Barrier coating composition for use in the manufacture of thermal insulation products with improved thermal insulation properties

Abstract

A coated thermal insulation product is disclosed, formed with a low GWP blowing agent composition capable of achieving at least 5 R / in thermal insulation values ​​on day 180. The coated thermal insulation product includes a foam product formed from a foaming composition comprising a matrix composition and a blowing agent composition comprising 15% to 60% by weight of fluorinated alkene and 40% to 85% by weight of a co-foaming agent. The foam product has a thickness of 3 g / m² on at least one surface. 2 and 225g / m 2 It is coated with the barrier coating composition.

Description

[Technical Field]

[0001] The present invention relates to a method for forming an insulating product, and more particularly to the manufacture of an insulating foam formed using a gas blowing agent. The present invention further relates to the use of a barrier coating for retaining gas in an insulating product in order to improve the thermal and insulating properties of the coated foam insulating product. [Background technology]

[0002] Polymer foams, such as extruded polymer foams or "XPS" foams, are generally produced by melting a polymer matrix composition to form a polymer melt, incorporating one or more blowing agents and other additives into the polymer melt under conditions that provide sufficient mixing of the blowing agent and polymer, while simultaneously preventing the mixture from foaming prematurely, for example, under pressure. This mixture is then typically extruded through a single-stage or multi-stage extrusion die, cooled, and the pressure on the mixture is reduced to foam the mixture and produce a foamed product. As is understood, the relative amounts of polymer, blowing agent, and additives; temperature; and the method of reducing pressure affect the quality of the resulting foamed product. Also, as is understood, the foaming mixture is maintained under relatively high pressure until it passes through the extrusion die and is expanded in the low-pressure region.

[0003] The solubility of conventional blowing agents such as chlorofluorocarbons ("CFCs") and certain alkanes in polymer melts tends to reduce melt viscosity and improve the cooling of the expanded polymer melt. For example, combinations of pentane with CFCs such as Freon 11 or 12 are partially soluble in polystyrene and have been used to produce polystyrene foams that exhibit generally acceptable appearance and physical properties such as surface finish, cell size and distribution, orientation, shrinkage, thermal insulation (R-value), and stiffness.

[0004] However, in response to environmental concerns regarding the use of such CFC compounds, the widespread use of these compounds and associated atmospheric releases in applications such as aerosol propellants, refrigerants, blowing agents, and specialty solvents has been dramatically reduced or eliminated in recent years through government regulations.

[0005] The departure from the use of CFCs has led to the use of alternative blowing agents such as hydrogen-containing chlorofluoroalkanes (HCFCs). However, HCFCs still contain some chlorine and are therefore said to have an ozone depletion potential (ODP).

[0006] Another type of blowing agent, hydrofluorocarbon (HFC), has been used as a more ozone-friendly option, offering desirable improvements such as zero ODP and lower (but still potentially significant) global warming potential (GWP). However, these compounds are expensive, tend to have poor availability in polystyrene, and can still have considerable GWP. For example, HFC-134a has a GWP of 1430.

[0007] Hydrofluoroolefin (HFO) blowing agents, a type of fluorinated alkene, are more environmentally friendly than conventional halogenated blowing agents. For example, HFOs have lower ODP and GWP values ​​compared to conventional fluorocarbon and hydrofluorocarbon blowing agents. While conventional blowing agent compositions containing certain HFOs can form foam insulation products with acceptable initial physical properties (i.e., thermal conductivity, R value, etc.), in any foam product foamed by trapping gas within the foam's bubbles, the gas diffuses, thereby adversely affecting the foam's thermal performance. Furthermore, due to such diffusion, there is a limit to the level of thermal performance that such foams can achieve.

[0008] Therefore, there is a need for foam insulation products formed with environmentally friendly blowing agents (ODP of 0.05 or less and GWP value of less than 150), which reduce the diffusion of glass blowing agent through the foam, achieve superior insulation or "R value" (both initial and after aging according to ASTM C578-22) compared to conventional insulation products, and maintain such insulation values ​​over time. [Overview of the project]

[0009] Various aspects of the concept of the present invention relate to coated thermal insulation products formed with a low GWP blowing agent composition and having at least 5 R / in thermal insulation values ​​at 180 days. The coated thermal insulation product includes a foam product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them, the foam product being formed from a foaming composition comprising a matrix composition and a blowing agent composition comprising 15% to 60% by weight of fluorinated alkene and 40% to 85% by weight of a co-foaming agent. The foam product has at least one surface coated with 3 g / m² 2 ~225g / m 2 The material is coated with a barrier coating composition. The barrier coating composition comprises 40% to 99.9% by weight of a barrier polymer having a minimum crystallinity of 10%, and 0.01% to 60% by weight of at least one additive. When the barrier coating composition is applied, it has a surface tension of 60 mN / m or less.

[0010] A further embodiment of the concept of the present invention relates to a coated polymer thermal insulation product, comprising a polymer foam product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them. The polymer foam product is formed from a foamable polymer composition comprising a polymer matrix composition and a foaming agent composition comprising 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of a fluorinated alkane co-foaming agent. The foam product has at least one surface, for example, each surface having a total density of 3 g / m². 2 ~225g / m 2It is coated with a barrier coating composition of an amount. The barrier coating composition includes a semi-crystalline polymer and at least one additive, and when the barrier coating composition is applied, it has a surface tension that is at most 20 mN / m higher than the surface energy of the polymer foam product, a solids content of 70% or less, and a viscosity of 50 cP to 5000 cP. The coated insulation product has an R / in value of at least 5 on the 180th day and a compressive strength of 10 to 110 psi, measured according to ASTM C578.

[0011] In some exemplary embodiments, the coated polymer insulation product has an R / in value of at least 5.5 on the 180th day.

[0012] In any of the exemplary embodiments, the fluorinated alkene may include one or more of (cis and / or trans)-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) and (cis and / or trans)-1,3,3,3-tetrafluoropropene (HFO-1234ze), and the co-foaming agent may include a hydrocarbon, a hydrofluorocarbon ("HFC"), a hydrochlorofluorocarbon ("HCFO"), carbon dioxide, methyl formate, methylal, water, or a mixture thereof.

[0013] In any of the exemplary embodiments, the barrier coating composition may have a viscosity of 5000 cP or less at 70% solids content, for example, 2500 cP or less at 70% solids content, 2000 cP or less at 70% solids content, 1500 cP or less at 70% solids content, 1000 cP or less at 70% solids content, 750 cP or less at 70% solids content, 500 cP or less at 70% solids content, 250 cP or less at 70% solids content, 150 cP or less at 70% solids content, and 115 cP or less at 70% solids content.

[0014] The barrier polymer may include, for example, one or more of the following: poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), poly(vinylidene fluoride), polyurethane, styrene-butadiene, polyvinyl chloride, poly(acrylate), polyamide, polyester, polystyrene, polyglycolic acid, poly(ethylene 2,5-franglicarboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

[0015] The barrier polymer is preferably at least semi-crystalline and has a minimum crystallinity of 20%, including minimum crystallinity of 25%, 30%, 35%, 40%, 50%, or 60%.

[0016] The barrier coating composition includes at least one additive, such as a wetting agent, rheology modifier, defoamer, pH adjuster; a flame retardant, antiblocking agent, UV stabilizer; etc.

[0017] In any of the exemplary embodiments, the additive may include a rheological modifier present in an amount of 0.01 to 20% by weight, based on the total solid content of the barrier coating.

[0018] In any of the exemplary embodiments, the additive may include at least one wetting agent present in an amount of 0.005 to 8% by weight, based on the total solids content of the barrier coating.

[0019] A further exemplary embodiment of the concept of the present invention relates to a method for producing a coated thermal insulation product having improved thermal insulation performance, the method comprising: mixing a matrix polymer with a foaming agent composition comprising 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of a co-foaming agent to form a foaming polymer composition; foaming the foaming polymer composition to produce a foam product having a first main surface, a second main surface on the opposite side, and a plurality of secondary surfaces extending between them; and coating at least one surface of the foam product with a total of 3 g / m² 2 ~225g / m 2The method involves applying a barrier coating in an amount of . The barrier coating is formed from a barrier coating composition comprising 40% to 99.9% by weight of a barrier polymer and 0.01% to 60% by weight of at least one additive, based on the total solids content of the barrier coating composition. When applied, the barrier coating composition has a surface tension of 40 mN / m or less, and the coated thermal insulation product has an R / in value of at least 5 on day 180.

[0020] Further exemplary embodiments of the concept of the present invention relate to a sheath system comprising at least one structural portion having a first surface and an opposite second surface, and at least one coated thermal insulation product bonded to one of the first and second surfaces of the structural portion. The coated thermal insulation product comprises a foam product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them, the foam product being formed from a foaming composition comprising a matrix composition and a foaming agent composition comprising 15% to 60% by weight of fluorinated alkene and 40% to 85% by weight of a co-foaming agent. The foam product has a coating of 3 g / m² on at least one surface. 2 ~225g / m 2 The product is coated with a barrier coating composition. The barrier coating composition comprises a barrier polymer having a minimum crystallinity of 10% in an amount of 40% to 99.9% by weight relative to the total solids content of the barrier coating composition, and at least one additive in an amount of 0.01% to 60% by weight. When the barrier coating composition is applied, it has a surface tension of 60 mN / m or less. The coated thermal insulation product has an R / in value of at least 5 on day 180.

[0021] The aforementioned and other objectives, features, and advantages of the general concept of the present invention will become more readily apparent by considering the following detailed description. [Brief explanation of the drawing]

[0022] Exemplary embodiments are provided below and will become apparent from a more specific description of the particular exemplary embodiments shown in the accompanying drawings. [Figure 1] This is a schematic diagram of an exemplary extruder useful for carrying out the methods of one or more embodiments shown and described herein. [Figure 2] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various barrier coating configurations according to Example 1. [Figure 3] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various barrier coating configurations according to Example 1. [Figure 4] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various PVDC coating weight configurations according to Example 2. [Figure 5] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 3. [Figure 6] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for barrier coating compositions of various concentrations injected into the extruder according to Example 4. [Figure 7] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various barrier coating configurations having coating A according to Example 5. [Figure 8] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various barrier coating configurations having coating B according to Example 5. [Figure 9] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 6. [Figure 10] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 7. [Modes for carrying out the invention]

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which the embodiments belong. Any methods and materials similar or equivalent to those described herein may be used in the implementation or testing of various embodiments, but preferred methods and materials are described herein. In the drawings, the thickness of lines, layers, and areas may be exaggerated for clarity. Note that similar numbers found throughout the drawings indicate similar elements. The terms “composition” and “composition of the present invention” may be used interchangeably herein.

[0024] As used herein and in the appended claims, the singular forms "a," "an," and "the" are intended to also include the plural forms unless otherwise clearly indicated by the context.

[0025] Unless otherwise indicated, all numbers used herein and in the claims, representing quantities, chemical and molecular properties, reaction conditions, etc., of components should be understood in all cases as being modified by the term "about." Therefore, unless otherwise indicated, the numerical parameters described herein and in the appended claims are approximations that may vary depending on the desired properties to be obtained by the exemplary embodiments of the present invention. At a minimum, each numerical parameter should be interpreted with regard to significant figures and common rounding techniques.

[0026] Unless otherwise indicated, any element, property, feature, or combination of elements, properties, and features may be used in any embodiment disclosed herein, regardless of whether the element, property, feature, or combination of elements, properties, and features is expressly disclosed in an embodiment. It will be readily apparent that a feature described in relation to any particular embodiment described herein may be applicable to other embodiments described herein, provided that the feature is compatible with that embodiment. In particular, a feature described herein in relation to a method may be applicable to an insulating product, and vice versa. A feature described herein in relation to a method may be applicable to a foamed composition, and vice versa. A feature described herein in relation to an insulating product may be applicable to a foamed composition, and vice versa.

[0027] All numerical ranges provided throughout this specification and the claims include all narrower numerical ranges that fall within such broader numerical ranges, as if all such narrower numerical ranges were explicitly described herein.

[0028] As used herein, the term “foaming agent” is understood to include physical foaming agents (e.g., dissolved gaseous agents) or chemical foaming agents (e.g., gases produced by decomposition). Foaming agents are generally added to a molten polymer under appropriate conditions, for example, in an extruder, to initiate foaming and produce a foamed product. The foaming agent expands the resin, forming cells (e.g., open or closed pores). As the resin solidifies or hardens, foam is produced by either the foaming agent trapped within the cells or ambient air replacing the foaming agent within the cells. The foaming agents discussed herein preferably consist of or include environmentally acceptable foaming agents (i.e., “low GWP” foaming agents) as recognized by those skilled in the art. Such low GWP foaming agents have GWP values ​​of 500 or less, for example, 250 or less, 200 or less, 150 or less, 125 or less, 100 or less, 75 or less, 50 or less, 25 or less, 20 or less, 15 or less, 10 or less, 8 or less, 5 or less, and 3 or less.

[0029] As used herein, unless otherwise specified, the amounts of blowing agents or other components or ingredients of a composition are expressed as weight percentages or weight % of each component in the composition.

[0030] As related to the present disclosure, "closed cell" refers to a foam having a plurality of cells, at least 95% of which are closed. However, in the present application, the cells may be "open cell", independent cells, or a mixture thereof (i.e., the specific embodiments disclosed herein may show an "open cell" foam structure or a blend of open cells and independent cells).

[0031] The term "R-value" is a unit used to measure the effectiveness of insulation and is the reciprocal of thermal conductivity. For a foam board material having substantially parallel faces, it is defined as the rate of heat energy flow (BTU / hour or watt) / unit area (square feet = ft 2 or square meters = m 2 ) / temperature difference (Fahrenheit or Kelvin) across the thickness of the slab material (inches or meters). The thermal performance of a polymeric insulation product is based on the R-value of the insulation product, which is a measure of the resistance of the product to heat flow. The R-value is defined by Equation (1). Equation (1): R = T1 / k Equation (1) In the equation, "T1" is the thickness of the insulation product in inches, "k" is the thermal conductivity of the insulation product in BTU·in / hr·ft 2 ·°F, and "R" is the R-value of the insulation material in hr·ft 2 ·°F / BTU.

[0032] As used herein, the thickness (T1) of an insulation product may be determined in accordance with ASTM C167-18, and both the k-value and the areal weight (lb / ft 2 units) may be determined in accordance with ASTM C578 or ASTM C177-19.

[0033] This disclosure relates to foams and foam insulation products, such as extruded or expanded polymer foams, which are formed in part from a composition comprising a foaming material, a foaming agent composition, and a barrier coating or barrier additive that stops or slows the diffusion rate of the foaming agent composition, thereby enabling the manufacture of foam insulation products having improved thermal insulation values ​​and the maintenance of such thermal insulation values ​​over time.

[0034] While this disclosure primarily describes polymer foam insulation materials, it should be understood that the concepts of the present invention are equally applicable to non-polymer foam insulation materials such as bubble glass insulation materials and aerogel insulation materials. In addition, while the following disclosure provides an exemplary method (extrusion molding) for forming insulation products, it should be understood that other methods for forming insulation products, such as spray foams and expanded foams, are intended herein.

[0035] Figure 1 shows an extruder 100 useful for manufacturing polymer thermal insulation products (e.g., XPS) according to the concept of the present invention. The extruder 100 may comprise a single or double (not shown) screw extruder, which includes a barrel 102 surrounding a screw 104 and has a spiral flight 106 above the screw 104. The screw 104 is surrounded by the barrel 102. The spiral flight 106 is configured to compress and thereby heat the material introduced into the screw extruder. As shown in Figure 1, the polymer composition may be delivered to the screw extruder from one or more (not shown) feed hoppers 108 as a fluid solid such as beads, granules, or pellets, or as a liquid or semi-liquid molten material.

[0036] As the basic polymer composition moves through the screw extruder, the spacing between flights 106 decreases, continuously defining smaller spaces through which the polymer composition is forced to flow by the rotation of the screw. This decreasing volume acts to raise the temperature of the polymer composition to obtain a polymer molten material (if a solid starting material is used) and / or to raise the temperature of the polymer molten material.

[0037] As the polymer composition moves through the screw extruder 100, it may pass through a barrel 102 equipped with associated devices 110, 112 for injecting one or more blowing agents and optional additives into the polymer composition, with one or more ports. In some embodiments, a barrier coating composition may be added through one or more ports, as described in more detail below. Once the blowing agent is introduced into the polymer composition, the resulting mixture is subjected to some additional blending sufficient to obtain a polymer foaming composition in which each component is distributed substantially uniformly throughout the polymer composition.

[0038] The polymer foaming composition is then forced through the extrusion die 114 and exits the die into a low-pressure region (which may be below atmospheric pressure), thereby allowing the foaming agent to expand and produce a polymer foam material. This pressure reduction may be obtained gradually as the extruded polymer foaming composition progresses through a continuously increasing opening provided in the die, or through several suitable devices (not shown) provided downstream of the extrusion die to control to some extent the pressure applied to the polymer foaming composition in a manner that reduces it. The polymer foam material may also be subjected to additional processing such as calendering, water immersion, cooling spray, or other operations to control the thickness and other properties of the resulting foam insulation product (hereinafter interchangeably referred to as “foam product,” “foam insulation product,” and / or “insulation product”).

[0039] As described above, the concept of the present invention relates to the discovery that applying a novel barrier coating composition to at least one surface of a foam insulation product can reduce the diffusion of the foaming agent and improve the thermal insulation performance of the foam. In any of the exemplary embodiments, the barrier coating composition may be applied to one or more surfaces of the insulation product. The insulation product has two opposing main surfaces (e.g., a top surface and an opposing bottom surface) and a plurality of secondary surfaces (e.g., two opposing sides and two opposing end surfaces) extending between them. The barrier coating composition can be applied to one or more surfaces of the insulation product using, for example, one of a variety of coating methods. For example, the barrier coating composition can be applied by roller, brush, spray coating, dip coating, spin coating, flow coating, curtain coating, etc. Other coating methods known and used in the art may be used and are intended to be within the scope of this disclosure.

[0040] The barrier coating composition is preferably applied to the insulation product as soon as possible after production (i.e., after extrusion, expansion, or other foam manufacturing method), for example, within a period of less than 12 hours of production, particularly within a period of less than 6 hours, less than 3 hours, less than 2 hours, less than 1 hour, or less than 30 minutes of production. According to any embodiment, the barrier coating may be applied to the product immediately after production. The coating is then dried to form a barrier coating on at least one surface of the insulation product. Although described as being applied to one or more main surfaces of the insulation product, it should be understood that the barrier coating composition may be applied in addition to, or alternatively, to one or more smaller surfaces of the polymer foam product. In any embodiment, the barrier coating composition may be applied to each surface of the insulation product. For example, the barrier coating composition may be applied to one or more edges of the resulting insulation product in addition to, or alternatively to, the top and / or bottom surfaces of the resulting polymer insulation product. The barrier coating may be applied to form a continuous coating on one or more surfaces of the insulation product, or the barrier coating may form only a partially discontinuous coating on one or more surfaces. In any of the exemplary embodiments, the barrier coating may be in the form of a film.

[0041] In any of the exemplary embodiments, the barrier coating composition may be applied directly to the surface of the thermal insulation product without an intervening layer between the surface of the thermal insulation product and the barrier coating composition. Additional coating layers, including additional coating layers of the barrier coating composition, may be optionally applied on top of the first barrier coating composition layer. However, in some examples, it is intended that one or more optional primer layers may be applied between the barrier coating composition and the surface of the thermal insulation product so that the barrier coating composition is applied indirectly to the surface of the thermal insulation product (for example, the barrier coating composition is applied to a primer layer on the surface of the thermal insulation product).

[0042] In any of the exemplary embodiments, the barrier coating composition may act as an adhesive for fixing one or more additional layers to the thermal insulation product.

[0043] Furthermore, in any of the exemplary embodiments, the barrier coating compositions described herein are intended to be incorporated into a foamed polymer composition. For example, instead of applying (or in addition to applying) the barrier coating composition as a coating on at least one surface of an insulating product, the barrier coating composition can be injected into a screw extruder. In embodiments where the polymer of the barrier coating composition is a resin, the polymer may be introduced into a feed hopper in pellet form. When injected into an extruder, certain properties of the barrier coating composition may differ from those of a barrier coating composition intended to be coated on the surface of a polymer insulating product, and such properties include, but are not limited to, the viscosity of the coating composition and the solid content filling of the barrier coating.

[0044] The barrier coating composition may include a dispersion, solution, or emulsion containing one or more polymers. The polymer may include one or more barrier polymers, such as poly(vinylidene chloride) (PVdC) and PVdC copolymers, polyvinyl alcohol (PVOH), poly(ethylene-co-vinyl alcohol) (EVOH), poly(vinylidene fluoride) (PVdF), polyurethane, styrene-butadiene (SBR), polyvinyl chloride (PVC), poly(acrylate) and copolymers, polyamide (e.g., nylon-6), polyester (e.g., PET), polystyrene (PS), polyglycolic acid (PGA), poly(ethylene 2,5-franzicarboxylate) (PEF), poly(butylene succinate) (PBS), bio-based ethylene (Bio-PE), waxes, such as natural waxes (carnauba and montane wax), petroleum-based waxes (paraffin, microcrystalline wax), or synthetic waxes derived from petroleum distillates or residues (polyethylene, polypropylene, Fischer-Tropsch wax), as well as combinations or copolymers thereof. Other polymers may be incorporated, provided they impart or at least do not hinder gas barrier properties to the coating.

[0045] In any exemplary embodiment, the barrier polymer may be a homopolymer or a copolymer comprising one or more comonomers, and examples include, but are not limited to, vinyl chloride; vinyl alcohol; vinyl esters, e.g., vinyl acetate; vinyl ether; acrylic acid; acrylic acid esters; acrylamides; methacrylic acid; methacrylic acid esters; methacrylamide; acrylonitrile; N-vinylpyrrolidone; methacrylonitrile; styrene; styrene derivatives; butadiene;-olefins, e.g., ethylene and propylene; itaconic acid; and maleic anhydride. Such comonomers also include copolymerizable surfactants such as sodium salts of allyl ether sulfonates (e.g., sodium 1-allyloxy-2-hydroxypropylsulfonate), 2-acrylamido-2-methylpropanesulfonic acid (AMPS) or one of its salts, e.g., sodium salt, 2-sulfoethyl methacrylic acid (2-SEM) or one of its salts, e.g., sodium salt, and phosphate esters of methacrylate-terminated polypropylene glycol or one of its salts, e.g., sodium salt, poly(ethylene oxide) methyl ether acrylate (PEOA), poly(ethylene oxide) methyl ether methacrylate (PEOMA).

[0046] In any of the exemplary embodiments, the barrier polymer is at least a semicrystalline polymer with a minimum crystallinity of 5%. In particular, a barrier polymer having a crystallinity of at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, provides a barrier coating composition with sufficient barrier properties. In any of the exemplary embodiments, the barrier polymer may have a crystallinity of at least 20%, for example, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, and at least 95%.

[0047] The barrier polymer may be added in solid form (e.g., resin) or in molten form (e.g., liquid) as a dispersion, solution, or emulsion ("barrier polymer material"). When the barrier polymer is added in dispersion form, the dispersion may be an aqueous dispersion (e.g., the polymer is dispersed in water) or a solvent-based dispersion.

[0048] When provided in the form of a dispersion, the barrier polymer may be present with a solids content of about 20% to about 100% by weight, based on the weight of the dispersion, including solids content in about 25% to about 85% by weight, about 30% to about 75% by weight, about 35% to about 65% by weight, about 40% to about 60% by weight, about 45% to about 56% by weight, or any other range or partial range contained therein.

[0049] Barrier polymers can also be characterized by the amount of barrier polymer present in the barrier coating composition, based on the total amount of solids present in the barrier coating composition. For example, the polymer may be present in amounts of about 40% to about 100% by weight, including, for example, about 50% to about 98% by weight, about 60% to about 96% by weight, about 70% to about 93% by weight, and about 75% to about 91% by weight (including any other endpoints or sub-ranges contained therein), based on the total amount of solids present in the barrier coating composition.

[0050] The barrier coating composition may contain one or more additives, whether added as part of the barrier polymer material or added directly to the composition, such as processing aids; surfactants (wetting agents); rheology modifiers; flame retardants; defoamers, such as emulsions and / or dispersions of mineral oil, paraffin oil, or vegetable oil; silicones; dispersions of polydimethylsiloxane (PDMS) fluids; pH adjusters; UV stabilizers; and silica hydrophobized with polydimethylsiloxane or other materials.

[0051] Examples of fluidity modifiers include, for example, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, poly(ethylene glycol), clay, fumed silica, cellulose and its derivatives, polysaccharides, alkali-swelling polymers (ASE, HASE, HMASE) (e.g., Solthix® A100), hydrophobic modified urethane-associating polymers (HEUR) (e.g., Rheobyke® 7600, 7610 available from BYK, Borchi® Gel L75N available from Milliken), alkali-acrylic emulsions, modified vinylpyrrolidone-vinyl acetate copolymer thickeners (e.g., Rheovis® VP 1231 available from BASF), polyurea, polyamides and calcium sulfonates, and combinations thereof.

[0052] The viscosity of the barrier coating composition is important to ensure that the coating can be applied by the intended method, such as spraying, coating, or dipping. Therefore, rheological modifiers are used, for example, less than about 4000 cP at about 75°F and 70% solids, less than about 3500 cP at about 75°F and 70% solids, less than about 3000 cP at about 75°F and 70% solids, less than about 2500 cP at about 75°F and 70% solids, less than about 2000 cP at about 75°F and 70% solids, less than about 1500 cP at about 75°F and 70% solids, less than about 1000 cP at about 75°F and 70% solids, less than about 750 cP at about 75°F and 70% solids, and about 7 It may be included in concentrations such as those that achieve a coating viscosity of less than 5000 cP at approximately 75°F and 70% solids, including less than 500 cP at 5°F and 70% solids, less than 250 cP at approximately 75°F and 70% solids, less than 200 cP at approximately 75°F and 70% solids, less than 150 cP at approximately 75°F and 70% solids, less than 100 cP at approximately 75°F and 70% solids, less than 300 cP at approximately 75°F and 70% solids, and less than 200 cP at approximately 75°F and 70% solids. In any of the exemplary embodiments, the viscosity of the barrier coating composition may be 5000 cP or less at about 75°F and 70% solids, for example, 50 cP to 3750 cP, 75 cP to 3000 cP, 90 cP to 2500 cP, 95 cP to 2000 cP at about 75°F and 70% solids, 100 cP to 1500 cP at about 75°F and 70% solids, and 150 cP to 1000 cP at about 75°F and 70% solids (including all sub-ranges and endpoints between these). Such viscosity is particularly important for obtaining a sprayable coating composition.

[0053] Accordingly, in various aspects of the concept of the present invention, the rheological modifier is included in the barrier coating composition in an amount of 0 to 20% by weight, based on the weight of the total solids content of the barrier coating composition, including 0.01% to 15% by weight, 0.05% to 12% by weight, 0.1% to 10% by weight, 0.15% to 8% by weight, 0.2% to 6% by weight, 0.25% to 4% by weight, and 0.0.01% to 2% by weight, including all sub-ranges and endpoints between them.

[0054] As described above, the barrier coating composition may contain a sufficient amount of pH adjuster to adjust the pH to a desired level. For example, organic bases and / or inorganic bases may be included to increase the pH of the barrier coating composition. In some exemplary embodiments, the base may be volatile or non-volatile. Exemplary volatile bases include, for example, ammonia and alkyl-substituted amines, such as methylamine, ethylamine or 1-aminopropane, dimethylamine, and ethylmethylamine. Exemplary non-volatile bases include, for example, sodium hydroxide, potassium hydroxide, sodium carbonate, and t-butylammonium hydroxide.

[0055] The pH of the barrier coating composition is preferably between 2 and 10, including pH values ​​between 3 and 8 and between 4 and 7. In any of the embodiments disclosed herein, the barrier coating composition may have a neutral pH of 6 to 7.

[0056] In various aspects of the concept of the present invention, the pH adjuster is included in the barrier coating composition in an amount of 0 to 15% by weight, based on the weight of the total solids content of the barrier coating composition, including 0.05% to 12% by weight, 0.1% to 10% by weight, 0.25% to 8% by weight, 0.4% to 6% by weight, 0.5% to 4% by weight, 0.75% to 2.5% by weight, and 0.10% to 2% by weight, encompassing all sub-ranges and endpoints between them.

[0057] Since the barrier coating composition can be applied to one or more surfaces of a foam insulation product, it is important that the coating can sufficiently wet the foam surface, spread over it, and achieve a uniform and even coating. To achieve sufficient wetting, the surface tension of the barrier coating composition needs to be adjusted to match the surface energy of the foam product. That is, the barrier coating composition is specifically formulated to have a surface tension 20 N / m or less higher than the surface energy of the foam product, and this includes surface tensions that are 15 N / m or less, 10 N / m or less, 8 N / m or less, 5 N / m or less, 2.5 N / m or less, and 1 N / m or less higher than the surface energy of the foam product. In any of the exemplary embodiments, the barrier coating composition has a surface tension approximately (±5%) equal to the surface energy of the foam product. In any of the exemplary embodiments, the barrier coating has a surface tension less than or equal to the surface energy of the foam product.

[0058] Insulated products may have surface energies of approximately 35 mN / m to 55 mN / m, including approximately 37 mN / m to 53 mN / m, 39 mN / m to 51 mN / m, and 40 mN / m to 50 mN / m (including all endpoints and sub-ranges between them).

[0059] In various embodiments of the concept of the present invention, the barrier coating composition may have a surface tension less than or equal to the surface energy of the thermal insulation product. The surface tension of the barrier coating composition may be about 30 mN / m to 55 mN / m, including about 34 mN / m to 50 mN / m, 36 mN / m to 48 mN / m, and 38 mN / m to 46 mN / m (including all endpoints and partial ranges between them). In this embodiment or other embodiments, the barrier coating composition may have a surface tension of 50 mN / m or less, 48 ​​mN / m or less, 47 mN / m or less, and 46 mN / m or less.

[0060] To adjust the surface tension of a barrier coating composition, the coating may contain one or more wetting agents, such as surfactants and oils. The surfactant may include one or more ionic surfactants, nonionic surfactants, cationic surfactants, amphoteric surfactants, and mixtures thereof. The term "amphoteric" surfactant is often used interchangeably with the term "bipolar" surfactant, meaning that each term is synonymous with a surfactant having both cationic and anionic centers bonded to the same molecule.

[0061] According to this disclosure, one or more surfactants may include or consist of one or more anionic surfactants. Examples of anionic surfactants include sulfates (e.g., alkyl sulfates, ammonium lauryl sulfate, sodium lauryl sulfate SLS, alkyl ether sulfates, sodium laureth sulfate, and sodium myreth sulfate); sulfonates (e.g., sodium dioctyl sulfosuccinate, perfluorooctanesulfonate, perfluorobutanesulfonate, alkyl sulfonates, and alkylbenzenesulfonates); carboxylates (e.g., alkyl carboxylates, fatty acid salts (soaps), sodium lauroyl sarcosinate, carboxylate fluorosurfactants, perfluoro Orononanoic acid and perfluorooctanoic acid); phosphates (e.g., alkylaryl ether phosphates, alkyl ether phosphates, mono and diphosphate esters of nonylphenol ethoxylates, phosphate esters of tridecyl alcohol ethoxylates, phosphate esters of isodecyl ethoxylates, and other phosphate esters of aromatic ethoxylates and aliphatic ethoxylates, phosphate esters of C10-C16 alkyl ethoxylates / propoxylates); salts of fluorinated fatty acids; silicones; stearates; etc., and mixtures thereof.

[0062] According to this disclosure, one or more surfactants may include or consist of one or more cationic surfactants. Examples of cationic surfactants include alkylamine salts such as laurylamine acetate; permanently charged quaternary ammonium cations (e.g., alkyltrimethylammonium salts, cetyltrimethylammonium bromide, cetyltrimethylammonium chloride, cetylpyridinium chloride, and benzethonium chloride); quaternary ammonium salts (e.g., lauryltrimethylammonium chloride and alkylbenzyldimethylammonium chloride), polyoxyethylene alkylamines, and mixtures thereof.

[0063] According to this disclosure, one or more surfactants may include or consist of one or more amphoteric surfactants. Examples of amphoteric surfactants include alkyl betaines such as lauryl betaine; alkylamidopropyl betaine (APB); cocamidopropyl betaine; alkylamidopropylamine N-oxide (APAO); alkyldimethylamine N-oxide (AO), cocoamphoacetate; cocoamphodiacetate; and mixtures thereof.

[0064] According to this disclosure, one or more surfactants may include or consist of one or more nonionic surfactants. Suitable nonionic surfactants include: block copolymers based on polyethylene glycol and polypropylene glycol; polyethers (e.g., ethylene oxide condensates and propylene oxide condensates, including linear and branched alkyl and alkalic polyethylene glycol and polypropylene glycol ethers and thioethers); alkyl polyglucosides (e.g., glycerol fatty acid esters, polyoxyethylene glycerol fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyethylene glycol fatty acid esters, and polyoxyethylene polyoxypropylene block copolymers having terminal hydroxyl groups, and combinations thereof); alkylphenoxypoly(ethyleneoxy)ethanol (e.g., heptylphenoxypoly(ethyleneoxy)ethanol and nonylphenoxypoly(ethyleneoxy)ethanol) having alkyl groups containing about 7 to about 18 carbon atoms and about 4 to about 240 ethyleneoxy units); hexyl containing sorbitan, sorbide, mannitol, and mannide Polyoxyalkylene derivatives of sorbitan; partially long-chain fatty acid esters (e.g., polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate, and sorbitan trioleate); condensates of hydrophobic bases and ethylene oxide, wherein the base is formed by condensing propylene oxide and propylene glycol; sulfur-containing condensates (e.g., ethylene oxide is condensed with nonyl or dodecyl ethylene oxide). Examples include ethylene oxide derivatives of long-chain carboxylic acids (e.g., lauric acid, myristic acid, palmitic acid, and oleic acid, e.g., tall oil fatty acids); ethylene oxide derivatives of long-chain alcohols (e.g., octyl, decyl, lauryl, or cetyl alcohols); and ethylene oxide / propylene oxide copolymers.

[0065] Examples of surfactants include Dynol 607, which is 2,5,8,1,1-tetramethyl-6-decyn-5,8-diol; SURFONYL® 420, SURFONYL® 440, and SURFONYL® 465 (commercially available from Evonik Corporation (Allentown, PA)), which are ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactants; Stanfax (sodium lauryl sulfate); SURFADOL® 420 (which is 2,4,7,9-tetramethyl-5-decyn-4,7-diol ethoxylate); and Surfynol Examples include 465 (ethoxylated 2,4,7,9-tetramethyl-5-decine-4,7-diol), Triton® GR-PG70 (1,4-bis(2-ethylhexyl) sodium sulfosuccinate), Triton® CF-10 (poly(oxy-1,2-ethanediyl), α-(phenylmethyl)-ω-(1,1,3,3-tetramethylbutyl)phenoxy), Hydropalat® WE 3135, a bifunctional block copolymer surfactant terminated with a primary hydroxyl group, and one or more of the nonionic wetting agents Hydropalat® WE 3694 and / or Hydropalat® WE 3323.

[0066] The wetting agent may be present in the barrier coating composition in an amount of 0 to about 15% by weight, based on the total solids content in the barrier polymer material, including about 0.001% to about 8% by weight, about 0.005% to about 7.5% by weight, about 0.01% to about 7% by weight, about 0.05% to about 6.5% by weight, about 0.075% to about 6% by weight, about 0.09% to about 5.5% by weight, about 0.1% to about 5% by weight, about 0.15% to about 4% by weight, or about 0.2% to 2.5% by weight (including all sub-ranges and endpoints between them).

[0067] Optionally, the barrier coating composition further comprises one or more film-forming additives. The film-forming additives may include, but are not limited to, graphene, nanoclay, or inorganic layered particles. Suitable film-forming additives include, but are not limited to, cellulose nanocrystals (CNC), organosilane, perfluoroalkyl ethyl methacrylate (PPFEMA), ormocer, biowax / wax, nanoclay / clay, and silicon dioxide (SiO₂). x Examples include aluminum oxide film (Al2O3), graphene / graphene oxide, molybdenum disulfide (MoS2), tungsten disulfide (WS2), niobium selenide (NbSe2), hexagonal boron nitride (hBN), and combinations thereof. Film-forming additives can help the barrier coating composition form a continuous film on the surface of the thermal insulation product and contribute to the barrier properties of the barrier coating. If included, film-forming additives may be present in the barrier coating composition in amounts of 0.1% to 50% by weight, including 0.5% to 25% by weight, 1% to 20% by weight, or 5% to 15% by weight, based on the total amount of solids present in the composition.

[0068] Optionally, the barrier coating composition may contain one or more fillers, such as platelet-type additives, including inorganic layered particles containing graphene, nanoclay, mica, talc, and aluminum flakes, or combinations thereof. In some exemplary embodiments, one or more fillers may be included in at least 0.25% by weight of the barrier coating composition, based on the total amount of solids present in the composition. One or more fillers may be included in about 0.5% by weight to about 50% by weight of the barrier coating composition, including about 1% to about 35% by weight, about 5% to about 30% by weight, and about 10% to about 25% by weight (including any endpoints and partial ranges between them), based on the total amount of solids present in the composition.

[0069] The barrier coating composition may optionally further contain one or more other additives such as UV absorbers / stabilizers, flame retardants, defoamers, antiblockers, pigments, oils, and matting agents. Examples of UV absorbers / stabilizers include, for example, benzotriazoles, polypropylenes, antioxidants, hindered amine light stabilizers (HALS) (e.g., BASF Tinuvin® 479-DW ECO, which is an aqueous preparation of a triazine-based UV absorber from BASF), 2-[3(2H-benzotriazole-2-yl)-4-hydroxyphenyl]ethyl methacrylate from Sigma Aldrich, Lowilite® 26 (which is a benzotriazole UV light absorber from the SI Group), liquid hydroxyphenyl triazine (HPT), e.g., Omnistab® UV400 available from Partner in Chemicals; amino ether functional group-based HALS stabilizers, e.g., Omnistab® LS123 available from Partner in Chemicals; and benzotriazole UV absorbers, e.g., Eversorb® 81 and Eversorb® 95 available from Everlight USA, Inc. If UV absorbers / stabilizers are present, they may be included in the barrier coating composition in amounts from 0% to 10% by weight, based on the total solids content of the barrier coating composition, including 0% to 10% by weight, for example, 0.5% to 8% by weight, 0.75% to 6% by weight, 1% to 5.5% by weight, 1.5% to 5% by weight, 1.75% to 3.5% by weight, or 2% to 3% by weight (including any endpoints and partial ranges between them).

[0070] Examples of flame retardants include, for example, halogenated materials, inorganic materials, nitrogen-based materials, antimony trioxide (e.g., FireGuard® ATO), expandable materials, phosphorus materials (e.g., tris(2-chloroethyl) phosphate available from Sigma Aldrich). Where a flame retardant is present, it may be included in the barrier coating composition in any amount to achieve a Limiting Oxygen Index (LOI) greater than 24% in accordance with EN ISO 4589-2. The LOI is the minimum amount (volume %) of oxygen in the nitrogen-oxygen mixture required to sustain the flammable combustion of the material, with a higher percentage indicating lower flammability of the material. In any of the exemplary embodiments, the flame retardant is included in an amount that achieves an LOI of at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% or more in accordance with EN ISO 4589-2. Such amounts may include 0% to 10% by weight, based on the total solids content of the barrier coating composition, including 0.1% to 8% by weight, 0.2% to 6% by weight, 0.3% to 5.5% by weight, 0.4% to 0.5% by weight, 0.8% to 3% by weight, or 1% to 2.5% by weight (including any endpoints and partial ranges between them).

[0071] Examples of defoaming agents include, for example, silicone-based defoaming agents (including silicone emulsions, polysiloxanes, etc.), paraffin-based defoaming agents, diols, oils, etc. (e.g., Foamstar® ST2410, a block copolymer-based defoaming agent available from BASF; Foamstar® ED 2522 NC, an ultra-low SVOC silicone emulsion defoaming agent; and Foamstar® ST 2210 NC (formerly Dehydran® 1620), a specially modified alcohol and polysiloxane adduct); BYK-035 9. This is a VOC-free mixture of paraffinic mineral oil and hydrophobic components, containing silicone, and available from BYK; examples include Surfadol® DF-75, a 100% active nonionic defoamer based on acetylenediol, Surfadol® 560 (silicone-containing defoamer), and Surfadol® 532 (acetylenediol molecular defoamer) (available from ACME Tech). If a defoamer is present, it may be included in the barrier coating composition in an amount of 0% to 10% by weight, based on the total solids content of the barrier coating composition, including 0.01% to 8% by weight, 0.05% to 6% by weight, 0.1% to 5% by weight, 0.13% to 3% by weight, 0.15% to 2% by weight, 0.17% to 1% by weight, or 0.18% to 0.5% by weight (including any endpoints and partial ranges between them).

[0072] As described above, the barrier coating composition may include an antiblocker. The antiblocker acts to block surface adhesion between layers of the film and may optionally also have a matte finish. The antiblocker protrudes microscopically from the surface of the film, forming irregularities (i.e., "small bumps"), which helps to minimize surface contact between the films, increasing the distance between the two layers and thereby minimizing blocking. Examples of antiblockers include silica-based materials and amorphous silica (e.g., amorphous pulverized silica, such as Gasil® 23F available from PQ Corporation), flux-fired diatomaceous earth (e.g., Dicalite WB-6), and coarse-grain wax emulsions (e.g., Liquilube® 405 available from Lubrizol), modified polypropylene wax (e.g., Lanco® 1390 F available from Lubrizol), and hydrophilic modified pulverized polyolefin wax (e.g., Lanco® PEW 1555 N available from Lubrizol). The antiblocker may be included in the barrier coating composition in an amount of 0 to 20% by weight, based on the weight of the total solids content of the barrier coating composition, including 0.01% to 15% by weight, 0.05% to 12% by weight, 0.1% to 10% by weight, 0.2% to 8% by weight, 0.5% to 6% by weight, 0.75% to 4% by weight, and 0.9% to 2% by weight, including all sub-ranges and endpoints between these.

[0073] Other additives are also conceivable and possible. The amount of any such additive may vary depending on the particular embodiment and may be 0% to 30% by weight, based on the total solids content present in the composition (collectively or individually), including 0.01% to 25% by weight, 0.02% to 22% by weight, 0.05% to 20% by weight, 0.1% to 18% by weight, 0.5% to 15% by weight, 1% to 12% by weight, 1.5% to 10% by weight, 2% to 8% by weight, 2.5% to 6% by weight, or 3% to 5% by weight (including any endpoints and partial ranges between them).

[0074] Table 1 provides exemplary barrier coating compositions. It should be understood that any composition range from exemplary range A may be combined with one or more composition ranges from exemplary range B and / or exemplary range C, and vice versa. Furthermore, any composition range in exemplary range A, exemplary range B, and exemplary range C may be combined with one or more of the composition ranges disclosed in the above paragraphs. The following composition ranges are intended to encompass and include any and all endpoints and sub-ranges within the disclosed ranges.

[0075] [Table 1]

[0076] The barrier polymer can be dispersed and blended in water and / or a solvent with any additives to form a barrier coating composition. As described above, the barrier coating composition is applied to at least one main surface of an insulating product and dried to form a barrier coating on the surface. In some exemplary embodiments, the barrier coating is applied directly onto the surface of the insulating product without using any adhesive, primer, or other layer between the barrier coating and the surface of the insulating product. Therefore, in any of the embodiments disclosed herein, the insulating product does not include any polyamide primer coating applied to the insulating product before the barrier coating composition.

[0077] Barrier coating compositions have a specific degree of crystallinity based on the crystallinity of the polymers used in the composition, but this crystallinity is influenced by various additives contained in the composition, such as wetting agents and rheology modifiers. Therefore, a specific balance must be struck between achieving a coating composition with desirable viscosity and surface tension properties and ensuring that the coating maintains sufficient crystallinity to provide a barrier function that prevents the foaming agent from diffusing from the foam product.

[0078] While not bound by theory, it is believed that by precisely balancing the overall crystallinity of the coating with its rheological and surface tension properties, it becomes possible to apply the coating with a relatively low coating weight. In particular, the barrier coating composition is 225 g / m². 2 Below 200g / m 2 Below 175g / m 2 Below 150g / m 2 Below 125g / m 2 Below 100g / m 2 Below 85g / m 2 Below 60g / m 2 Below 45g / m 2 Below 30g / m 2 Includes the following, 250g / m 2 It is applied with a coating weight of less than 5 g / m². In one exemplary embodiment, the barrier coating composition is 5 g / m². 2 ~200g / m 2 , 10g / m 2 ~185g / m 2 15g / m 2 ~150g / m 2 18g / m 2 ~130g / m 2 20g / m 2 ~115g / m 2 25g / m 2 ~100g / m 2 30g / m 2 ~90g / m 2 35g / m 2 ~85g / m 2 , and 40g / m 2 ~80g / m 2 Contains 3g / m 2 ~225g / m 2 The coating weight can be applied to one or more surfaces of a polymer foam board (including all endpoints and partial areas between them).

[0079] Optionally, multiple coatings may be applied to one or more surfaces of a polymer insulation product. Such additional coatings may be added, for example, to enhance the properties of a barrier coating or to protect the barrier coating. In some embodiments, one or more additional coatings can impart hydrophobicity or water resistance to the coated insulation product. It should be understood that at least one additional coating can be formed by applying a coating composition to a surface, drying the coating composition, and thereby forming at least one additional coating. The coating composition may be, for example, a dispersion (e.g., aqueous or solvent-based), a liquid, etc.

[0080] As described above, one or more additional coatings may be applied on top of the barrier coating so that the barrier coating is positioned between the one or more additional coatings and the polymer insulation product. In other embodiments, one or more additional coatings may be applied between the barrier coating and the surface of the insulation product. The one or more additional coatings are not particularly limited and may be the same as or different from the barrier coating. In some embodiments, the barrier coating is a first layer of coating, and at least one additional coating is a second layer of the same coating. In some embodiments, the barrier coating comprises a first polymer including polyvinylidene dichloride (PVDC), polyvinyl alcohol, polyvinylidene fluoride (PVDF), polyvinyl chloride (PVC), ethylene vinyl alcohol, polyurethane, styrene butadiene (SBR), and combinations or copolymers thereof, and at least one additional coating comprises a different polymer including polyvinylidene dichloride (PVDC), polyvinyl alcohol, polyvinylidene fluoride (PVDF), polyvinyl chloride (PVC), ethylene vinyl alcohol, polyurethane, styrene butadiene (SBR), and combinations or copolymers thereof. In some embodiments, at least one additional coating comprises one or more polyurethanes, epoxys, acrylics, or combinations thereof.

[0081] In such embodiments, an additional coating layer is applied on top of a barrier-coated thermal insulation product, and the additional coating preferably has a surface tension specifically matched to the surface energy of the barrier-coated thermal insulation product. Therefore, one or more additional coatings are specifically formulated to have a surface tension that is 20 mN / m or less above the surface energy of the barrier-coated thermal insulation product, including being 15 mN / m or less, 10 mN / m or less, 8 mN / m or less, 5 mN / m or less, 2.5 mN / m or less, and 1 mN / m or less above the surface energy of the barrier-coated thermal insulation product. Similarly, when a coating layer is applied between a foam product and a barrier coating composition, the surface tension of the barrier coating composition needs to be specifically formulated to be 20 mN / m or less, 15 mN / m or less, or 10 mN / m or less above the surface energy of the coated foam product.

[0082] Alternatively, or in addition to the above-mentioned coating layer, the barrier coating composition may be injected into the extruder through a port or the like and directly incorporated into the foamed composition.

[0083] In any of the exemplary embodiments disclosed herein, the foaming composition may comprise any material that can be foamed, such as a foaming polymer (hereinafter referred to as the “matrix polymer”) and bubble glass (the “matrix material”). The matrix polymer may be thermoplastic or thermosetting. A particular polymer composition may be selected to provide sufficient mechanical strength and / or a process to be utilized to form the final foamed polymer product. In addition, the matrix polymer is preferably chemically stable, i.e., generally unreactive within the temperature range expected during the formation and subsequent use of the polymer foam.

[0084] As used herein, the term "polymer" is a general term encompassing the terms "homopolymer," "copolymer," "terpolymer," and combinations of homopolymers, copolymers, and / or terpolymers. Non-limiting examples of foaming polymers suitable for use as matrix polymers in this specification include alkenyl aromatic polymers, polyvinyl chloride ("PVC"), chlorinated polyvinyl chloride ("CPVC"), polyethylene, polypropylene, polycarbonate, polyisocyanurate, polyetherimide, polyamide, polyester, polycarbonate, polymethyl methacrylate, polyacrylate, polyphenylene oxide, polyurethane, phenolic resin, polyolefin, styrene acrylonitrile ("SAN"), acrylonitrile butadiene styrene, acrylic / styrene / acrylonitrile block terpolymer ("ASA"), polysulfone, polyurethane, polyphenylene sulfide, acetal resin, polyamide, polyaramid, polyimide, polyacrylic acid esters, ethylene-propylene copolymer, styrene-butadiene copolymer, vinyl acetate-ethylene copolymer, rubber-modified polymer, thermoplastic polymer blends, and combinations thereof.

[0085] In some exemplary embodiments, the foaming matrix polymer is an alkenyl aromatic polymer material. Suitable alkenyl aromatic polymer materials include alkenyl aromatic homopolymers and copolymers of alkenyl aromatic compounds with copolymerizable ethylenically unsaturated comonomers. In addition, the alkenyl aromatic polymer material may contain small amounts of non-alkenyl aromatic polymers. The alkenyl aromatic polymer material may be formed from one or more alkenyl aromatic homopolymers, one or more alkenyl aromatic copolymers, one or more blends of alkenyl aromatic homopolymers and copolymers, or blends of them with non-alkenyl aromatic polymers.

[0086] Examples of alkenyl aromatic polymers include, but are not limited to, alkenyl aromatic polymers derived from alkenyl aromatic compounds such as styrene, alpha-methylstyrene, ethylstyrene, vinylbenzene, vinyltoluene, chlorostyrene, and bromostyrene. In at least one embodiment, the alkenyl aromatic polymer is polystyrene.

[0087] In some embodiments, small amounts of monoethylenically unsaturated monomers, such as C2-C6 alkyl acids and esters, ionomer derivatives, and C2-C6 dienes, can be copolymerized with alkenyl aromatic monomers to form alkenyl aromatic polymers. Non-limiting examples of copolymerizable monomers include acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, itaconic acid, acrylonitrile, maleic anhydride, methyl acrylate, ethyl acrylate, isobutyl acrylate, n-butyl acrylate, methyl methacrylate, vinyl acetate, and butadiene.

[0088] In some embodiments, the matrix polymer may be substantially formed from polystyrene (e.g., more than 95%), and in certain exemplary embodiments, it may be formed entirely from polystyrene. The matrix polymer may be present in the foaming polymer composition in amounts of about 60% to about 99% by weight, about 60% to about 96% by weight, about 70% to about 95% by weight, or about 85% to about 94% by weight. In some embodiments, the matrix polymer may be present in amounts of about 90% to about 99% by weight. As used herein, the terms "% by weight" and "% by weight" are used interchangeably and mean a percentage based on 100% of the total weight of the dry components.

[0089] In any of the exemplary embodiments, the barrier coating compositions described herein may be incorporated into a foaming composition. For example, instead of applying (or in addition to applying) the barrier coating composition as a coating on at least one surface of an insulating product, the barrier coating composition may be injected into a screw extruder 100. In embodiments where the polymer of the barrier coating composition is a resin, the polymer may be introduced into the feed hopper 108 in pellet form. When injected into an extruder, certain properties of the barrier coating composition may differ from those of a barrier coating composition intended to be coated on the surface of a polymer insulating product, and such properties include, but are not limited to, the viscosity of the coating composition and the solid content of the barrier coating composition.

[0090] As shown above, foam insulation products are formed from a composition containing a blowing agent composition. According to one aspect of the present invention, the blowing agent composition comprises one or more of CO2, fluorinated blowing agents such as hydrofluorocarbons (HFCs), hydrochlorofluorocarbons, hydrofluoroethers, hydrofluoroolefins (HFOs), hydrochlorofluoroolefins (HCFOs), hydrobromofluoroolefins, hydrofluoroketones, hydrochloroolefins, and fluoroiodocarbons, alkyl esters such as methyl formate, ethanol, water, hydrocarbons, or mixtures thereof. In other exemplary embodiments, the blowing agent comprises one or more of CO2, ethanol, HFOs, HCFOs, HFCs, and mixtures thereof.

[0091] In any of the exemplary embodiments, the blowing agent composition may include materials having a low global warming potential ("GWP"), such as fluorinated alkenes containing hydrofluoroolefins (HFOs) and hydrochlorofluoroolefins (HCFOs). Examples of hydrofluoroolefin blowing agents in the blowing agent composition of the present invention include 3,3,3-trifluoropropene (HFO-1243zf); 2,3,3-trifluoropropene; (cis and / or trans)-1,3,3,3-tetrafluoropropene (HFO-1234ze), particularly the trans isomer; 1,1,3,3-tetrafluoropropene; 2,3,3,3-tetrafluoropropene (HFO-1234yf); 1,2,3,3,3-pentafluoropropene (HFO-12 25yc); 1,1,3,3,3-Pentafluoropropene (HFO-1225zc); 1,1,2,3,3-Pentafluoropropene (HFO-1225yc); Hexafluoropropene (HFO-1216); 2-Fluoropropene, 1-Fluoropropene; 1,1-Difluoropropene; 3,3-Difluoropropene; 4,4,4-Trifluoro-1-Butene; 2,4,4,4-Tetrafluoro-1-Butene; 3,4,4,4-Tetrafluoro-1-Butene; Octafluoro-2- Pentene (HFO-1438); 1,1,3,3,3-pentafluoro-2-methyl-1-propene; octafluoro-1-butene; 2,3,3,4,4,4-hexafluoro-1-butene; 1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz); 1,2-difluoroethene (HFO-1132); 1,1,1,2,4,4,4-heptafluoro-2-butene; 3-fluoropropene, 2,3-difluoropropene; 1,1,3-trifluoropropene; 1,3,3-trifluoropropene; 1,1,2-trifluoropropene; 1-fluorobutene; 2-fluorobutene; 2-fluoro-2-butene; 1,1-difluoro-1-butene; 3,3-difluoro-1-butene; 3,4,4-trifluoro-1-butene; 2,3,3-trifluoro-1-butene; 1,1,3,3-tetrafluoro-1-butene; 1,4,4,4-tetrafluoro-1-butene; 3,3,4,4-tetrafluoro-1-butene; 4,4-difluoro-1-butene;Possible examples include 1,1,1-trifluoro-2-butene; 2,4,4,4-tetrafluoro-1-butene; 1,1,1,2-tetrafluoro-2-butene; 1,1,4,4,4-pentafluoro-1-butene; 2,3,3,4,4-pentafluoro-1-butene; 1,2,3,3,4,4,4-heptafluoro-1-butene; 1,1,2,3,4,4,4-heptafluoro-1-butene; and 1,3,3,3-tetrafluoro-2-(trifluoromethyl)-propene. It should be understood that any of the above molecules may exist as cis isomers, trans isomers, or blends thereof. In some exemplary embodiments, the foaming agent or co-foaming agent includes HFO-1234ze and / or HFO-1336mzz.

[0092] In any of the exemplary embodiments, examples of fluorinated alkene blowing agents include 1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) (including its cis isomer (HFO-1336mzz-Z) and / or trans (HFO-1336mzz-E) isomer); and (cis and / or trans)-1,3,3,3-pentafluoropropene (HFO-1234ze). HFO-1336mzz-Z has a GWP of 2 and an ozone depletion potential (ODP) of 0. HFO-1336mzz-Z is commercially available under the trade name Opteon® 1100. Similarly, HFO-1234ze has a GWP of less than 1 and an ODP of 0. In some exemplary embodiments, the low GWP fluorinated alkenes have a GWP of less than 50, for example, less than 30, less than 25, less than 15, less than 10, less than 5, less than 2.5, or less than 1. In any of the exemplary embodiments, the blowing agent may include HFO-1336mzz-Z and substantially contain no additional fluorinated alkenes. In other embodiments, the blowing agent may include a blend of (cis and / or trans)HFO-1336mzz and (cis and / or trans)HFO-1234ze.

[0093] If present, fluorinated alkenes are present in the blowing agent composition in at least 0.5% by weight, based on the weight of the blowing agent composition, including at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 18% by weight, at least 20% by weight, at least 23% by weight, at least 25% by weight, at least 27% by weight, and at least 30% by weight. In any of the exemplary embodiments, the fluorinated alkene is present in the blowing agent composition in an amount of 98% by weight or less, including amounts of 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 52% by weight or less, 50% by weight or less, 47% by weight or less, 45% by weight or less, 42% by weight or less, 40% by weight or less, 37% by weight or less, 35% by weight or less, 32% by weight or less, 30% by weight or less, and 25% by weight or less. In any of the exemplary embodiments, the fluorinated alkene may be present in the blowing agent composition in amounts of 3% to 98% by weight, including, for example, 5% to 85% by weight, 15% to 75% by weight, 20% to 65% by weight, 25% to 60% by weight, 28% to 57% by weight, 30% to 55% by weight, and 35% to 52% by weight (including all endpoints and partial ranges between them).

[0094] Alternatively, the amount of fluorinated alkenes may be characterized by the amount present in the foaming polymer composition. Thus, when characterized in this way, fluorinated alkenes may be present in the foaming polymer composition in an amount of at least 0.1% by weight, including at least 0.2% by weight, at least 0.5% by weight, at least 0.7% by weight, at least 1.0% by weight, at least 1.2% by weight, at least 1.5% by weight, at least 2% by weight, at least 2.3% by weight, at least 2.5% by weight, at least 2.7% by weight, at least 3.0% by weight, at least 3.5% by weight, at least 3.7% by weight, at least 3.9% by weight, and at least 4% by weight. In any of the exemplary embodiments, fluorinated alkenes may be present in the foaming polymer composition in amounts of 10% by weight or less, including amounts of 8% by weight or less, 6% by weight or less, 4.5% by weight or less, 4% by weight or less, 3.8% by weight or less, 3.5% by weight or less, 3% by weight or less, 2.5% by weight or less, 2.3% by weight or less, 2% by weight or less, 1.8% by weight or less, 1.5% by weight or less, 1.2% by weight or less, 1% by weight or less, 0.8% by weight or less, and 0.6% by weight or less, in an amount of 10% by weight or less.

[0095] In any of the embodiments disclosed herein, fluorinated alkenes may be present in the blowing agent composition in amounts of 0.5% to 7% by weight, including, for example, 0.8% to 6% by weight, 1% to 4.8% by weight, 1.2% to 4.5% by weight, 1.4% to 4.2% by weight, 1.8% to 4% by weight, and 2% to 3.8% by weight (including all endpoints and partial ranges between them).

[0096] According to any aspect of this disclosure, a fluorinated alkene may exist as a blend of two or more fluorinated alkenes. For example, a fluorinated alkene may include a blend of a first fluorinated alkene and a second fluorinated alkene, where the weight ratio of the first alkene to the second alkene is 1:99 to 99:1, for example, 5:95 to 95:5, 8:92 to 92:8, 10:90 to 90:10, 15:85 to 85:15, 20:80 to 80:20, 25:75 to 75:25, 35:65 to 65:35, 40:60 to 60:40, and 45:55 to 55:45. In any embodiment, the first fluorinated alkene may be present in the blowing agent composition in an amount of 5% to 60% by weight (including all endpoints and partial ranges between them), for example, including 8% to 55% by weight, 10% to 50% by weight, 12% to 45% by weight, 15% to 40% by weight, 18% to 38% by weight, and 20% to 35% by weight. In these or other embodiments, the second fluorinated alkene may be present in the blowing agent composition in an amount of 0.5% to 50% by weight (including all endpoints and partial ranges between them), for example, including 1% to 45% by weight, 3% to 40% by weight, 5% to 35% by weight, 5.5% to 30% by weight, 8% to 28% by weight, and 10% to 25% by weight. The first fluorinated alkene may include C4 to C6 fluorinated alkenes having a molecular weight of at least 150 g / mol. An exemplary first fluorinated alkene is, for example, 1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) (including its cis (HFO-1336mzz-Z) isomer and / or trans (HFO-1336mzz-E) isomer). The second fluorinated alkene may include C2-C3 fluorinated alkenes having a molecular weight of less than 150 g / mol. An exemplary second fluorinated alkene is 1,3,3,3-tetrafluoropropene (HFO-1234ze) (including its cis (HFO-1234ze-Z) isomer and / or trans (HFO-1234ze-E) isomer).

[0097] Alternatively, the amount of fluorinated alkenes may be characterized by the molar amount per 100 grams of matrix polymer. Thus, when characterized in this way, fluorinated alkenes may be present in the foaming polymer composition in a total amount of less than 0.1 moles per 100 grams of matrix polymer (including 0.05 moles or less, 0.03 moles or less, 0.02 moles or less, 0.018 moles or less, and 0.01 moles or less). In any of the exemplary embodiments, fluorinated alkenes may be present in the foaming polymer composition in amounts of 0 moles to less than 0.1 moles per 100 grams of matrix polymer, including 0.0005 moles to 0.025 moles, 0.001 moles to 0.022 moles, 0.005 moles to 0.02 moles, and 0.01 moles to 0.019 moles per 100 grams of matrix polymer (including all endpoints and sub-ranges between them). Surprisingly, it has been found that by including a ratio of at least 50:50 between the first and second alkenes, a reduction in the total amount of fluoroalkenes in the matrix polymer can be achieved while still producing an insulating foam with sufficient mechanical and thermal properties. In such embodiments, the total amount of fluoroalkenes is less than 0.027 moles, less than 0.025 moles, or less than 0.02 moles per 100 grams of matrix polymer.

[0098] The blowing agent composition may further optionally include one or more co-blowing agents, such as hydrocarbons, hydrofluorocarbons ("HFCs"), hydrochlorofluorocarbons ("HCFOs"), carbon dioxide, methyl formate, methylal, and water. If a co-blowing agent is present, it is present in the blowing agent composition in an amount of at least 0.1% by weight, including, for example, at least 0.3% by weight, at least 0.5% by weight, at least 0.75% by weight, at least 1% by weight, at least 2% by weight, at least 3% by weight, at least 5% by weight, at least 7% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 18% by weight, at least 20% by weight, at least 23% by weight, at least 25% by weight, at least 27% by weight, and at least 30% by weight. In any of the exemplary embodiments, the co-foaming agent is present in the foaming agent composition in an amount of 98% by weight or less, including amounts of 95% by weight or less, 90% by weight or less, 85% by weight or less, 80% by weight or less, 75% by weight or less, 70% by weight or less, 65% by weight or less, 60% by weight or less, 55% by weight or less, 52% by weight or less, 50% by weight or less, 47% by weight or less, 45% by weight or less, 42% by weight or less, 40% by weight or less, 37% by weight or less, 35% by weight or less, 32% by weight or less, 30% by weight or less, and 25% by weight or less. In any of the exemplary embodiments, the co-foaming agent may be present in the foaming agent composition in amounts of 5% to 98% by weight, including, for example, 10% to 85% by weight, 15% to 80% by weight, 20% to 75% by weight, 25% to 70% by weight, 30% to 68% by weight, and 35% to 65% by weight (including all endpoints and partial ranges between them).

[0099] As mentioned above, the foaming agent may contain one or more hydrocarbons. Suitable hydrocarbons include, but are not limited to, C1-C6 aliphatic hydrocarbons such as methane, ethane, propane, n-butane, isobuatane, and neopentane, as well as C1-C3 aliphatic alcohols such as methanol, ethanol, n-propanol, and isopropyl alcohol.

[0100] The blowing agent may optionally contain one or more hydrofluorocarbons. The specific hydrofluorocarbons used are not particularly limited. A non-exhaustive list of suitable blowing HFCs includes: 1,1-difluoroethane (HFC-152a), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane (HFC-134), 1,1,1-trifluoroethane (HFC-143a), difluoromethane (HFC-32), 1,3,3,3-pentafluoropropane (HF0-1234ze), pentafluoroethane (HFC-125), fluoroethane (HFC-161), 1,1,2,2,3,3-hexafluoropropane (HFC-236ca), and 1,1,1,2,3,3-hexafluoropropane. Examples include ruolopropane (HFC-236ea), 1,1,1,3,3,3-hexafluoropropane (HFC-236fa), 1,1,1,2,2,3-hexafluoropropane (HFC-245ca), 1,1,2,3,3-pentafluoropropane (HFC-245ea), 1,1,1,2,3-pentafluoropropane (HFC-245eb), 1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,1,1,4,4,4-hexafluorobutane (HFC-356mff), 1,1,1,3,3-pentafluorobutane (HFC-365mfc), and combinations thereof. In some exemplary embodiments, the foaming agent includes HFC-152a. Exemplary HFC blowing agents or blends thereof are marketed under the trade name FORMACEL® and include, but are not limited to, FORMACEL® B and FORMACEL® Z6.

[0101] An exemplary blowing agent composition, based on the total weight of the blowing agent composition, comprises 15% to 60% by weight of a fluorinated alkene selected from HFO-1336mzz, HFO-1234ze, or a mixture thereof, 40% to 85% by weight of HFC-152a, and optionally the remainder being carbon dioxide (including all endpoints and partial ranges between them). In other words, an exemplary blowing agent composition, based on the total weight of the blowing polymer composition, comprises 2.5% to 4.8% by weight of HFO-1336mzz and / or HFO-1234ze, 3% to 5.5% by weight of HFC-152a, and optionally carbon dioxide, or, based on the total weight of the blowing polymer composition, comprises 2% to 5% by weight of HFO-1336mzz and / or HFO-1234ze, 2.5% to 6% by weight of HFC-152a, and optionally carbon dioxide. Further exemplary blowing agent compositions may include, based on the total weight of the blowing polymer composition, 3.2% to 4.2% by weight of HFO-1234ze and / or HFO-1336mzz, 3.0% to 4.8% by weight of HFC-152a, and optionally carbon dioxide; or, based on the total weight of the blowing polymer composition, 3% to 4.5% by weight of HFO-1234ze and / or HFO-1336mzz, 2.8% to 5% by weight of HFC-152a, and optionally carbon dioxide.

[0102] The co-foaming agent may also include one or more hydrochlorofluoroolefins (HCFOs), such as HCFO-1233; 1-chloro-1,2,2,2-tetrafluoroethane (HCFC-124); 1,1-dichloro-1-fluoroethane (HCFC-141b); 1,1,1,2-tetrafluoroethane (HFC-134a); 1,1,2,2-tetrafluoroethane (HFC-134); 1-chloro-1,1-difluoroethane (HCFC-142b); 1,1,1,3,3-pentafluorobutane (HFC-365mfc); 1,1,1,2,3,3,3-heptafluoropropane (HFC-227ea); tnchlorofluoromethane (CFC-11); dichlorodifluoromethane (CFC-12); and dichlorofluoromethane (HCFC-22).

[0103] The term "HCFO-1233" is used herein to refer to all trifluoromonochloropropenes. Trifluoromonochloropropenes include both cis and trans-1,1,1-trifluoro-3,chloropropene (HCFO-1233zd or 1233zd). The terms "HCFO-1233zd" or "1233zd" are used herein collectively to refer to 1,1,1-trifluoro-3-chloropropene, regardless of whether it is in cis or trans form. The terms "cis-HCFO-1233zd" and "trans-HCFO-1233zd" are used herein to describe the cis and trans or trans isomers of 1,1,1-trifluoro,3-chloropropene, respectively.

[0104] In some embodiments, the blowing agent composition may contain two or more non-fluorinated blowing agents, such as hydrocarbons and carbon dioxide. In other exemplary embodiments, the blowing agent formulation may not contain carbon dioxide and / or water. In various exemplary embodiments, the blowing agent composition does not contain hydrofluorocarbons and / or hydrofluoroolefins.

[0105] In any of the exemplary embodiments, the blowing agent may contain or consist of CO2. CO2 may be present in amounts of 25% or more by weight, 50% or more by weight, 55% or more by weight, 60% or more by weight, 65% or more by weight, 70% or more by weight, 75% or more by weight, 80% or more by weight, 85% or more by weight, 90% or more by weight, 92% or more by weight, 95% or more by weight, 96% or more by weight, or even 98% or more by weight, based on the total weight of the blowing agent composition.

[0106] Exemplary blowing agent compositions include, based on the total weight of the blowing agent composition, 0 to 80% by weight of fluorinated alkenes and 20% to 100% by weight of carbon dioxide (including all endpoints and partial ranges between them). For example, a blowing agent composition may include, based on the total weight of the blowing agent composition, 0 to 60% by weight of fluorinated alkenes selected from HFO-1336mzz and HFO-1234ze, or mixtures thereof, and 40% to 100% by weight of carbon dioxide (including all endpoints and partial ranges between them). In other words, an exemplary blowing agent composition may include, based on the total weight of the blowing polymer composition, a composition containing 3% by weight or less of fluorinated alkenes and at least 2% by weight of carbon dioxide, and may also include, based on the total weight of the blowing polymer composition, 0 to 4% by weight of fluorinated alkenes and 2.5% to 7% by weight of carbon dioxide. Further exemplary foaming agent compositions may include, based on the total weight of the foaming polymer composition, 0.2 to 2% by weight of fluorinated alkene and 2.5 to 6% by weight of carbon dioxide.

[0107] Exemplary foaming agent compositions include compositions comprising 1.8 to 4% by weight of carbon dioxide and 0.7 to 2.5% by weight of one or more co-foaming agents, based on the total weight of the foaming polymer composition, and compositions comprising 2 to 3.6% by weight of carbon dioxide and 0.9 to 2% by weight of one or more co-foaming agents, and may also include 1 to 5% by weight of carbon dioxide and 0.2 to 3.5% by weight of one or more co-foaming agents, such as methyl formate, methylal, ethanol, isobutane, propylene carbonate, etc., based on the total weight of the foaming polymer composition. Further exemplary foaming agent compositions may include 2.5 to 3.5% by weight of carbon dioxide and 1 to 1.7% by weight of methyl formate (or other suitable co-foaming agent), based on the total weight of the foaming polymer composition. In these or other embodiments, the foaming agent composition may contain a limited amount of fluorinated alkenes, for example, 3% by weight or less based on the total weight of the foaming polymer composition, specifically, 0-2.8% by weight, 0.2-2.6% by weight, 0.5-2.4% by weight, 0.8-2.1% by weight, 1-1.8% by weight, and 1.2-1.6% by weight (including all endpoints and partial ranges between them).

[0108] Further exemplary blowing agent compositions may include 50% to 100% by weight of CO2 and 0% to 50% by weight of one or more hydrocarbons, such as isobutane; 60% to 99% by weight of CO2 and 1% to 40% by weight of one or more hydrocarbons; 70% to 98% by weight of CO2 and 2% to 30% by weight of one or more hydrocarbons; 80% to 96% by weight of CO2 and 3% to 12% by weight of one or more hydrocarbons (including all endpoints and partial ranges between them).

[0109] When the blowing agent is characterized by the weight percentage present in the foaming polymer composition, the blowing agent composition is present in at least 3.0% by weight, including at least 3.5% by weight, at least 4% by weight, at least 4.5% by weight, at least 5% by weight, at least 5.5% by weight, at least 6% by weight, at least 6.5% by weight, and at least 7% by weight. In any of the exemplary embodiments, the blowing agent may be present in the foaming polymer composition in an amount of 10% by weight or less, including amounts of 9% by weight or less, 8.5% by weight or less, 8% by weight or less, 7.8% by weight or less, 7.5% by weight or less, 7.2% by weight or less, 7% by weight or less, 6.9% by weight or less, 6.8% by weight or less, 6.65% by weight or less, 6.5% by weight or less, 6% by weight or less, 5.8% by weight or less, 5.5% by weight or less, 5% by weight or less, 4.9% by weight or less, and 4.8% by weight or less.

[0110] Alternatively, the amount of the blowing agent can be characterized by the amount of molars of the blowing agent composition per 100 grams of polymer composition. Thus, when characterized in this way, the blowing agent composition may be present in the foaming polymer composition in amounts of 0.001 moles to less than 0.1 moles per 100 grams of polymer, for example, 0.01 moles to 0.09 moles, 0.03 moles to 0.08 moles, and 0.04 moles to 0.075 moles per 100 grams of polymer.

[0111] In embodiments in which the barrier coating composition is injected into a screw feeder or incorporated into a foaming polymer mixture by other means, it should be understood that the water contained in the barrier coating composition adds to the amount of foaming agent and, therefore, the foaming power of the foaming agent.

[0112] Surprisingly, it has been found that the use of relatively low application weights of barrier coating compositions, such as those described herein, can result in thermal insulation products with better and more sustained thermal insulation performance compared to otherwise identical foam products without barrier coatings. For example, conventional polymer thermal insulation products containing low GWP blowing agents generally achieve thermal insulation R values ​​of 5 or less per inch.

[0113] Optional additives such as infrared attenuators, processing aids, nucleating agents, plasticizers, pigments, elastomers, extrusion aids, antioxidants, fillers, antistatic agents, biocides, termite killers, surfactants, colorants, oils, waxes, flame retardant synergists, and / or UV absorbers / stabilizers may be incorporated into the foaming composition. These optional additives may be included in amounts necessary to obtain the desired characteristics of the foaming gel or the resulting extruded foam product. Additives may be added to the foaming composition or incorporated into the foaming composition before, during, or after the polymerization process used to produce the polymer.

[0114] As described above, the foaming composition may further contain at least one infrared attenuating agent (IAA) to increase the R value of the resulting foam product. Non-limiting examples of infrared attenuating agents suitable for use in the composition include graphite containing nanographite, carbon black, amorphous carbon powder, asphalt, granular asphalt, crushed glass, talc, glass fiber strands, mica, black iron oxide, metal flakes (e.g., aluminum flakes), carbon nanotubes, platelet-type nanographene, carbon nanofibers, activated carbon, titanium dioxide, and combinations thereof. In some exemplary embodiments, the infrared attenuating agent is present in the foaming composition in an amount of 0 to 5.0% by weight of the total composition. In other embodiments, the infrared attenuating agent may be present in an amount of 0.05 to 3.0% by weight, 0.08 to 2.0% by weight, or 0.1 to 1.0% by weight. In some exemplary embodiments, the infrared attenuating agent is present in the composition in an amount of 0.5% by weight or less.

[0115] In at least one exemplary embodiment, the infrared attenuator is nanographite. The nanographite can be multilayered by furnace high-temperature expansion from acid-treated natural graphite or by microwave heating expansion from moisture-saturated natural graphite. In addition, the nanographite may be multilayer nanographite having at least one dimension having a thickness of less than 100 nm. In some exemplary embodiments, the graphite may be mechanically processed, such as by air jet milling, to grind the nanographite particles. Grinding of the particles ensures that the nanographite flakes and other dimensions of the particles are less than 150 microns.

[0116] The nanographite may or may not be chemically modified or surface-modified, and may be incorporated into a polyethylene methyl acrylate copolymer (EMA) used as both the medium and the support for the nanographite. Other possible supports for the nanographite include, but are not limited to, polymer supports such as polymethyl methacrylate (PMMA), polystyrene, polyvinyl alcohol (PVOH), and polyvinyl acetate (PVA). In exemplary embodiments, the nanographite is substantially uniformly distributed throughout the foam. As used herein, the phrase "substantially uniformly distributed" means that the substance (e.g., nanographite) is uniformly or substantially uniformly distributed within the foam.

[0117] Infrared attenuators increase the R value of foams containing HFO and / or HFC blowing agents, but the addition of infrared attenuators also tends to reduce the cell size of cells in the foam, resulting in an undesirable final foamed product. In particular, smaller cell sizes tend to increase board bulk density, increase product cost, and reduce the process window during the extrusion process. Surprisingly, however, it has been found that the amount of infrared attenuator included in the foaming composition can be reduced or eliminated when the barrier coating composition is applied to or within a polymer foam. Thus, in any of the exemplary embodiments, the foaming polymer composition and the resulting foamed product contain less than 0.25 wt% of infrared attenuator, such as graphite, including less than 0.2 wt%, less than 0.15 wt%, less than 0.10 wt%, and less than 0.05 wt%. In any of the exemplary embodiments, the foaming composition and the resulting foamed product do not contain infrared attenuator, such as graphite. It should be understood that in such embodiments, the size of the foam cells can be controlled by including a nucleating agent (e.g., an inorganic substance such as talc, clay, and / or calcium carbonate) in the foaming composition. In some embodiments, an infrared attenuating agent may be included in the barrier coating composition in addition to, or instead of, the foaming polymer.

[0118] The foaming composition may further contain a flame retardant in an amount of up to 5.0% by weight or more. For example, a flame retardant chemical can be added in the extruded foam manufacturing process to impart flame retardant characteristics to the extruded foam product. Non-limiting examples of flame retardant chemicals suitable for use in the compositions of the present invention include brominated aliphatic compounds such as hexabromocyclododecane (HBCD) and pentabromocyclohexane, brominated phenyl ethers, halogenated polymer flame retardants such as tetrabromophthalic acid esters and brominated polymer flame retardants, phosphoric acid compounds, and combinations thereof.

[0119] Once the foaming agent composition, barrier coating composition, and optional additional additives have been introduced into the foaming composition, the resulting mixture is subjected to some additional blending sufficient to distribute each of the additives substantially uniformly throughout the polymer composition to obtain an extruded or expandable composition.

[0120] The foaming compositions disclosed herein can be used to produce rigid foam insulation products by any manufacturing process, such as extrusion, spraying, expansion, reaction mixing, and bubbling. Such foam products have a cellular structure having cells defined by cell membranes and struts. The struts are formed at the intersections of the cell membranes, and the cell membranes cover the interconnected cellular windows between the struts.

[0121] In some exemplary embodiments, the insulation product has an average density of less than 10 pcf (pounds per cubic foot), including less than 5 pcf, less than 3 pcf, and less than 2.5 pcf, when manufactured under atmospheric conditions. However, if the insulation product is manufactured under high pressure, the density may be lower. In any of the exemplary embodiments, the insulation product has a density of 2.40 pcf or less, or 2.25 pcf or less, or 2.20 pcf or less, or 2.00 pcf or less, or 1.60 pcf or less. In any of the exemplary embodiments, the insulation product has an average density of 1.40 pcf to 2.40 pcf, including 1.40 pcf to 2.25 pcf, 1.40 pcf to 2.00 pcf, 1.40 pcf to 1.60 pcf, 1.45 pcf to 1.55 pcf, 2.10 pcf to 2.30 pcf, and 2.20 pcf to 2.28 pcf.

[0122] It should be understood that the phrase "substantially closed cells" means that all or nearly all cells in the cellular structure of an insulation product are closed. For example, "substantially closed cells" may mean that 30.0% or less of the cells are open, and in particular, 10.0% or less, or 5.0% or less, are open or otherwise "unclosed" cells. A closed cell structure helps to increase the R value of the formed foamed insulation product. However, it should be understood that while it is within the scope of various embodiments to manufacture open cell structures, such open cell structures are not exemplary embodiments.

[0123] The average cell size of the insulation product may range from 0.005 mm (5 microns) to 0.6 mm (600 microns), or in some exemplary embodiments, from 0.05 mm (50 microns) to 0.4 mm (400 microns), or from 0.1 mm (100 microns) to 0.2 mm (200 microns).

[0124] When coated with the barrier coating composition of the present invention, the coated thermal insulation products disclosed herein exhibit a thermal insulation value (R value) greater than 5 per inch and maintain an R value of at least 5 after 180 days. In any of the exemplary embodiments, the coated thermal insulation products may have an R value of at least 5.2, or at least 5.5, at least 5.7, at least 6, at least 6.5, at least 7, and at least 7.5 per inch after 180 days. In any of the exemplary embodiments, the R value per inch may be at least 5.5, or at least 5.7, or at least 6, or at least 6.5, or at least 7 after 7 days, 25 days, 60 days, or 180 days. Thus, in some embodiments, the thermal insulation products may contain an R value of 5 to more than 7.0 or more than 8.0 per inch in accordance with ASTM C578.

[0125] In addition, foaming compositions can be used to produce foam products having high compressive strength, which defines the foam material's ability to withstand axial compressive forces. In some exemplary embodiments, the foam has a compressive strength in the range of about 6 to 120 psi. In some exemplary embodiments, the foam product has a compressive strength of 10 to 110 psi, including 20 to 100 psi, 30 to 80 psi, and 35 to 60 psi. In various exemplary embodiments, the foam product has a compressive strength of 40 to 50 psi.

[0126] The thermal insulation products contemplated herein may be used to form a variety of products such as rigid insulation boards, thermal insulation foams, packaging products, building insulation (e.g., residential, commercial, and industrial buildings), and underground insulation (e.g., highways, airport runways, railways, and underground utility insulation). Thermal insulation products may also be used in multi-material sheath systems. A sheath system may include one or more panels that can be attached to the frame of a structure to form a sheath that encloses at least one part of the structure as a wall portion (e.g., a vertical surface) and / or a roof portion. A panel may include any combination of one or more structural parts, one or more barrier layers, and one or more thermal insulation panels. A structural part may comprise a single layer or a multi-layer structure. For example, the structural part of a panel may include a variety of different materials such as fiberglass, wood, wood composites (i.e., oriented strand board ("OSB")), magnesium oxide board, plywood layers, foil poly structural layers, high-density polyethylene (HDPE) layers, polymer composites, or any other structural layers. In some embodiments, the structural component is a structural barrier layer comprising glass fiber, polycarbonate, polypropylene, high-density polyethylene, or wood composite material. One or more insulation layers may comprise or consist of the subjective insulation foam products disclosed herein. In any of the exemplary embodiments, the sheath system may comprise an insulation product bonded to the structural component, or a barrier layer bonded to a first surface of the insulation product and a structural component bonded to a second surface of the insulation product.

[0127] The concept of the present invention has been described above both in general terms and with respect to various exemplary embodiments. While the general concept of the present invention has been described in terms of what are considered exemplary embodiments, a wide variety of alternative forms known to those skilled in the art can be selected within the general disclosure. In addition, the following examples are intended to better illustrate the present invention, but are not intended to limit the general inventive concept of the present invention. [Examples]

[0128] Extruded polystyrene foam samples were prepared using a co-rotating twin-screw extrusion foam line. Polystyrene was melted in the extruder and mixed with an injected blowing agent composition to form a homogeneous foamed composition. The foamed compositions (excluding the blowing agent) of comparative samples B-E and samples A-D contained polystyrene and a flame retardant masterbatch. The foamed compositions of comparative samples A and F and samples F and G (excluding the blowing agent) contained 100% by weight of polystyrene, a flame retardant masterbatch, and a graphite masterbatch. The blowing agent blend was present in a constant amount across all samples. The blowing agent blend contained 30-40% by weight of fluorinated alkenes and 60-70% by weight of fluorinated alkanes, with the remainder being CO2. As the amount of fluorinated alkenes decreased, the amount of CO2 was increased to maintain a constant level of total blowing agent. Next, the foamed composition was extruded to produce 1-inch XPS foam samples, each having a density of approximately 1.83 pcf.

[0129] For the coated samples, a barrier coating composition containing PVOH (aqueous dispersion of polyvinyl alcohol) was applied. The characteristics of each sample are shown in Table 2 below.

[0130] [Table 2]

[0131] As shown in Table 2, reducing the concentration of fluorinated alkenes in the uncoated foam sample from 3% by weight to 1.5% by weight resulted in a change in the k-value at day 180 from 0.2009 to 0.2262 BTU·in / h·ft. 2 The temperature increases to -°F, and the R value of the sample decreases to less than 4.5. However, when the foam sample was coated with the barrier coating composition, the sample was able to achieve an adiabatic value of R-5 even when the concentration of fluorinated alkenes decreased to less than 2% by weight.

[0132] Furthermore, each of Examples A to C, containing at least 2 wt% fluorinated alkene, exhibited a 180-day R / inch value greater than 5, and Examples A and B, having at least 2.5 wt% fluorinated alkene concentrations, exhibited a 180-day R / inch value greater than 5.5. The incorporation of graphite into Example F further increased the 180-day R / inch value to 5.78.

[0133] Furthermore, the removal of graphite from the foam composition resulted in an increase in the k coefficient (comparative examples B-E compared to comparative example A), and the effect on the k coefficient decreased as the amount of fluorinated alkene blowing agent increased. However, the use of the barrier coating of the present invention on the foam (examples A-D) reduced the k coefficient to a level lower than that of the control (comparative sample A).

[0134] In particular, Figures 2 and 3 show that the combination of a PVOH-based barrier coating and an increased level of fluorinated alkene blowing agent yielded the greatest improvement in thermal insulation properties. However, Figures 2 and 3 also show that less blowing agent can be used to achieve the same or improved thermal insulation properties. [Examples]

[0135] A barrier coating composition containing DIOFAN® A050 (a PVDC dispersion containing approximately 58% by weight of solids, commercially available from Solvay) was applied to various surfaces of 1-inch XPS foam samples using a brush at various coating weights as shown in Table 3 below. The XPS foam was formed using a foaming agent composition containing a blend of HFO-1336mzz-Z and HFC-152a.

[0136] [Table 3]

[0137] As shown in Table 3 and Figure 4, the effectiveness of the barrier coating in significantly slowing the diffusion rate of the foaming agent increased with increasing coating weight, as indicated by improved R values ​​and decreased k values ​​at day 180, compared to the control (comparative example G). [Examples]

[0138] A barrier coating composition containing an aqueous dispersion of styrene-butadiene rubber was brush-applied to one or more surfaces of a 1-inch sample of extruded polystyrene foam, and dried to form a barrier-coated polystyrene foam. The polystyrene foam was formed using a foaming agent composition containing a blend of HFO-1336mzz-Z and HFC-152a. The application locations of the barrier coating composition are shown in Table 4 below.

[0139] [Table 4]

[0140] As shown in Figure 5, each sample (Samples U-W) coated at least on the top and bottom with the barrier coating composition showed improved thermal properties (lower k-value and increased R-value) compared to the control sample (Comparative Example M) and the sample (Sample X) coated only on the edges. [Examples]

[0141] Extruded polystyrene foam samples were prepared using a co-rotating twin-screw single extrusion foam production line. Polystyrene was melted in the extruder and mixed with an injected foaming agent composition to form a homogeneous foamed composition. The foamed composition (excluding the foaming agent) contained polystyrene, a flame-retardant masterbatch, and a graphite masterbatch, which are reported as "solids content" in Table 5 below. Aqueous dispersions of styrene-butadiene rubber (50% by weight solids in water) were injected directly into the extruder at various concentrations. Polystyrene foams were formed using a foaming agent composition containing a consistent blend of HFO-1336mzz-Z and HFC-152a across all samples. The foamed composition was then extruded to produce 1-inch XPS foam samples. Each foamed composition is shown in Table 5 below.

[0142] [Table 5]

[0143] Table 6 below lists the properties of the obtained XPS foam samples.

[0144] [Table 6]

[0145] As shown in Table 6 and the graph in Figure 6, the resulting XPS foam containing 0.05% to 0.25% by weight of SBR dispersion showed improved thermal insulation properties (e.g., lower k-value) compared to the control (comparative example N). In addition, the data shown in Table 6 demonstrate that barrier coating compositions can be injected during the foaming process without adversely affecting the foam properties. For example, the compressive strength and compressive modulus of each example increased compared to the control sample (comparative example N). [Examples]

[0146] One of two types of barrier coatings (aqueous dispersion of ethylene vinyl alcohol (EVOH) or aqueous dispersion of polyvinyl alcohol (PVOH)) in varying amounts was applied by brush to various surfaces of a 1-inch XPS foam sample. The application locations of the barrier coating compositions are shown in Table 7 below.

[0147] [Table 7]

[0148] As shown in Table 7 and the graphs in Figures 7-8, both EVOH and PVOH coatings were effective in significantly slowing the diffusion rate of the foaming agent, as indicated by improved R values ​​and reduced k values ​​at day 180 compared to the control (comparative example O). In example LL, PVOH improved the R value of the foam sample by approximately 23% compared to the control (comparative example O). Furthermore, the results show that it is not necessarily true that more coating results in better thermal conductivity. Rather, approximately 36.81 g / m² coated on the sample 2 Example LL, which has the coating, exhibits better 180-day thermal conductivity values ​​than Examples KK, JJ, and MM, which have heavier applications of the PVOH-based barrier coating. Therefore, to achieve optimal performance, a balance must be struck between the coating weight and its impact on the thermal conductivity of the foam product. [Examples]

[0149] As shown in Table 8 below, various barrier coatings and combinations of barrier coatings were applied to 1-inch XPS foam samples. PUD 1 and PUD 2 are two different commercially available polyurethane dispersions. For samples OO and PP, the PVOH coating system was first applied to the foam surface and dried, and then PUD 1 or PUD 2 was applied on top of the PVOH coating.

[0150] [Table 8]

[0151] As shown in Figure 9, the coatings themselves to which PUD1 and PUD2 were applied (comparative examples Q and R, respectively) did not provide barrier properties to the foam. However, when applied to the surface of an applied PVOH coating (samples OO and PP, respectively), they enhanced the barrier properties of the PVOH coating (sample NN). While not theoretically bound, it is thought that applying PUD or a hydrophobic coating to a PVOH or EVOH coating, which is more hydrophilic and susceptible to moisture, can protect the hydrophilic coating and enhance its resistance properties. [Examples]

[0152] Extruded polystyrene foams containing various foaming agent compositions were prepared and coated with barrier coating compositions according to the concept of the present invention, and the effect of the barrier coating on the thermal conductivity properties of the foams was evaluated. Each foaming composition is shown in Table 9 below.

[0153] [Table 9]

[0154] A barrier coating composition containing DIOFAN® A050 (a PVDC dispersion containing approximately 58% by weight of solids, commercially available from Solvay) was applied to various surfaces of 1-inch XPS foam samples using a brush, in various coating weights as shown in Table 10 below.

[0155] [Table 10]

[0156] As shown in Table 10 and the graph in Figure 10, the effectiveness of the barrier coating in significantly slowing the diffusion rate of the foaming agent increased with increasing coating weight, as indicated by improved R values ​​and decreased k values ​​at day 180 compared to the control. [Examples]

[0157] Extruded polystyrene foam samples were prepared using a co-rotating twin-screw extrusion foam line. Polystyrene was melted in the extruder and mixed with an injected blowing agent composition to form a homogeneous foamed composition. Each foamed composition was identical and contained 100% by weight of polystyrene, a flame retardant masterbatch, and a graphite masterbatch. The blowing agent blend, which included a blend of fluorinated alkenes and hydrofluorocarbons, was present at a constant level across all samples in both concentration and composition.

[0158] The foamed composition was extruded to produce 1-inch XPS foam samples, each with a density of approximately 2.2 pcf.

[0159] Comparative sample 1 remained uncoated, while samples 1-5 were coated with exemplary barrier coating compositions on at least one side using a hand sprayer, as outlined in Table 11 below. The barrier coating compositions are shown in Table 12 below.

[0160] [Table 11]

[0161] [Table 12]

[0162] The thermal conductivity of each sample was tested according to ASTM C578 (70 F and 45% relative humidity) at the following intervals: day 7 (k7), day 20 (k20), day 30 (k30), day 60 (k60), day 120, and day 180. The results are provided in Table 13 below.

[0163] [Table 13]

[0164] As shown in Table 13, the uncoated comparison sample showed a reading of 0.175 BTU·in / h·ft as early as day 20. 2 Although the thermal conductivity k-value k20 exceeded °F, each of the samples of the present invention coated with the barrier coating composition showed a thermal conductivity of 0.175 BTU·in / h·ft after 180 days. 2 Below °F, 0.18 BTU·in / h·ft after 180 days. 2 The k coefficient was maintained at less than °F. [Examples]

[0165] Extruded polystyrene foam samples were prepared using a co-rotating twin-screw extrusion foam line. Polystyrene was melted in the extruder and mixed with an injected blowing agent composition to form a homogeneous foamed composition. Each foamed composition was identical and contained 100% by weight of polystyrene, a flame retardant masterbatch, and a graphite masterbatch. Based on the total weight of the blowing agent, a blowing agent blend containing approximately 50% by weight of CO2 and approximately 50% by weight of a blend of HFO and HFC was included in a constant proportion and total amount across all foam samples.

[0166] The foamed composition was extruded to produce 1-inch XPS foam samples, each with a density of approximately 2.3 pcf.

[0167] Comparative sample 2 remained uncoated, while samples 6-10 were coated with exemplary barrier coating compositions on at least one side surface using a hand sprayer, as outlined in Table 14 below. The barrier coating compositions are shown in Table 15 below.

[0168] [Table 14]

[0169] [Table 15]

[0170] The thermal conductivity of each sample was tested according to ASTM C578 (70°F and 45% relative humidity) at the following intervals: day 7 (k7), day 20 (k20), day 30 (k30), and day 60 (k60). The results and performance are provided in Table 16 below.

[0171] [Table 16]

[0172] As shown in Table 16, the uncoated comparative sample showed a reading of 0.2 BTU·in / h·ft as early as day 20 (k20). 2 Although the thermal conductivity k-value exceeded °F, each of the samples of the present invention coated with the barrier coating composition showed a thermal conductivity of 0.2 BTU·in / h·ft even after 60 days. 2 The k coefficient was maintained at less than °F.

[0173] While the present invention is described with reference to specific means, materials, and embodiments, those skilled in the art will readily identify the essential features of the invention from the foregoing description and can make various changes and modifications to suit various uses and features without departing from the spirit and scope of the invention as set forth above and in the appended claims.

Claims

1. A coated thermal insulation product, A foam product having a first main surface, a second main surface on the opposite side, and a plurality of secondary surfaces extending between them, wherein the foam product is a) Matrix composition, and b) A foaming product formed from a foaming composition comprising a foaming agent composition containing 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of at least one co-foaming agent, 3 g / m ２ ~225g / m ２ A total amount of a barrier coating present on at least one surface of the foam product, wherein the barrier coating is Based on the total solids content of the barrier coating composition, the barrier polymer is 40% to 99.9% by weight, wherein the barrier polymer has a minimum crystallinity of 10%, and A barrier coating is formed from the barrier coating composition, which comprises 0.01% to 60% by weight of at least one additive based on the total solid content of the barrier coating composition, wherein the barrier coating composition has a surface tension of 60 mN / m or less, and the coated thermal insulation product has at least 5 R / in values ​​on day 180.

2. The coated thermal insulation product according to claim 1, wherein the fluorinated alkene is one or more of (cis and / or trans)-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) and (cis and / or trans)-1,3,3,3-tetrafluoropropene (HFO-1234ze).

3. The coated thermal insulation product according to any one of claims 1 to 2, wherein the co-foaming agent comprises a hydrocarbon, a hydrofluorocarbon ("HFC"), a hydrochlorofluorocarbon ("HCFO"), carbon dioxide, methyl formate, methylal, water, or a mixture thereof.

4. The coated thermal insulation product according to any one of claims 1 to 3, wherein the coated thermal insulation product has an R / in value of at least 5.5 on day 180.

5. The barrier coating composition has a viscosity of 5000 cP or less with a solid content of 70%, and the coated thermal insulation product is according to any one of claims 1 to 4.

6. The coated thermal insulation product according to any one of claims 1 to 5, wherein the barrier polymer comprises any one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), poly(vinylidene fluoride), polyurethane, styrene-butadiene, polyvinyl chloride, poly(acrylate), polyamide, polyester, polystyrene, polyglycolic acid, poly(ethylene 2,5-francicarboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

7. The coated thermal insulation product according to any one of claims 1 to 6, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

8. The coated thermal insulation product according to any one of claims 1 to 7, wherein the barrier polymer has a minimum crystallinity of 30%.

9. The coated thermal insulation product according to any one of claims 1 to 8, wherein the barrier polymer has a minimum crystallinity of 60%.

10. The coated thermal insulation product according to any one of claims 1 to 9, wherein the additive comprises a wetting agent, a rheology modifier, a flame retardant, an antiblocking agent, an antifoaming agent, a pH adjuster, a UV stabilizer, or a mixture thereof.

11. The coated thermal insulation product according to any one of claims 1 to 10, wherein the additive comprises a rheology modifier present in an amount of 0.01% to 20% by weight, based on the total solid content of the barrier coating.

12. The coated thermal insulation product according to any one of claims 1 to 11, wherein the additive comprises at least one wetting agent present in an amount of 0.005% to 8% by weight, based on the total solid content of the barrier coating.

13. The coated thermal insulation product according to any one of claims 1 to 12, wherein the additive comprises at least one UV stabilizer present in an amount of 0.05% to 12% by weight, based on the total solid content of the barrier coating.

14. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solid content of 40% to 99% by weight, A rheological modifier with a solid content of 0.01% to 15% by weight, A wetting agent with a solid content of 0% to 8% by weight, pH adjuster with a solid content of 0-8% by weight, Flame retardant with a solid content of 0-5% by weight, A UV stabilizer with a solid content of 0.05% to 12% by weight, A coated thermal insulation product according to any one of claims 1 to 13, including the above.

15. The barrier coating has a pH of 3 to 9, and the coated thermal insulation product is as described in any one of claims 1 to 14.

16. The barrier coating is present on each surface of the foam product, the coated thermal insulation product according to any one of claims 1 to 15.

17. The coated thermal insulation product according to any one of claims 1 to 16, wherein the matrix material is a matrix polymer selected from the group consisting of alkenyl aromatic polymers, styrene polymers, styrene copolymers, styrene block copolymers, polyolefins, halogenated vinyl polymers, acrylonitrile copolymers, polycarbonates, polyisocyanurates, polyesters, polyacrylates, polyurethanes, phenolic resins, polysulfones, polyphenylene sulfide, acetal resins, polyamides, polyaramids, polyimides, polyetherimides, rubber-modified polymers, thermoplastic polymer blends, and combinations thereof.

18. A coated polymer insulation product, A polymer foam product having a first main surface, a second main surface on the opposite side, and a plurality of secondary surfaces extending between them, wherein the foam product is a) A polymer matrix composition comprising a polymer matrix material and 0.05 to 5% by weight of an infrared attenuating agent, and b) A polymer foam product formed from a foaming polymer composition comprising a foaming agent composition comprising 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of a fluorinated alkane co-foaming agent, On each surface of the aforementioned foam product, 3 g / m² ２ ~225g / m ２ A barrier coating present in a total amount, wherein the barrier coating is formed from a barrier coating composition comprising a semicrystalline polymer and at least one rheology modifier, the barrier coating composition having a surface tension 20 mN / m or less above the surface energy of the polymer foam and a viscosity of 50 cP to 5000 cP with a solid content of 70% or less, The coated insulation product is a coated polymer insulation product having, as measured according to ASTM C578, a 180-day R / in value of at least 5 and a compressive strength of 10 to 110 psi.

19. The coated polymer insulation product according to claim 18, wherein the coated polymer insulation product has an R / in value of at least 5.5 on day 180.

20. The foaming agent composition has a GWP of less than 50, and the coated polymer insulation product is as described in claim 18 or claim 19.

21. The barrier coating composition has a viscosity of 250 cP or less with a solid content of 70%, and is a coated polymer heat insulating product according to any one of claims 18 to 20.

22. The coated polymer thermal insulation product according to any one of claims 18 to 21, wherein the barrier polymer comprises any one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), poly(vinylidene fluoride), polyurethane, styrene-butadiene, polyvinyl chloride, poly(acrylate), polyamide, polyester, polystyrene, polyglycolic acid, poly(ethylene 2,5-francicarboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

23. The coated polymer thermal insulation product according to any one of claims 18 to 22, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

24. The coated polymer thermal insulation product according to any one of claims 18 to 23, wherein the barrier polymer has a minimum crystallinity of 30%.

25. The coated polymer thermal insulation product according to any one of claims 18 to 24, wherein the wetting agent is present in an amount of 0.005% to 8% by weight of solids based on the total solids content of the barrier coating.

26. The coated polymer thermal insulation product according to any one of claims 18 to 25, wherein the barrier coating composition further comprises at least one additive, the additive comprising a wetting agent, an antifoaming agent, a pH adjuster, a UV stabilizer, a flame retardant, an antiblocking agent, hydrophobic silica, or a mixture thereof.

27. The coated polymer thermal insulation product according to claim 26, wherein the additive comprises a rheology modifier present in an amount of 0.01% to 20% by weight of solids based on the total solids content of the barrier coating.

28. The coated polymer thermal insulation product according to claim 26, wherein the additive comprises a UV stabilizer present in an amount of solids from 0.05% to 12% by weight, based on the total solids content of the barrier coating.

29. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solid content of 40% to 99% by weight, A rheological modifier with a solid content of 0.01% to 15% by weight, A wetting agent with a solid content of 0% to 8% by weight, pH adjuster with a solid content of 0-8% by weight, 0-5% by weight of flame retardant, A UV stabilizer with a solid content of 0.05% to 12% by weight, A coated polymer thermal insulation product according to any one of claims 18 to 28, including the above.

30. The barrier coating has a pH of 3 to 9, and the coated polymer thermal insulation product is according to any one of claims 18 to 29.

31. The coated polymer insulation product according to any one of claims 18 to 30, wherein the coated polymer insulation product has an R value of at least 5.5 / inch after 180 days.

32. The coated thermal insulation product according to any one of claims 18 to 31, wherein the barrier coating is present on each surface of the foam product.

33. A method for manufacturing a coated thermal insulation product having improved thermal insulation values, The method involves mixing a matrix polymer with a foaming agent composition to form a foaming polymer composition, wherein the foaming agent composition comprises 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of a co-foaming agent. The foaming polymer composition is foamed to produce a foamed product having a first main surface, a second main surface on the opposite side, and a plurality of secondary surfaces extending between them. A barrier coating of 3 g / m² is applied to at least one surface of the aforementioned foam product. ２ ~225g / m ２ The barrier coating is applied in a total amount, and the barrier coating is Based on the total solids content of the barrier coating composition, the barrier polymer is 40% to 99.9% by weight, wherein the barrier polymer has a minimum crystallinity of 10%, and Based on the total solid content of the barrier coating composition, the barrier coating composition is formed from the barrier coating composition containing at least one additive in an amount of 0.01% to 60% by weight, The barrier coating composition has a surface tension of 60 mN / m or less, and the coated thermal insulation product has at least 5 R / in values ​​on day 180, in a method.

34. The method according to claim 33, wherein the fluorinated alkene is one or more of (cis and / or trans)-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) and (cis and / or trans)-1,3,3,3-tetrafluoropropene (HFO-1234ze).

35. The method according to claim 33 or 34, wherein the co-foaming agent comprises a hydrocarbon, a hydrofluorocarbon ("HFC"), a hydrochlorofluorocarbon ("HCFO"), carbon dioxide, methyl formate, methylal, water, or a mixture thereof.

36. The method according to any one of claims 33 to 35, wherein the coated thermal insulation product has an R / in value of at least 5.5 on day 180.

37. The barrier coating composition according to any one of claims 33 to 36, wherein the barrier coating composition has a viscosity of 5000 cP or less with a solid content of 70%.

38. The method according to any one of claims 33 to 37, wherein the barrier polymer comprises one or more of the following: poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), poly(vinylidene fluoride), polyurethane, styrene-butadiene, polyvinyl chloride, poly(acrylate), polyamide, polyester, polystyrene, polyglycolic acid, poly(ethylene 2,5-francicarboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

39. The method according to any one of claims 33 to 38, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

40. The method according to any one of claims 33 to 39, wherein the barrier polymer has a minimum crystallinity of 30%.

41. The method according to any one of claims 33 to 40, wherein the barrier polymer has a minimum crystallinity of 60%.

42. The aforementioned additives include wetting agents, rheology modifiers, defoaming agents, pH adjusters, UV stabilizers, flame retardants, antiblocking agents, or mixtures thereof. The method according to any one of claims 33 to 41, including the method described in any one of claims 33 to 41.

43. The method according to any one of claims 33 to 42, wherein the additive comprises a rheology modifier present in an amount of 0.01% to 20% by weight, based on the total solid content of the barrier coating.

44. The method according to any one of claims 33 to 43, wherein the additive comprises at least one wetting agent present in an amount of 0.005% to 8% by weight, based on the total solid content of the barrier coating.

45. The method according to any one of claims 33 to 44, wherein the additive comprises at least one UV stabilizer present in an amount of 0.05% to 12% by weight, based on the total solid content of the barrier coating.

46. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solid content of 40% to 99% by weight, A rheological modifier with a solid content of 0.01% to 20% by weight, A wetting agent with a solid content of 0% to 8% by weight, pH adjuster with a solid content of 0-8% by weight, Flame retardant with a solid content of 0-5% by weight, A UV stabilizer with a solid content of 0.05% to 12% by weight, The method according to any one of claims 33 to 45, including the method described in any one of claims 33 to 45.

47. The barrier coating has a pH of 3 to 9, according to the method according to any one of claims 33 to 46.

48. The method according to any one of claims 33 to 47, wherein the barrier coating is present on each surface of the foam product.

49. The method according to any one of claims 33 to 48, wherein the matrix material comprises a matrix polymer selected from the group consisting of alkenyl aromatic polymers, styrene polymers, styrene copolymers, styrene block copolymers, polyolefins, halogenated vinyl polymers, acrylonitrile copolymers, polycarbonates, polyisocyanurates, polyesters, polyacrylates, polyurethanes, phenolic resins, polysulfones, polyphenylene sulfide, acetal resins, polyamides, polyaramids, polyimides, polyetherimides, rubber-modified polymers, thermoplastic polymer blends, and combinations thereof.

50. It is a sheath system, A structural portion having a first surface and an opposing second surface, The structural portion comprises at least one coated thermal insulation product bonded to one of the first or second surfaces, wherein the coated thermal insulation product is A foam product having a first main surface, an opposing second main surface, and four secondary surfaces extending between them, wherein the foam product is a) Matrix composition, and b) A foaming product formed from a foaming composition comprising a foaming agent composition comprising 15% to 60% by weight of a fluorinated alkene and 40% to 85% by weight of a co-foaming agent, 3 g / m ２ ~225g / m ２ A total amount of a barrier coating present on at least one surface of the foam product, wherein the barrier coating is Based on the total solids content of the barrier coating composition, the barrier polymer is 40% to 99.9% by weight, wherein the barrier polymer has a minimum crystallinity of 10%, and A sheath system comprising: a barrier coating formed from the barrier coating composition comprising 0.01% to 60% by weight of at least one additive based on the total solid content of the barrier coating composition, wherein the barrier coating composition has a surface tension of 60 mN / m or less, and the coated thermal insulation product has at least 5 R / in values ​​on day 180.

51. The sheath system according to claim 50, wherein the fluorinated alkene is one or more of (cis and / or trans)-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) and (cis and / or trans)-1,3,3,3-tetrafluoropropene (HFO-1234ze).

52. The sheath system according to claim 50 or claim 51, wherein the co-foaming agent comprises a hydrocarbon, a hydrofluorocarbon ("HFC"), a hydrochlorofluorocarbon ("HCFO"), carbon dioxide, methyl formate, methylal, water, or a mixture thereof.

53. The sheath system according to any one of claims 50 to 52, wherein the coated thermal insulation product has an R / in value of at least 5.5 on day 180.

54. The sheath system according to any one of claims 50 to 53, wherein the barrier coating composition has a viscosity of 5000 cP or less with a solid content of 70%.

55. The sheath system according to any one of claims 50 to 54, wherein the barrier polymer comprises one or more of the following: poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), poly(vinylidene fluoride), polyurethane, styrene-butadiene, polyvinyl chloride, poly(acrylate), polyamide, polyester, polystyrene, polyglycolic acid, poly(ethylene 2,5-francicarboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

56. The sheath system according to any one of claims 50 to 55, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

57. The sheath system according to any one of claims 50 to 56, wherein the barrier polymer has a minimum crystallinity of 30%.

58. The sheath system according to any one of claims 50 to 57, wherein the barrier polymer has a minimum crystallinity of 60%.

59. The aforementioned additives include wetting agents, rheological modifiers, defoaming agents, pH adjusters, UV stabilizers, or mixtures thereof. A sheath system according to any one of claims 50 to 58, including the following:

60. The sheath system according to any one of claims 50 to 59, wherein the additive comprises a rheology modifier present in an amount of 0.01% to 20% by weight, based on the total solid content of the barrier coating.

61. The sheath system according to any one of claims 50 to 60, wherein the additive comprises at least one wetting agent present in an amount of 0.005% to 8% by weight, based on the total solid content of the barrier coating.

62. The sheath system according to any one of claims 50 to 61, wherein the additive comprises at least one UV stabilizer present in an amount of 0.05% to 12% by weight, based on the total solid content of the barrier coating.

63. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solid content of 40% to 99% by weight, A rheological modifier with a solid content of 0.01% to 15% by weight, A wetting agent with a solid content of 0% to 8% by weight, pH adjuster with a solid content of 0-8% by weight, 0-5% by weight of flame retardant, A UV stabilizer with a solid content of 0.05% to 12% by weight, A sheath system according to any one of claims 50 to 62, including the following:

64. The barrier coating has a pH of 3 to 9, as described in any one of claims 50 to 63.

65. The sheath system according to any one of claims 50 to 64, wherein the barrier coating is present on each surface of the foam product.

66. The sheath system according to any one of claims 50 to 65, wherein the matrix material comprises a matrix polymer selected from the group consisting of alkenyl aromatic polymers, styrene polymers, styrene copolymers, styrene block copolymers, polyolefins, halogenated vinyl polymers, acrylonitrile copolymers, polycarbonates, polyisocyanurates, polyesters, polyacrylates, polyurethanes, phenolic resins, polysulfones, polyphenylene sulfide, acetal resins, polyamides, polyaramids, polyimides, polyetherimides, rubber-modified polymers, thermoplastic polymer blends, and combinations thereof.

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