Grant
- 2014-06-24 CN CN201480039997.XA patent/CN105377988A/en active Pending
- 2014-06-24 CN CN201910204954.7A patent/CN110041690A/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6121338A (en) * | 1997-09-25 | 2000-09-19 | Imperial Chemical Industries Plc | Process for rigid polyurethane foams |
US20040092616A1 (en) * | 2000-11-09 | 2004-05-13 | Ernesto Occhiello | Process for producing rigid polyurethane foams and finished articles obtained therefrom |
Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9493621B2 (en) | 2013-07-23 | 2016-11-15 | Sabic Global Technologies B.V. | Rigid foam and associated article and method |
US10665364B2 (en) | 2013-08-16 | 2020-05-26 | Shore Acres Enterprises Inc. | Corrosion protection of buried metallic conductors |
JP2016532726A (en) * | 2013-10-03 | 2016-10-20 | サビック グローバル テクノロジーズ ベスローテン フェンノートシャップ | Flexible polyurethane foam and related methods and articles |
EP3433093B1 (en) | 2016-07-20 | 2019-09-04 | Brugg Rohr Ag Holding | Thermally insulated medium pipes having hfo-containing cell gas |
US11879586B2 (en) | 2016-07-20 | 2024-01-23 | Brugg Rohr Ag Holding | Thermally insulated medium pipes having HFO-containing cell gas |
IT201600077120A1 (en) * | 2016-07-22 | 2018-01-22 | Doors & More S R L | HIGH DENSITY COMPACT POLYESOCYANURATE |
WO2018015938A1 (en) * | 2016-07-22 | 2018-01-25 | Doors & More S.R.L. | High fire-resistant polyisocyanurate, and use thereof to manufacture fire door or window frames and/or profiles therefor |
IT201700020006A1 (en) * | 2017-02-22 | 2018-08-22 | Doors & More S R L | USE OF POLYESOCYANURATE FOR EXAMPLE FOR THE CONSTRUCTION OF SECURITY WINDOWS OR COMPARTMENTS |
IT201700020013A1 (en) * | 2017-02-22 | 2018-08-22 | Doors & More S R L | USE OF COMPACT POLYISOCYANURATE FOR THE CONSTRUCTION OF PROFILES FOR SECURITY FRAMES |
US10333234B2 (en) | 2017-08-14 | 2019-06-25 | Shore Acres Enterprises Inc. | Corrosion-protective jacket for electrode |
US11349228B2 (en) | 2017-08-14 | 2022-05-31 | Shore Acres Enterprises Inc. | Corrosion-protective jacket for electrode |
US11757211B2 (en) | 2017-08-14 | 2023-09-12 | Shore Acres Enterprises Inc. | Electrical grounding assembly |
US11121482B2 (en) | 2017-10-04 | 2021-09-14 | Shore Acres Enterprises Inc. | Electrically-conductive corrosion-protective covering |
US11894647B2 (en) | 2017-10-04 | 2024-02-06 | Shore Acres Enterprises Inc. | Electrically-conductive corrosion-protective covering |
US11421392B2 (en) | 2019-12-18 | 2022-08-23 | Shore Acres Enterprises Inc. | Metallic structure with water impermeable and electrically conductive cementitous surround |
WO2021165149A1 (en) * | 2020-02-19 | 2021-08-26 | Evonik Operations Gmbh | Polyurethane insulating foams and production thereof |
US20230049261A1 (en) * | 2021-07-28 | 2023-02-16 | Momentive Performance Materials Inc. | Flexible foams comprising additives for improving hardness |
Also Published As
Publication number | Publication date |
---|---|
JP6158431B2 (en) | 2017-07-05 |
EP3036288B1 (en) | 2020-02-19 |
US9493621B2 (en) | 2016-11-15 |
KR101669073B1 (en) | 2016-10-25 |
CN105377988A (en) | 2016-03-02 |
WO2015012989A1 (en) | 2015-01-29 |
JP2016529332A (en) | 2016-09-23 |
US20160145405A1 (en) | 2016-05-26 |
EP3036288A4 (en) | 2017-03-29 |
KR20160028461A (en) | 2016-03-11 |
EP3036288A1 (en) | 2016-06-29 |
CN110041690A (en) | 2019-07-23 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US9493621B2 (en) | Rigid foam and associated article and method | |
US9447227B2 (en) | Flexible polyurethane foam and associated method and article | |
US9266997B2 (en) | Polyurethane foam and associated method and article | |
KR20110022585A (en) | Process for preparing rigid polyisocyanurate foams using natural-oil polyols | |
CN111732712A (en) | Flame-retardant polyurethane foam and preparation method thereof | |
RU2629020C2 (en) | Sugar-based polyurethanes, methods of their obtaining and application | |
CN102070412B (en) | Flame-retardant polyether glycol and preparation method thereof, combined polyether and polyurethane foam | |
EP3027667B1 (en) | Rigid foam and associated article | |
KR20220051846A (en) | Flame Retardant Polyurethane Foam with Alternative Foaming Agent with Improved Processability | |
CN109422910B (en) | Blowing agents comprising orthoformate and carbonate alkanolamine salts and use in polyurethane continuous panel foam materials | |
CN109422911B (en) | Foaming agent comprising orthomethanolate and propanolamine salts and use for polyurethane refrigerator-freezer foam materials | |
AU2012386487B2 (en) | Sugar-based polyurethanes, methods for their preparation, and methods of use thereof | |
CN109422915B (en) | Blowing agent comprising orthomethanolate and ethanolamine salts and use for polyurethane slabstock foam materials |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: SABIC INNOVATIVE PLASTICS IP B.V., NETHERLANDS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PETERS, EDWARD NORMAN;REEL/FRAME:031097/0439 Effective date: 20130828 |
|
AS | Assignment |
Owner name: SABIC GLOBAL TECHNOLOGIES B.V., NETHERLANDS Free format text: CHANGE OF NAME;ASSIGNOR:SABIC INNOVATIVE PLASTICS IP B.V.;REEL/FRAME:033591/0673 Effective date: 20140402 |
|
AS | Assignment |
Owner name: SABIC GLOBAL TECHNOLOGIES B.V., NETHERLANDS Free format text: CORRECTIVE ASSIGNMENT TO CORRECT REMOVE 10 APPL. NUMBERS PREVIOUSLY RECORDED AT REEL: 033591 FRAME: 0673. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME;ASSIGNOR:SABIC INNOVATIVE PLASTICS IP B.V.;REEL/FRAME:033649/0529 Effective date: 20140402 |
|
AS | Assignment |
Owner name: SABIC GLOBAL TECHNOLOGIES B.V., NETHERLANDS Free format text: CORRECTIVE ASSIGNMENT TO CORRECT THE 12/116841, 12/123274, 12/345155, 13/177651, 13/234682, 13/259855, 13/355684, 13/904372, 13/956615, 14/146802, 62/011336 PREVIOUSLY RECORDED ON REEL 033591 FRAME 0673. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME;ASSIGNOR:SABIC INNOVATIVE PLASTICS IP B.V.;REEL/FRAME:033663/0427 Effective date: 20140402 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |