Methods of forming polyol premixes and foamable compositions and foams formed therefrom

Abstract

This invention relates to thermoset, thermal insulating panel, pour-in-place and pour-in-place foams having desirable and unexpectedly low thermal conductivity, and to compositions, method and systems which use and / or are used to make such foams comprising: (a) providing thermosetting foam forming component and a blowing agent for forming predominantly closed cells in the foam, wherein the blowing agent comprises: (i) cis-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzzm(Z)) and cyclopentane, with the HFO-1336mzzm(Z) and cyclopentane in the blowing agent together comprising at least about 50% by weight of the total of all components in the blowing agent and (ii) the weight ratio of HFO-1336mzzm(Z) to cyclopentane in the blowing agent is from about 45:55 to less than 68:32 and (b) forming foam from said provided foamable composition.

Description

REFERENCE TO RELATED APPLICATIONS[0001]The present application is related to and claims the priority benefit of U.S. Provisional Application 62 / 560,596, filed Sep. 19, 2017 and of U.S. Provisional Application 62 / 563,393, filed Sep. 26, 2017, each of which is incorporated herein by reference.FIELD OF THE INVENTION[0002]This invention relates to methods of forming polyol premixes, to methods of forming foamable compositions and foams, and to foamable compositions and foams formed from these.BACKGROUND OF THE INVENTION[0003]Polyurethane (PU) and polyisocyanurate (PIR) foams in general have numerous and widely varying applications and can be formed from a wide variety of materials appropriate for this purpose. For example, one such application is to provide thermal insulation.[0004]Polyurethane foams are produced by reacting a polyisocyanate with one or more polyols in the presence of one or more blowing agents, one or more catalysts, one or more surfactants and optionally other ingredi...

AI Technical Summary

Benefits of technology

The patent is about a special polyol premix that has a special ingredient that reduces the time it takes to defrost. When this ingredient is added, it makes the polyol premix much faster to defrost compared to without it. The special polyol premix should defrost in no more than 30 minutes.

Problems solved by technology

Applicants have come to appreciate that one difficulty that can arise with combinations of some polyols and with certain blowing agents is the problem of frothing.

For example, this problem can result in an unwanted increase in the time required to create a homogeneous and stable pre-mix that can be packaged and stored for use later.

This problem can also be manifest at the time the stored polyol premix is opened or tapped.

In such cases, the drum or container in which the polyol has been stored will undergo a level of agitation that can develop unwanted frothing and / or the temperature at which the drum or container is opened or tapped is relatively elevated, which in turn can result in a defective foam being formed or will add a highly disadvantageous delay before use in order to allow the frothing to cease.

Another disadvantage of such frothing that may occur is that the frothing can cause the polyol premix to escape from the container and into the environment, which can potentially constitute a costly and potentially dangerous chemical spill in the area of use.

Frothing in both of these contexts is generally considered a disadvantage because it requires the formulator and / or the user to include de-frothing time in the processs.

Furthermore, frothing can be a disadvantage because it can make it harder to obtain the proper flow of the dispensed polyol premix and can degrade the foam quality if it is present when the A-side and the B-side are brought together.