Barrier coating composition for use in the manufacture of insulating products having reduced halogenated foaming agent

Abstract

Disclosed are coated insulating products in which the concentration of fluorinated blowing agent is reduced while maintaining acceptable thermal properties (e.g., a 180-day R / in value of at least 4.8). The coated insulating product comprises a foamed product formed from a foamed composition comprising a matrix composition and a blowing agent composition, wherein the blowing agent composition contains less than 3.5% by weight of fluorinated alkene based on the total weight of the foamed composition. The foamed product has at least one surface with a concentration of 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.

Description

[Technical Field]

[0001] The present invention relates to a method for forming an insulating product, and more particularly to the production of an insulating foam formed using a gas foaming agent. The present invention provides the use of a barrier coating to retain gas in the insulating product and reduce the level of halogenated foaming agent while maintaining desired thermal and insulating performance. [Background technology]

[0002] Polymer foams, such as extruded polymer foams or "XPS" foams, are typically produced by melting a polymer matrix composition to form a polymer melt, and then incorporating one or more blowing agents and other additives into the polymer melt under conditions that allow the blowing agent and polymer to be completely mixed, for example, under pressure, while preventing premature foaming of the mixture. 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 cause foaming and produce a foamed product. As is understood, the relative amounts of polymer, blowing agent, and additives; temperature; and the method of reducing pressure all affect the quality of the resulting foamed product. Also, as is understood, foaming mixtures are maintained under relatively high pressure until they pass through the extrusion die and can expand 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 Freon 12 are partially soluble in polystyrene and have been used to produce polystyrene foams that exhibit generally acceptable appearance and surface finish, as well as physical properties such as bubble size and distribution, orientation, shrinkage, insulation properties (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 CFCs has led to the use of alternative blowing agents such as hydrogen-containing chlorofluoroalkanes (HCFCs). However, because HCFCs still contain some chlorine, they are said to have an ozone depletion potential (ODP).

[0006] Another type of blowing agent, hydrofluorocarbons (HFCs), have been used as a more ozone-friendly alternative, 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 solubility 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 compared to conventional fluorocarbon and hydrofluorocarbon blowing agents. However, these compounds tend to be expensive, and it is necessary to minimize the amount of compound required to produce polymer insulating products with desirable physical properties.

[0008] Carbon dioxide is a particularly attractive candidate as a blowing agent from both environmental and economic perspectives. Carbon dioxide is inexpensive and has a low (negligible) global warming potential. However, the technical challenges associated with successfully using carbon dioxide as a blowing agent to date are significant considering the relatively low solubility of carbon dioxide in polystyrene resins, high diffusivity, and poor processability. A further technical challenge is that carbon dioxide does not contribute to thermal insulation performance. Thus, while the thermal conductivity of carbon dioxide is comparable to that of HFC-134a, carbon dioxide has been previously found to rapidly diffuse from the foam, resulting in a decrease in insulation or "R-value".

[0009] Therefore, there is a need for a method of producing polymeric insulation products that reduce or eliminate the use of halogenated blowing agents overall while maintaining sufficient insulation or "R-value".

Summary of the Invention

[0010] Various aspects of the concepts of the present invention are directed to coated insulation products with reduced fluorinated blowing agent concentrations while maintaining acceptable thermal properties (e.g., an 180-day R / in value of at least 4.8). The coated insulation product includes a foamed product having a first major surface, an opposing second major surface, and a plurality of minor surfaces extending therebetween, formed from a foamable composition that includes a matrix composition and a blowing agent composition that includes less than 3.5 weight percent fluorinated alkene based on the total weight of the foamable composition. The foamed product has at least one surface coated with a barrier coating composition of 3 g / m 2 ~225 g / m 2 The barrier coating composition includes 40 weight percent to 99.9 weight percent of a barrier polymer having a minimum crystallinity of 10% and 0.01 weight percent to 60 weight percent of at least one additive. The barrier coating composition has a surface tension of 60 mN / m or less when applied.

[0011] A further embodiment of the concept of the present invention relates to a coated polymer insulating 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, the foamable polymer composition comprising a polymer matrix composition and a foaming agent composition comprising 3% by weight or less of a fluorinated alkene and at least 1.5% by weight of CO2, based on the total weight of the foam composition. The foam product has at least one surface, for example, each surface, etc., with a density of 3 g / m². 2 ~225g / m 2 The product is coated with a total amount of barrier coating composition. The barrier coating composition comprises a semicrystalline polymer and at least one surfactant, and when applied, has a surface tension of 60 mN / m or less on the surface energy of the polymer foam product and a viscosity of 50 cP to 5000 cP with a solids content of 70% or less. The coated insulating product has a 180-day R / in value of at least 4.8 and a compressive strength of 10 to 110 psi, as measured according to ASTM C578.

[0012] In some exemplary embodiments, the coated polymer insulating product has an R value of at least 5.0 / inch after 180 days.

[0013] In any of the exemplary embodiments, the blowing agent composition may contain at least 2% by weight of CO2 and less than 3% by weight of a fluorinated alkene, based on the total weight of the blowing composition. The blowing agent may further contain methyl formate.

[0014] In any exemplary embodiment, the barrier coating composition may have a viscosity of 5000 cP or less at 70% solids, for example, 2500 cP or less at 70% solids, 2000 cP or less at 70% solids, 1500 cP or less at 70% solids, 1000 cP or less at 70% solids, 750 cP or less at 70% solids, 500 cP or less at 70% solids, 250 cP or less at 70% solids, 150 cP or less at 70% solids, and 115 cP or less at 70% solids.

[0015] 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.

[0016] 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%.

[0017] The barrier coating composition includes at least one additive such as a wetting agent, a rheological modifier, an antifoaming agent, a pH adjuster, a flame retardant, an antiblocking agent, and a UV stabilizer.

[0018] In any exemplary embodiment, 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.

[0019] In any exemplary embodiment, 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.

[0020] A further exemplary embodiment of the concept of the present invention relates to a method for producing a coated insulating product with a reduced fluorinated blowing agent content, the method comprising: mixing a matrix polymer with a blowing agent composition to form a foaming polymer composition; foaming the foaming polymer composition to produce a foamed product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them; and applying 3 g / m² to at least one surface of the foamed product. 2 ~225g / m 2The method includes applying a barrier coating in a total amount. 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 60 mN / m or less, and the coated insulating product has a 180-day R / in value of at least 4.8.

[0021] Further exemplary embodiments of the concept of the present invention relate to a coating system comprising at least one structural portion having a first surface and an opposing second surface, and at least one coating insulating product bonded to one of the first and second surfaces of the structural portion. The coating insulating product comprises a foamed product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them, formed from a foamed composition, the foamed composition comprising a matrix composition and a foaming agent composition containing less than 3.5% by weight of a fluorinated alkene based on the total weight of the foamed composition. The foamed product has at least one surface with a density of 3 g / m² 2 ~225g / m 2 The product 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 applied, the barrier coating composition has a surface tension of 60 mN / m or less. The coated insulating product has a 180-day R / in value of at least 4.8.

[0022] The aforementioned and other objectives, features, and advantages of the comprehensive concept of the present invention will become more readily apparent by considering the following detailed description. [Brief explanation of the drawing]

[0023] 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 2. [Figure 4] 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 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 various concentrations of the barrier coating composition 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 samples containing 0.50 wt% isobutane and various barrier coating configurations according to Example 4. [Figure 8] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 5. [Figure 9] This graph shows the thermal conductivity k value (y-axis) as a function of time (x-axis) for various concentrations of the barrier coating composition injected into the extruder according to Example 6. [Figure 10] This graph shows the thermal conductivity k value (y-axis) as a function of time (x-axis) for various barrier coating configurations using coating A according to Example 7. [Figure 11] This graph shows the thermal conductivity k value (y-axis) as a function of time (x-axis) for various barrier coating configurations using coating B according to Example 7. [Figure 12] This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 8. [Figure 13]This graph shows the thermal conductivity k-value (y-axis) as a function of time (x-axis) for various samples from Example 9. [Modes for carrying out the invention]

[0024] 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 to 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.

[0025] As used herein and in the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless otherwise clearly indicated by the context.

[0026] 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 "approximately." Therefore, unless otherwise specified, 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.

[0027] Unless otherwise specified, 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. Similarly, a feature described herein in relation to an insulating product may be applicable to a foamed composition, and vice versa.

[0028] All numerical ranges provided throughout this specification and the claims include all narrower numerical ranges that fall within such broader ranges, as if all such narrower ranges were explicitly described herein.

[0029] 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 typically added under appropriate conditions, for example, to a molten polymer in an extruder, to initiate foaming and produce a foamed product. The foaming agent expands the resin, forming bubbles (e.g., continuous or independent pores). As the resin solidifies or hardens, foam is produced by either the foaming agent trapped within the bubbles or ambient air replacing the foaming agent within the bubbles. 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, e.g., 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.

[0030] As used herein, unless otherwise specified, the values of the blowing agent or other components or ingredients of a composition are expressed as weight percent or wt% of each component in the composition.

[0031] With respect to the present disclosure, "closed cell" refers to a foam having a plurality of cells, at least 95% of which are closed cells. However, in the present application, the cells may be "open cells", closed cells, or a mixture thereof (i.e., certain embodiments disclosed herein may exhibit an "open cell" foam structure or a blend of open cells and closed cells).

[0032] The term "R-value" is a unit used to measure the thermal insulation effect and is the reciprocal of the thermal conductivity. For a foam board material having substantially parallel faces, the R-value is the heat energy (BTU / hr or watts) per unit area (square feet = ft 2 or square meters = m 2 ) per 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 (1) Where "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 in hr·ft 2 ·°F / BTU.

[0033] As used herein, the thickness (T1) of an insulation product can be determined in accordance with ASTM C167-18, and both the k-value and the areal weight (lb / ft 2 ) can be determined in accordance with ASTM C578 or ASTM C177-19.

[0034] This disclosure relates to foams and foamed insulating products, such as extruded or expanded polymer foams, formed from a foaming material, a foaming agent composition, and a composition containing a barrier coating or barrier additive that stops or slows the diffusion rate of the foaming agent composition, thereby enabling the use of lower concentrations of conventional halogenated foaming agents, such as hydrofluorocarbons (HFCs), hydrochlorofluorocarbons, hydrofluoroethers, hydrofluoroolefins (HFOs), and hydrochlorofluoroolefins (HCFOs), and replacing the removed amount of halogenated foaming agent with carbon dioxide. The resulting insulating foams, surprisingly, do not contain subjet barrier coatings or additives and achieve R values ​​comparable to those of insulating products containing conventional concentrations of fluorinated foaming agents.

[0035] While the subject matter disclosure primarily describes polymer foam insulation, it should be understood that the concepts of the present invention are equally applicable to non-polymer foam insulation such as bubble glass insulation and aerogel insulation. In addition, the following disclosure provides an exemplary method (extrusion method) for forming insulating products, but it should be understood that other methods for forming insulating products such as spray foam and expanded foam are intended herein.

[0036] Figure 1 shows an extruder 100 useful for manufacturing polymer insulating products (e.g., XPS) according to the concept of the present invention. The extruder 100 may include a single-screw or twin-screw (not shown) screw extruder, which includes a barrel 102 surrounding a screw 104 provided with helical flights 106. The screw 104 is surrounded by the barrel 102. The helical flights 106 are configured to compress and thereby heat the material introduced into the screw extruder. As shown in Figure 1, the polymer composition may be transported from one or more (not shown) feed hoppers 108 to the screw extruder as a fluid solid such as beads, granules, or pellets, or as a liquid or semi-liquid molten material.

[0037] As the basic polymer composition advances through the screw extruder, the spacing between flights 106 decreases, continuously narrowing the space through which the polymer composition is forced to pass due to the rotation of the screw. This decrease in volume acts to raise the temperature of the polymer composition to obtain a polymer melt (when using solid starting material) and / or to raise the temperature of the polymer melt.

[0038] As the polymer composition advances through the screw extruder 100, one or more ports may be provided through the barrel 102, each equipped with associated devices 110, 112 for injecting one or more blowing agents and optional additives into the polymer composition. In some embodiments, a barrier coating composition may be added through one or more of the ports, as described in more detail below. Once the blowing agents are introduced into the polymer composition, the resulting mixture is subjected to some additional blending sufficient to disperse each component substantially uniformly throughout the polymer composition, thereby obtaining a polymer foaming composition.

[0039] The polymer foaming composition is then extruded 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 advances through a continuously increasing opening provided in the die, or through some suitable device (not shown) provided downstream of the extrusion die to control to some extent the pressure applied to the polymer foaming composition. 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 foamed insulating product (hereinafter interchangeably referred to as “foamed product,” “foamed insulating product,” and / or “insulating product”).

[0040] 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 foamed insulating 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 insulating product. The insulating 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 insulating product using, for example, any 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 also be employed and are intended within the scope of the disclosure of the present invention.

[0041] The barrier coating composition is preferably applied to the insulating product as soon as possible after production (i.e., after extrusion, expansion, or other foam production method), for example, within a period of less than 12 hours after 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 after 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 insulating product. Although it has been described as being applied to one or more main surfaces of the insulating product, it should be understood that the barrier coating composition may also be applied additionally or alternatively to one or more secondary surfaces of the insulating product. In any embodiment, the barrier coating composition may be applied to each surface of the insulating product. For example, the barrier coating composition may be applied to one or more edges of the insulating product in addition to, or instead of, the top and / or bottom surfaces of the resulting polymer insulating product. The barrier coating may be applied to form a continuous coating on one or more surfaces of the insulating 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.

[0042] In any of the exemplary embodiments, the barrier coating composition may be applied directly to the surface of an insulating product without an intervening layer between the surface of the insulating product and the barrier coating composition. Optionally, an additional coating layer, including an additional coating layer of the barrier coating composition, may be applied on the first barrier coating composition layer. However, in some cases, one or more optional primer layers may be applied between the barrier coating composition and the surface of the insulating product, thereby indirectly applying the barrier coating composition to the surface of the insulating product (for example, applying the barrier coating composition to a primer layer on the surface of the insulating product).

[0043] In any of the exemplary embodiments, the barrier coating composition may act as an adhesive for fixing one or more additional layers to the insulating product.

[0044] Furthermore, in any of the exemplary embodiments, it is intended that the barrier coating compositions described herein can be incorporated into a foamed composition. For example, instead of applying (or in addition to applying) the barrier coating composition as a coating to 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 can be introduced into a feed hopper in the form of pellets. It should be understood that certain properties of the barrier coating composition injected into the extruder may differ from those of a barrier coating composition intended to be coated onto the surface of a polymer insulating product, such properties include, but are not limited to, the viscosity of the coating composition and the solid content filling of the barrier coating.

[0045] 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 can also be incorporated, provided they can impart gas barrier properties to the coating, or at least do not inhibit them.

[0046] In any exemplary embodiment, the barrier polymer may be a homopolymer or a copolymer comprising one or more comonomers, for example, but not limited to vinyl chloride; vinyl alcohol; vinyl esters, such as vinyl acetate; vinyl ethers; acrylic acid; acrylic acid esters; acrylamides; methacrylic acid; methacrylic acid esters; methacrylamide; acrylonitrile; N-vinylpyrrolidone; methacrylonitrile; styrene; styrene derivatives; butadiene; olefins, such as 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 its salts, e.g., sodium salt, 2-sulfoethyl methacrylic acid (2-SEM) or its salts, e.g., sodium salt, and phosphate esters of methacrylate-terminated polypropylene glycol or its salts, e.g., sodium salt, poly(ethylene oxide) methyl ether acrylate (PEOA), poly(ethylene oxide) methyl ether methacrylate (PEOMA).

[0047] In any of the exemplary embodiments, the barrier polymer is at least a semicrystalline polymer with a minimum crystallinity of 5%. In particular, barrier polymers having a crystallinity of at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, provide 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%.

[0048] 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.

[0049] When provided in the form of a dispersion, the barrier polymer can be present with a solids content of about 20% to about 100% by weight based on the weight of the dispersion, including, for example, solids content of 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 endpoint or sub-range solids content contained therein.

[0050] The barrier polymer may 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, based on the total amount of solids present in the barrier coating composition, and may include, 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 present therein.

[0051] 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); rheological 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.

[0052] Examples of rheological 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-swellable 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.

[0053] The viscosity of the barrier coating composition is important to ensure that the coating can be applied by the specific method intended, such as spraying, coating, or dipping. Therefore, the rheological modifier may be included in concentrations such as those that achieve a coating viscosity of less than about 5000 cP at about 75°F and 70% solids or less, including less than about 4000 cP at about 75°F and 70% solids or less, less than about 3500 cP at about 75°F and 70% solids or less, less than about 3000 cP at about 75°F and 70% solids or less, less than about 2500 cP at about 75°F and 70% solids or less, less than about 2000 cP at about 75°F and 70% solids or less, less than about 1500 cP at about 75°F and 70% solids or less, and less than about 1000 cP at about 75°F and 70% solids or less. The following include temperatures below approximately 75°F and 70% solids content with less than approximately 750 cP, below approximately 500 cP, below approximately 250 cP, below approximately 75°F and 70% solids content with less than approximately 200 cP, below approximately 75°F and 70% solids content with less than approximately 150 cP, below approximately 100 cP, below approximately 75°F and 70% solids content with less than approximately 300 cP, and below approximately 75°F and 70% solids content with less than approximately 200 cP. 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% or less 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.

[0054] Accordingly, in various embodiments 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 solid 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 0.3% to 2% by weight, encompassing all sub-ranges and endpoints between these.

[0055] 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 a volatile base or a non-volatile base. 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.

[0056] The pH of the barrier coating composition is preferably between 2 and 10, including pH values ​​of 3 to 8 and 4 to 7. In any of the embodiments disclosed herein, the barrier coating composition may have a neutral pH of 6 to 7.

[0057] In various embodiments 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 0.9% to 2% by weight, encompassing all sub-ranges and endpoints between these.

[0058] Since the barrier coating composition can be applied to one or more surfaces of a foamed insulating product, it is important that the coating adequately wets the foam surface, spreads over it, and achieves 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 foamed product. Specifically, the barrier coating composition is formulated to have a surface tension of 40 mN / m or less on the surface energy of the foamed product, including surface tensions of 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 on the surface energy of the foamed product. In any of the exemplary embodiments, the barrier coating composition has a surface tension approximately (+ / - 5%) equal to the surface energy of the foamed product. In any of the exemplary embodiments, the barrier coating has a surface tension less than or equal to the surface energy of the foamed product.

[0059] Insulating 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, encompassing all endpoints and partial ranges between these.

[0060] 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 insulating 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, including all endpoints and partial ranges between these. 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.

[0061] To adjust the surface tension of the 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 a cationic and anionic center bonded to the same molecule.

[0062] According to this disclosure, one or more surfactants may include or consist of one or more anionic surfactants. Exemplary 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 Examples include: lononanoic 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; and mixtures thereof.

[0063] 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.

[0064] 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.

[0065] According to this disclosure, one or more surfactants may comprise 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 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)ethanols (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); hexitols including sorbitan, sorbide, mannitane, 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, dodecyl, Examples include: condensates prepared by condensing higher alkyl mercaptans such as tetradecyl mercaptans, or alkylthiophenols containing about 6 to about 15 carbon atoms in the alkyl group; ethylene oxide derivatives of long-chain carboxylic acids (e.g., lauric acid, myristic acid, palmitic acid, and oleic acid, such as 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.

[0066] Examples of surfactants include Dynol 607, which is 2,5,8,11-tetramethyl-6-dodecine-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-decine-4,7-diol surfactants; Stanfax (sodium lauryl sulfate); SURFADOL® 420 (which is 2,4,7,9-tetramethyl-5-dodecine-4,7-diol ethoxylate); and Surfynol. Examples include 465 (ethoxylated 2,4,7,9-tetramethyl 5-dodecine-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.

[0067] The wetting agent may be present in the barrier coating composition in amounts ranging from 0 to about 15% by weight, based on the total solids content in the barrier polymer material, for example, 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 these.

[0068] 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, perfluoroalkylethyl 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 insulating 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, comprising 0.5% to 25% by weight, 1% to 20% by weight, or 5% to 15% by weight of the barrier coating composition, based on the total amount of solids present in the composition.

[0069] Optionally, the barrier coating composition may include 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 an amount of 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 an amount of 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.

[0070] 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, and hindered amine light stabilizers (HALS) (e.g., BASF Tinuvin® 479-DW ECO, 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, a benzotriazole UV light absorber from SI Group; liquid hydroxyphenyl-triazine (HPT) stabilizers such as Omnistab® UV400 available from Partner in Chemicals; amino ether functional group-based HALS stabilizers such as Omnistab® LS123 available from Partner in Chemicals; and benzotriazole UV absorbers such as Eversorb® 81 and Eversorb® 95 available from Everlight USA, Inc.). If present, UV absorbers / stabilizers may be included in the barrier coating composition in amounts of 0% to 10% by weight, based on the total solids content of the barrier coating composition, including 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 these.

[0071] 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 present, flame retardants may be included in the barrier coating composition in any amount to achieve a limiting oxygen index (LOI) of more 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 flame 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, and include any endpoints and partial ranges between these.

[0072] 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 defoaming agent available from BASF; Foamstar® ED 2522 NC, an ultra-low SVOC silicone emulsion defoaming agent; Foamstar® ST 2210 NC (formerly Dehydran® 1620), a specially modified alcohol and polysiloxane adduct; and BYK-035 9, a VOC-free mixture of paraffin-based mineral oil and hydrophobic components containing silicone, available from BYK; ACME Examples of defoamers available from Tech include Surfadol® DF-75, a 100% active nonionic defoamer based on acetylenediol, Surfadol® 560 (silicone-containing defoamer), and Surfadol® 532 (acetylenediol molecular defoamer). If present, the defoamer 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 0.01% to 8% by weight, 0.05% to 6% by weight, 0.06% to 5% by weight, 0.08% to 3% by weight, 0.1% to 2% by weight, 0.15% to 1% by weight, or 0.18% to 0.5% by weight, including any endpoints and partial ranges between these.

[0073] 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 matte properties. 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 (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 Lubrizofl), 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, encompassing all sub-ranges and endpoints between these.

[0074] Other additives are also conceived and possible. The amount of such additives may vary depending on the particular embodiment and may generally range from 0% to 30% by weight, based on the total solids content of the barrier coating 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 these.

[0075] 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 composition ranges disclosed in the above paragraphs. The following composition ranges are intended to encompass and include all endpoints and sub-ranges within the disclosed ranges.

[0076] [Table 1]

[0077] The barrier polymer can be dispersed in water and / or a solvent with any additives and mixed 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 to the surface of the insulating product without the use of adhesives, primers, or other layers between the barrier coating and the surface of the insulating product. Thus, in any of the embodiments disclosed herein, the insulating product does not have a polyamide primer coating applied to the insulating product before the barrier coating composition.

[0078] Barrier coating compositions have a specific degree of crystallinity based on the crystallinity of the polymers used in the composition, but this crystallinity is affected by various additives contained in the composition, such as wetting agents and rheological 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 foamed product.

[0079] While not intended to be constrained 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 The following, and 30g / m 2 Including the following application weight, 250g / m 2 It is applied with a coating weight of less than 5 g / m². In one of the exemplary embodiments, 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 It may be applied to one or more surfaces of a polymer foam board with a coating weight, including all endpoints and partial areas between them.

[0080] Optionally, multiple coatings may be applied to one or more surfaces of the polymer insulating product. Such additional coatings may be added, for example, to enhance the properties of the barrier coating or to protect the barrier coating. In embodiments, one or more additional coatings can impart hydrophobicity or water resistance to the coated insulating 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.

[0081] 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 insulating product. In other embodiments, one or more additional coatings may be applied between the barrier coating and the surface of the insulating product. The one or more additional coatings are not particularly limited and may be the same as or different from the barrier coating. In 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 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 the embodiment, at least one additional coating comprises one or more polyurethanes, epoxys, acrylics, or combinations thereof.

[0082] In such embodiments, an additional coating layer is applied on top of a barrier coating insulating product, and the additional coating preferably has a surface tension specifically adjusted to match the surface energy of the barrier coating insulating product. Therefore, one or more additional coatings are specifically formulated to have a surface tension of 20 mN / m or less on the surface energy of the barrier coating insulating product, including 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 on the surface energy of the barrier coating insulating 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 on the surface energy of the coated foam product.

[0083] 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.

[0084] In any of the exemplary embodiments disclosed herein, the foaming composition may comprise any material that can be foamed, such as a foaming polymer (referred to herein 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 to the process used 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.

[0085] 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 blocker polymer ("ASA"), polysulfone, polyurethane, polyphenylene sulfide, acetal resin, polyamide, polyaramid, polyimide, polyacrylic acid esters, copolymers of ethylene and propylene, copolymers of styrene and butadiene, copolymers of vinyl acetate and ethylene, rubber-modified polymers, thermoplastic polymer blends, and combinations thereof.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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 an amount 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 embodiments, the matrix polymer may be present in an amount 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.

[0090] In any of the exemplary embodiments, the barrier coating compositions described herein can be incorporated into a foamed composition. For example, instead of applying (or in addition to applying) the barrier coating composition as a coating to at least one surface of an insulating product, the barrier coating composition can be injected into a screw extruder 100. In embodiments where the polymer of the barrier coating composition is a resin, the polymer can be introduced into the feed hopper 108 in pellet form. It should be understood that certain properties of the barrier coating composition injected into the extruder may differ from those of a barrier coating composition intended to be coated onto the surface of a polymer insulating product, including, but not limited to, the viscosity of the coating composition and the solids content of the barrier coating composition.

[0091] As described above, the foamed insulating product is formed from a composition containing a foaming agent composition. According to one aspect of the present invention, the foaming agent composition comprises one or more of CO2, fluorinated foaming 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 foaming agent comprises one or more of CO2, ethanol, HFOs, HCFOs, HFCs, and mixtures thereof.

[0092] 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 25ye) 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-l-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.

[0093] 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 (HFO-1336mzz-Z) and / or trans (HFO-1336mzz-E) isomers); and (cis and / or trans)-1,3,3,3-tetrafluoropropene (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.

[0094] Fluorinated alkenes, if present, may be present in the blowing agent composition in amounts of 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, 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 an amount 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 these.

[0095] 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 an amount of 10% by weight, 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.

[0096] In any embodiment disclosed herein, the fluorinated alkene may be present in the foaming polymer composition in an amount 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, encompassing all endpoints and partial ranges between these.

[0097] According to any aspect of the present 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, including, 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. According to any embodiment, the first fluorinated alkene may be present in the blowing agent composition in an amount of 5 to 60% by weight, including, for example, 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, encompassing all endpoints and partial ranges between these. 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, for example, 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, encompassing all endpoints and partial ranges between these. The first fluorinated alkene may include C4 to C6 fluorinated alkenes having a molecular weight of at least 150 g / mol. An example of a first fluorinated alkene is 1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz) (including its cis (HFO-1336mzz-Z) and / or trans (HFO-1336mzz-E) isomers). A second fluorinated alkene may include C2-C3 fluorinated alkenes having a molecular weight of less than 150 g / mol. An example of a second fluorinated alkene is 1,3,3,3-tetrafluoropropene (HFO-1234ze) (including its cis (HFO-1234ze-Z) and / or trans (HFO-1234ze-E) isomers).

[0098] Alternatively, the amount of fluorinated alkenes may be characterized by the amount in moles per 100 grams of matrix polymer. Thus, when characterized in this way, the total amount of fluorinated alkenes can be present in the foaming polymer composition in amounts 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, the total amount of fluorinated alkenes can be present in amounts of 0 moles to less than 0.1 moles per 100 grams of matrix polymer, including 0.0001 moles to 0.025 moles, 0.0005 moles to 0.022 moles, 0.001 moles to 0.02 moles, and 0.005 moles to 0.019 moles per 100 grams of matrix polymer, encompassing all endpoints and sub-ranges between these. Surprisingly, it was 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 insulating foams with sufficient mechanical and thermal performance. 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.

[0099] Surprisingly, it has been found that the total concentration of fluorinated alkenes can be substantially reduced from the blowing agent composition by the use of the subject barrier coating composition, and in some embodiments, can be eliminated, without adversely affecting the thermal properties of the polymer foam (i.e., still achieving a minimum 180-day R / in value of at least 4.8, preferably at least 5). In such embodiments, the blowing agent composition may not contain fluorinated alkenes, or may contain them in amounts of less than 4% by weight, less than 3.5% by weight, less than 3% by weight, less than 2.5% by weight, or less than 2% by weight, based on the total weight of the polymer insulating product.

[0100] The blowing agent composition may optionally contain one or more co-blowing agents, such as hydrocarbons, hydrofluorocarbons ("HFCs"), hydrochlorofluorocarbons ("HCFOs"), carbon dioxide, methyl formate, methylal, and water. If present, the co-blowing agents may be included in the blowing agent composition in amounts of at least 0.1% by weight, including 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, 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% or less, which includes 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 an amount 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, encompassing all endpoints and partial ranges between these.

[0101] 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 isopropanol.

[0102] The blowing agent may optionally contain one or more hydrofluorocarbons. The specific hydrofluorocarbons used are not particularly limited. Non-exclusive examples of suitable blowing HFC blowing agents include 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-hexafluoro Examples include propane (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®, including, but not limited to, FORMACEL® B and FORMACEL® Z6.

[0103] Exemplary blowing agent compositions, based on the total weight of the blowing agent composition, include 15% to 60% by weight of a fluorinated alkene selected from HFO-1336mzz, HFO-1234ze, or mixtures thereof, 40% to 85% by weight of HFC-152a, and optionally the remainder being carbon dioxide, encompassing all endpoints and partial ranges between these. In other words, exemplary blowing agent compositions, based on the total weight of the blowing polymer composition, may include 2% to 5% by weight of HFO-1336mzz and / or HFO-1234ze, 2.5% to 6% by weight of HFC-152a, and optionally the remainder being carbon dioxide, and compositions, based on the total weight of the blowing polymer composition, may include 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. Further exemplary blowing agent compositions may include, 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; and 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.

[0104] The 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).

[0105] 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.

[0106] 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.

[0107] As described above, aspects of the concept of the present invention relate to the finding that the total concentration of fluorinated alkenes can be substantially reduced from the blowing agent composition by the use of the subject barrier coating composition, and in some embodiments can be eliminated, without adversely affecting the thermal properties of the polymer foam (i.e., still achieving a minimum 180-day R / in value of at least 4.8, preferably at least 5). In such embodiments, the blowing agent composition 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.

[0108] In addition to CO2, the blowing agent composition may optionally contain co-blowing agents, such as methyl formate, methylal, ethanol, isobutane, propylene carbonate, etc., in amounts of 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, 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-blowing agent may be present in the blowing agent composition in an amount of 50% or less, including amounts of 45% by weight or less, 40% by weight or less, 38% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, and 10% by weight or less. In any of the exemplary embodiments, the co-foaming agent may be present in the foaming agent composition in an amount of 1% to 50% by weight, which includes, for example, 3% to 45% by weight, 5% to 40% by weight, 8% to 35% by weight, 10% to 30% by weight, and 12% to 27% by weight, and includes all endpoints and sub-ranges between these.

[0109] In other words, the co-foaming agent may be included in the foaming polymer composition in amounts of up to 5% by weight, based on the total weight of the foaming polymer composition, including amounts of 0.1% to 4.5% by weight, 0.25% to 4% by weight, 0.5% to 3.5% by weight, 0.75 to 3.25% by weight, 1 to 3% by weight, 1.25 to 2.5% by weight, and 1.3 to 2% by weight, based on the total weight of the foaming polymer composition.

[0110] Exemplary blowing agent compositions, based on the total weight of the blowing agent composition, contain 0 to 80% by weight of fluorinated alkenes and 20% to 100% by weight of carbon dioxide, encompassing all endpoints and partial ranges between these. For example, a blowing agent composition may contain 0 to 60% by weight of fluorinated alkenes selected from HFO-1336mzz, HFO-1234ze, or mixtures thereof, and 40% to 100% by weight of carbon dioxide, encompassing all endpoints and partial ranges between these. In other words, an exemplary blowing agent composition may contain 0 to 4% by weight of fluorinated alkenes and 2.5% to 7% by weight of carbon dioxide, based on the total weight of the foaming polymer composition, and may include a composition containing 3% or less of fluorinated alkenes and at least 2% by weight of carbon dioxide, based on the total weight of the foaming polymer composition. Further exemplary blowing agent compositions may contain 0.2 to 2% by weight of fluorinated alkenes and 2.5% to 6% by weight of carbon dioxide, based on the total weight of the foaming polymer composition.

[0111] Exemplary blowing agent compositions may contain, based on the total weight of the blowing polymer composition, 1 to 5% by weight of carbon dioxide and 0.2 to 3.5% by weight of one or more co-blowing agents, such as methyl formate, methylal, ethanol, isobutane, propylene carbonate, etc., and include compositions containing 1.8 to 4% by weight of carbon dioxide and 0.7 to 2.5% by weight of one or more co-blowing agents, and compositions containing 2 to 3.6% by weight of carbon dioxide and 0.9 to 2% by weight of one or more co-blowing agents. Further exemplary blowing agent compositions may contain 2.5 to 3.5% by weight of carbon dioxide and 1 to 1.7% by weight of methyl formate (or other suitable solubilizer), based on the total weight of the blowing 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 of fluorinated alkenes based on the total weight of the foaming polymer composition, which includes amounts of 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, encompassing all endpoints and partial ranges between these.

[0112] 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, and 80% to 96% by weight of CO2 and 3% to 12% by weight of one or more hydrocarbons, encompassing all endpoints and partial ranges between these.

[0113] 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 2% by weight, which includes at least 2.8% by weight, at least 3% by weight, at least 3.3% by weight, at least 3.5% by weight, at least 3.8% by weight, at least 4% by weight, at least 4.3% by weight, at least 4.5% by weight, at least 4.7% by weight, and at least 5% 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, which includes 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. In any embodiment intended herein, the foaming agent composition may be present in the foaming composition in an amount of 2% to 7% by weight, comprising 2.5% to 6.8% by weight, 2.7% to 6.5% by weight, 2.9% to 6% by weight, and 3% to 5.5% by weight.

[0114] 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 can be present in the foaming polymer composition in amounts of 0.001 moles to less than 0.1 moles per 100 grams of polymer, which includes 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 composition.

[0115] 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 increases the amount of foaming agent and therefore increases the foaming force.

[0116] Surprisingly, it has been found that the use of the barrier coating compositions described herein allows for a reduction or elimination of fluorinated blowing agents compared to the same foamed product without barrier coating, resulting in polymer insulating products with sufficient insulation values. For example, conventionally, a minimum level of fluorinated blowing agent was required to achieve polymer insulating products with an R value of at least 5. Although more readily available, cost-effective, and environmentally friendly, CO2 could not constitute the majority of the blowing agent composition because it diffuses almost entirely from the foam during production, resulting in unacceptably low insulation values. However, in some exemplary embodiments, the amount of fluorinated blowing agent can be reduced and replaced with CO2 without adversely affecting thermal performance. Therefore, although the total amount of foaming agent used in polymer insulating products may not change, the amount of fluorinated foaming agent may be reduced by at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 50% by weight, at least 55% by weight, or at least 50% by weight and replaced with CO2, and still polymer insulating products having an insulation value of at least R-5 can be produced.

[0117] 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. The 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.

[0118] As described above, the foaming composition may further contain at least one infrared attenuating agent (IAA) to increase the R value of the resulting foamed 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.

[0119] 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.

[0120] Nanographite may or may not be chemically modified or surface-modified, and may be incorporated into polyethylene methyl acrylate copolymer (EMA) used as both a medium and a support for the nanographite. Other possible supports for 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.

[0121] 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 bubble size of air bubbles in the foam, resulting in an undesirable final foamed product. In particular, smaller bubble sizes tend to increase board bulk density, increase product cost, and reduce 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% by weight of an infrared attenuator, such as graphite, including less than 0.2% by weight, less than 0.15% by weight, less than 0.10% by weight, and less than 0.05% by weight. In any of the exemplary embodiments, the foaming composition and the resulting foamed product do not contain an infrared attenuator, such as graphite. In such embodiments, it should be understood that the size of the foam bubbles 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 attenuator may be included in the barrier coating composition in addition to, or instead of, the foaming polymer.

[0122] 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.

[0123] After the foaming agent composition, barrier coating composition, and optional additional additives are introduced into the foaming polymer 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.

[0124] The foaming polymer compositions disclosed herein can be used to produce rigid foamed polymer insulating products by any manufacturing process, such as extrusion, expansion, reaction mixing, spraying, and bubbling. Such foamed products have a cellular structure with bubbles defined by cell membranes and struts. The struts are formed at the intersections of the cell membranes, and the cell membranes cover cell windows that interconnect the struts.

[0125] In some exemplary embodiments, polymer insulating products have an average density of less than 10 pcf (pounds per cubic foot) when produced under atmospheric conditions, including less than 5 pcf, less than 3 pcf, and less than 2.5 pcf. However, when polymer insulating products are produced under vacuum, the density may be lower. In any of the exemplary embodiments, the polymer insulating 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 polymer insulating 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.

[0126] It should be understood that the phrase "substantially closed-cell" means that all or nearly all of the bubbles in the bubble structure of an insulating product are closed. For example, "substantially closed-cell" may mean that 30.0% or less of the bubbles are open-cell, and in particular, 10.0% or less, or 5.0% or less, are open-cell or otherwise "unclosed" bubbles. A closed-cell structure helps to increase the R value of the formed foamed insulating product. However, it should be understood that while generating an open-cell structure is within the scope of various embodiments, such an open-cell structure is not an exemplary embodiment.

[0127] The average bubble size of polymer insulating products may range from 0.005 mm (5 microns) to 0.6 mm (600 microns), and in some exemplary embodiments, it may range 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).

[0128] The coated insulating products disclosed herein, when coated with the subject barrier coating composition, exhibit an insulating value (R value) greater than 4.5 per inch and maintain an R value of at least 4.5 after 180 days. In any of the exemplary embodiments, the coated insulating product may have an R value of at least 5, or at least 5.3, or at least 5.5, or at least 5.7, or at least 6 per inch after 180 days. In any of the exemplary embodiments, the R value per inch may be at least 5, or at least 5.5, or at least 6, or at least 6.5, or at least 7 after 7 days, 25 days, 60 days, or 180 days.

[0129] Furthermore, the foaming composition can produce foamed products having high compressive strength, which defines the foamed material's ability to withstand axial pressure. In some exemplary embodiments, the foam has a compressive strength in the range of about 6 to 120 psi. In some exemplary embodiments, the compressive strength of the foamed product is 10 to 110 psi, including 20 to 100 psi, 30 to 80 psi, and 35 to 60 psi. In various exemplary embodiments, the compressive strength of the foamed product is 40 to 50 psi.

[0130] The insulating products intended herein can be used to form a variety of products, including rigid insulating boards, insulating 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). Insulating products can also be used in multi-material covering systems. A covering system may include one or more panels that can be attached to the frame of a structure to form a covering 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 insulating panels. Structural parts may include single-layer materials or multi-layer structures. For example, the structural parts 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-structured layers, high-density polyethylene (HDPE) layers, polymer-based composites, or any other structural layers. In some embodiments, the structural portion is a structural barrier layer comprising glass fiber, polycarbonate, polypropylene, high-density polyethylene, or wood composite material. One or more insulating layers include, or may consist of, the insulating foam products of the subject disclosed herein. In any of the exemplary embodiments, the coating system may include an insulating product bonded to the structural portion, or a barrier layer bonded to a first surface of the insulating product and a structural portion bonded to a second surface of the insulating product.

[0131] The concept of the present invention has been described above both comprehensively and with respect to various exemplary embodiments. While the comprehensive concept of the present invention has been described with respect to what are considered exemplary embodiments, a wide variety of alternative forms known to those skilled in the art can be selected within the comprehensive disclosure. In addition, the following examples are intended to better illustrate the present invention, but are not intended to limit the comprehensive concept of the present invention. [Examples]

[0132] Example 1 Samples of extruded polystyrene foam were prepared using a co-rotating twin-screw extruded foam production line. Polystyrene was melted in the extruder and mixed with an injected blowing agent composition to form a homogeneous foamed composition. The foamed composition (excluding the blowing agent) of each sample contained polystyrene, a flame retardant masterbatch, and a graphite (or infrared attenuator) masterbatch. The blowing agent blend was present in a nearly constant total amount across all samples. The blowing agent blends are provided in Table 2 below (based on the total weight of the foamed composition) and generally contained fluorinated alkenes and / or CO2, thereby gradually decreasing in concentration and being replaced by CO2. Methyl formate, a co-blowing agent, was included in the blowing agent blend. The foamed compositions were then extruded to a density of approximately 2.1–2.2 lb / ft. 3 A 1-inch XPS foam sample was generated.

[0133] [Table 2]

[0134] During formation, eight XPS foam samples (Examples 1-8) were coated on all surfaces with a partially crystalline PVDC-based barrier coating composition at the coating weights detailed in Table 3 below. Eight additional samples of the corresponding compositions were left uncoated as Comparative Examples 1-8.

[0135] The characteristics of each sample are shown in Table 3 below. For each example, the thermal conductivity was measured at time intervals of approximately 7, 20, 30, 60, 120, and 180 days. The k-value (Btu·in / h·ft) at 180 days was calculated. 2 The values ​​(°F) are reported in Table 3. The 180-day R-value is calculated from the reciprocal of the 180-day k-value and is also reported in Table 3, along with the compressive strength and compressive modulus (measured according to ASTM C578 and CAN UL S701), as well as the open-cell content (%).

[0136] [Table 3]

[0137] As is conventionally known, the R value for 5 is 0.20 Btu·in / h·ft 2 This is achieved with a thermal conductivity of less than 30°F. As shown in the graph in Figure 2, in the uncoated XPS foam sample, replacing HFO with an increased amount of CO2 increased the k value throughout the board, and even after only 7 days, it did not achieve an R value of 5 or higher. However, each of Examples 1-8 achieved an R-5 insulation value after 7 days, and Examples 2 and 8 maintained an R-5 insulation value even after 60 days. Since both Examples 2 and 8 contained an unprecedentedly high concentration of CO2, the result was 30 g / m 2 The use of subject barrier coating compositions with less than a coating weight was found to facilitate the production of R-5 XPS insulating products with a large proportion of CO2-containing foaming agents and, if present, minimal HFO.

[0138] The graph in Figure 2 further illustrates the improvement in the k-value over time that the barrier coating provides to XPS foam samples. Specifically, the coating significantly improves the k-value of the XPS foam, even when using a blowing agent composed mostly of CO2 rather than fluorinated alkenes, and in particular, enables the production of XPS foam products with a low coating weight (30 g / m²) and an R-value of at least 5. 2 It is effective in cases of less than [amount].

[0139] Example 2 Extruded polystyrene foam samples were prepared using a co-rotating twin-screw extrusion foam line. Polystyrene was melted in the extruder and mixed with the injected blowing agent composition to form a homogeneous foamed composition. The foamed compositions of comparative samples B-E and samples A-D (excluding blowing agent) contained polystyrene and a flame retardant masterbatch. The foamed compositions of comparative samples A and F, and samples F and G (excluding 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 increased to maintain a constant total amount of blowing agent. The foamed compositions were then extruded to produce 1-inch XPS foam samples, each with a density of approximately 1.83 pcf.

[0140] The coated samples were coated with a barrier coating composition containing PVOH (aqueous dispersion of polyvinyl alcohol). The characteristics of each sample are shown in Table 4 below.

[0141] [Table 4]

[0142] As shown in Table 4, 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 180-day k-value from 0.2009 to 0.2262 Btu. * in / h·ft 2 As the temperature increases to °F, 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 insulation value of R-5 even when the concentration of fluorinated alkenes was reduced to less than 2% by weight.

[0143] Furthermore, removing graphite from the foam composition increased the k coefficient (Comparative Examples B-E compared to Comparative Example A), and the effect on the k coefficient was small even when the amount of fluorinated alkene foaming agent increased. However, when the barrier coating of the present invention was used in the foam (Examples A-D), the k coefficient decreased to a lower value than the control (comparative sample A).

[0144] In particular, as shown in Figures 3 and 4, the greatest improvement in insulation properties was achieved by combining an increase in the amount of PVOH-based barrier coating and fluorinated alkene blowing agent. However, the graphs in Figures 3 and 4 show that equivalent or improved insulation properties can be obtained even with less blowing agent.

[0145] Example 3 A barrier coating composition containing DIOFAN® A050 (a PVDC dispersion containing approximately 58% by weight of solids, commercially available from Solvay) was brush-applied to various surfaces of 1-inch XPS foam samples at various coating weights, as shown in Table 5 below. The XPS foam was formed using a foaming agent composition containing a blend of HFO-1336mzz-Z and HFC-152a.

[0146] [Table 5]

[0147] As shown in Table 5 and the graph in Figure 5, the effect of the barrier coating on significantly slowing the diffusion rate of the foaming agent increased with increasing coating weight. This is indicated by the improvement in the R value and the decrease in the 180-day k value compared to the control (Comparative Example G).

[0148] Example 4 Extruded polystyrene foams containing various foaming agent compositions were prepared and coated with barrier coating compositions according to the concept of the present invention. The effect of the barrier coating on the thermal conductivity of the foam was evaluated. Each foaming composition is shown in Table 6 below.

[0149] [Table 6]

[0150] In Examples K-O, a barrier coating containing DIOFAN® A050 was applied to all surfaces of the foam samples, including the edges, at varying coating weights. Comparative samples H-L were control samples and no barrier coating was applied. In Example P, each main surface (e.g., top and bottom) was coated with a DIOFAN® A050-based coating, but the secondary surfaces were not. In Examples Q-S, the top and bottom surfaces were coated, along with one, two, and three secondary surfaces, respectively. In Example T, only four secondary surfaces were coated.

[0151] For each example, the thermal conductivity was measured at time intervals of approximately 7, 20, 30, 60, 120, and 180 days. Thermal conductivity (k-value) (Btu·in / h·ft) 2 The values ​​(°F) are reported in Table 7. The R-value at 180 days is calculated from the reciprocal of the thermal conductivity over 180 days, and this is also reported in Table 7.

[0152] [Table 7]

[0153] The graph in Figure 6 plots the thermal conductivity (k-coefficient) (y-axis), measured as a function of days (x-axis), for samples containing both 1% by weight isobutane and 0.25% by weight isobutane as foaming agents (Comparative Examples H and K, and Examples K and N), regardless of the presence or absence of barrier coating. From Table 7 and Figure 6, it can be seen that applying a DIOFAN® A050-based coating is effective in reducing the thermal conductivity of polymer insulating products, and as a result, the R-value of the polymer insulating product remains above 5 over a long period of time compared to an identical polymer insulating product except for the uncoated one. In particular, for the samples tested in this example, an R-value of 5 corresponds to 0.20 Btu·in / h·ft 2 This is achieved with a thermal conductivity of less than 5°F. As shown in Figure 6, no comparative example achieved an R value of 5 at any point. However, Example N achieved approximately k 15An R value of 5 was achieved, and in Example K, k 30 The R value of 5 was maintained, which is a significant improvement over the comparative example and supports the conclusion that an R-5 insulation value can be achieved when a polymer insulating layer formed with CO2 (excluding any fluorinated alkenes) is manufactured with the barrier coating composition disclosed herein.

[0154] The graph in Figure 7 plots the thermal conductivity (k-coefficient) (y-axis), measured as a function of time (days), for samples containing 0.50 wt% isobutane and various surfaces with barrier coatings (Comparative Example J and Examples P-T). As shown in Figure 7, the application of the barrier coating to the main surface of the polymer insulating product has the greatest effect, while coating only the edges has almost no effect (see Example T).

[0155] Example 5 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 8 below.

[0156] [Table 8]

[0157] As shown in the graph in Figure 8, each sample (Examples U-W) with at least the top and bottom surfaces coated 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 with only the edges coated (Example X).

[0158] Example 6 Samples of extruded polystyrene foam were prepared using a co-rotating twin-screw single extruded 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 9 below. Aqueous dispersions of styrene-butadiene rubber (50% by weight solids content 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 9 below.

[0159] [Table 9]

[0160] Table 10 below lists the properties of the obtained XPS foam samples.

[0161] [Table 10]

[0162] As shown in Table 10 and the graph in Figure 9, the resulting XPS foam containing 0.05% to 0.25% by weight of SBR dispersion showed improved insulation properties (e.g., lower k-value) compared to the control (Comparative Example N). In addition, the data shown in Table 9 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).

[0163] Example 7 Various amounts of one of two types of barrier coatings (aqueous dispersion of ethylene vinyl alcohol (EVOH) or aqueous dispersion of polyvinyl alcohol (PVOH)) were brushed onto various surfaces of a 1-inch XPS foam sample. The application locations of the barrier coating compositions are shown in Table 11 below.

[0164] [Table 11]

[0165] As shown in Table 11 and the graphs in Figures 10-11, both EVOH and PVOH coatings were effective in significantly slowing the diffusion rate of the foaming agent, as indicated by the improvement in the R value and the decrease in the k value at 180 days 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 leads to better thermal conductivity. Rather, approximately 36.81 g / m² coated on the sample was sufficient. 2 Example LL, which has the coating, exhibits better 180-day thermal conductivity values ​​than Examples KK, JJ, and MM, which have larger amounts of PVOH-based barrier coating applied, respectively. 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.

[0166] Example 8 As shown in Table 13 below, various barrier coatings and combinations of barrier coatings were applied to 1-inch XPS foam samples. PUD1 and PUD2 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 PUD1 or PUD2 was applied on top of the PVOH coating.

[0167] [Table 12]

[0168] As shown in Figure 12, when PUD1 and PUD2 coatings were applied individually (Comparative Examples Q and R, respectively), no barrier properties were imparted to the foam. However, when applied to the surface of an already applied PVOH coating (Sample OO and PP, respectively), the barrier properties of the PVOH coating were enhanced (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.

[0169] Example 9 Extruded polystyrene foams containing various foaming agent compositions were prepared and coated with barrier coating compositions according to the concept of the present invention. The effect of the barrier coating on the thermal conductivity properties of the foam was evaluated. Each foaming composition is shown in Table 13 below.

[0170] [Table 13]

[0171] A barrier coating composition containing DIOFAN® A050 (a PVDC dispersion containing approximately 58% by weight of solids, commercially available from Solvay) was brush-applied to various surfaces of 1-inch XPS foam samples at various coating weights, as shown in Table 14 below.

[0172] [Table 14]

[0173] As shown in Table 14 and the graph in Figure 13, the effect of the barrier coating on significantly slowing the diffusion rate of the foaming agent increased with increasing coating weight. This is indicated by an improvement in the R value and a decrease in the 180-day k value compared to the control.

[0174] Example 10 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.

[0175] The foamed composition was extruded to produce 1-inch XPS foam samples, each with a density of approximately 2.2 pcf.

[0176] Comparative sample 1 remained uncoated, while samples 1-5 were coated on at least one side with exemplary barrier coating compositions using a hand sprayer, as outlined in Table 15 below. The barrier coating compositions are shown in Table 16 below.

[0177] [Table 15]

[0178] [Table 16]

[0179] The thermal conductivity of each sample was tested according to ASTM C578 (70°F and 45% relative humidity) at intervals of 7 days (k7), 20 days (k20), 30 days (k30), 60 days (k60), 120 days, and 180 days, and the performance is shown in Table 17 below.

[0180] [Table 17]

[0181] As shown in Table 17, the uncoated comparison sample reached 0.175 BTU·in / h·ft as early as day 20 (k20). 2Although they exhibited a thermal conductivity k value exceeding °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.

[0182] Example 11 Extruded polystyrene foam samples were prepared using a co-rotating twin-screw extruded 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.

[0183] The foamed composition was extruded to produce 1-inch XPS foam samples, each with a density of approximately 2.3 pcf.

[0184] Comparative sample 2 remained uncoated, while samples 6–10 were coated on at least one side with exemplary barrier coating compositions using a hand sprayer, as outlined in Table 18 below. The barrier coating compositions are shown in Table 19 below.

[0185] [Table 18]

[0186] [Table 19]

[0187] The thermal conductivity of each sample was tested according to ASTM C578 (70°F and 45% relative humidity) at intervals of 7 days (k7), 20 days (k20), 30 days (k30), and 60 days (k60), and the performance is shown in Table 20 below.

[0188] [Table 20]

[0189] As shown in Table 20, the uncoated comparison sample already showed a reading of 0.2 BTU·in / h·ft as early as day 20 (k20). 2 Although the k-value of each sample 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.

[0190] While the present invention has been described with reference to specific means, materials, and embodiments, those skilled in the art will readily recognize 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 described above and in the appended claims.

Claims

1. Insulated coating product, A foamed product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them, wherein the foamed product is formed from a foaming composition, and the foaming composition is a) Matrix composition, and b) A foamed product comprising a foaming agent composition containing less than 3.5% by weight of a fluorinated alkene based on the total weight of the foaming composition, 3 g / m ２ ~225g / m ２ A barrier coating present on at least one surface of the foamed product in total amount, wherein the barrier coating is formed from a barrier coating composition, and the barrier coating composition is Based on the total solid content of the barrier coating composition, a barrier polymer comprising 40% to 99.9% by weight, having a minimum crystallinity of 10%, and A coated insulating product comprising a barrier coating comprising at least one additive in an amount of 0.01% to 60% by weight 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 insulating product has a 180-day R / in value of at least 4.

8.

2. The foaming agent composition contains at least 2% by weight of CO based on the total weight of the foaming composition. ２ The coated insulating product according to claim 1, further comprising less than 3% by weight of a fluorinated alkene.

3. The foaming agent composition contains at least 2.5% by weight of CO2 based on the total weight of the foaming composition. ２ and a coated insulating product according to any one of claims 1 to 2, comprising less than 2% by weight of a fluorinated alkene.

4. The coated insulating product according to any one of claims 1 to 3, further comprising methyl formate as the foaming agent.

5. The coated insulating product according to any one of claims 1 to 4, wherein the foaming composition contains a total foaming agent concentration of 2.5% to 6.5% by weight.

6. The coated insulating product according to any one of claims 1 to 5, wherein the foaming composition comprises a total foaming agent concentration of 3% by weight and 5.5% by weight.

7. The coated insulating product according to any one of claims 1 to 6, wherein the barrier coating composition has a viscosity of 5000 cP or less with a solid content of 70%.

8. The coated insulating product according to any one of claims 1 to 7, 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.

9. The coated insulating product according to any one of claims 1 to 8, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

10. The coated insulating product according to any one of claims 1 to 9, wherein the barrier polymer has a minimum crystallinity of 30%.

11. The coated insulating product according to any one of claims 1 to 10, wherein the barrier polymer has a minimum crystallinity of 60%.

12. The coated insulating product according to any one of claims 1 to 11, wherein the additive comprises a wetting agent, a rheological modifier, a flame retardant, an antiblocking agent, an antifoaming agent, a pH adjuster, a UV stabilizer, or a mixture thereof.

13. The coated insulating product according to any one of claims 1 to 12, wherein the additive comprises a rheological modifier present in an amount of 0.01% to 20% by weight based on the total solid content of the barrier coating.

14. The coated insulating product according to any one of claims 1 to 13, 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.

15. The coated insulating product according to any one of claims 1 to 14, 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.

16. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solids 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 coated insulating product according to any one of claims 1 to 15, comprising at least one UV stabilizer with a solid content of 0.05% to 12% by weight.

17. The coated insulating product according to any one of claims 1 to 16, wherein the barrier coating has a pH of 3 to 9.

18. The coated insulating product according to any one of claims 1 to 17, wherein the barrier coating is present on each surface of the foamed product.

19. A coated insulating product according to any one of claims 1 to 18, 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, vinyl halogenated 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.

20. A coated polymer insulating product, A polymer foam product having a first main surface, an opposing second main surface, and a plurality of secondary surfaces extending between them, wherein the foam product is formed from a foamable polymer composition, and the foamable polymer composition is a) Polymer matrix composition, and b) Based on the total weight of the foaming composition, 3% by weight or less of fluorinated alkenes and at least 1.5% by weight of CO ２ A polymer foam product comprising a foaming agent composition containing, 3 g / m² on each surface of the aforementioned foamed product ２ ~225g / m ２ A barrier coating present in total amount, the barrier coating is formed from a barrier coating composition comprising a semicrystalline polymer and at least one rheological modifier, the barrier coating composition having a surface tension of 20 mN / m or less on the surface energy of the polymer foam and a viscosity of 50 cP to 5000 cP with a solid content of 70% or less, and the barrier coating comprises, The coated insulating product is a coated polymer insulating product having a 180-day R / in value of at least 4.8 and a compressive strength of 10 to 110 psi, as measured according to ASTM C578.

21. The foaming agent composition contains, based on the total weight of the foaming composition, less than 2% by weight of fluorinated alkenes and at least 2.5% by weight of CO2. ２ A coated polymer insulating product according to claim 20, comprising:

22. The coated insulating product according to claim 20 or 21, further comprising methyl formate as the foaming agent.

23. The coated polymer insulating product according to any one of claims 20 to 22, wherein the foaming polymer composition contains a total foaming agent concentration of 2.5% to 6.5% by weight.

24. The coated polymer insulating product according to any one of claims 20 to 23, wherein the foaming polymer composition comprises total foaming agent concentrations of 3% by weight and 5.5% by weight.

25. The coated polymer insulating product according to any one of claims 20 to 24, wherein the barrier coating composition has a viscosity of 5000 cP or less with a solid content of 70%.

26. The coated polymer insulating product according to any one of claims 20 to 25, 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-fransil carboxylate), poly(butylene succinate), bio-based ethylene, and copolymers thereof.

27. The coated polymer insulating product according to any one of claims 20 to 26, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

28. The coated polymer insulating product according to any one of claims 20 to 27, wherein the barrier polymer has a minimum crystallinity of 30%.

29. The coated polymer insulating product according to any one of claims 20 to 28, wherein the wetting agent is present in an amount of solids from 0.005% to 8% by weight, based on the total solids content of the barrier coating.

30. The coated polymer insulating product according to any one of claims 20 to 29, wherein the barrier coating composition further comprises at least one additive, the additive comprising a rheological modifier, an antifoaming agent, a pH adjuster, a UV stabilizer, a flame retardant, an antiblocking agent, or a mixture thereof.

31. The coated polymer insulating product according to claim 30, wherein the additive comprises a rheological modifier present in an amount of solids of 0.01% to 20% by weight based on the total solids content of the barrier coating.

32. The coated polymer insulating product according to claim 29, 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.

33. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solids 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 0.005% to 8% by weight, A pH adjuster with a solid content of 0.05% to 8% by weight, Flame retardant with a solid content of 0-5% by weight, A coated polymer insulating product according to any one of claims 19 to 31, comprising at least one UV stabilizer with a solid content of 0.05% to 12% by weight.

34. The coated polymer insulating product according to any one of claims 20 to 33, wherein the barrier coating has a pH of 3 to 9.

35. The coated polymer insulating product according to any one of claims 20 to 34, wherein the R value of the coated polymer insulating product after 180 days is at least 5.0 per inch.

36. The coated insulating product according to any one of claims 20 to 35, wherein the barrier coating is present on each surface of the foamed product.

37. A method for manufacturing a coated insulating product with reduced fluorinated foaming agent content, The method involves mixing a matrix polymer with 2.5% to 6.5% by weight of a foaming agent composition to form a foamed polymer composition, wherein the foaming agent composition contains less than 3.5% by weight of a fluorinated alkene based on the total weight of the foamed composition. The foaming polymer composition is foamed to produce a foamed product having a first main surface, an opposing second main surface, and four secondary surfaces extending between them. Apply a barrier coating to at least one surface of the foamed product at a total amount of 3 g / m ２ to 225 g / m ２ such that the barrier coating is formed from a barrier coating composition, and the barrier coating composition is Based on the total solid content of the barrier coating composition, a barrier polymer comprising 40% to 99.9% by weight, having a minimum crystallinity of 10%, and A method comprising applying, the barrier coating composition comprising at least one additive in an amount of 0.01% to 60% by weight, based on the total solid content of the barrier coating composition, wherein the barrier coating composition has a surface tension of 40 mN / m or less, and the coated insulating product has a 180-day R / in value of at least 4.

8.

38. The foaming agent composition contains at least 2% by weight of CO based on the total weight of the foaming composition. ２ The method according to claim 37, further comprising less than 3% by weight of a fluorinated alkene.

39. The foaming agent composition contains at least 2.5% by weight of CO2 based on the total weight of the foaming composition. ２ The method according to claim 37 or 38, comprising less than 2% by weight of a fluorinated alkene.

40. The method according to any one of claims 37 to 39, wherein the foaming agent further comprises methyl formate.

41. The method according to any one of claims 37 to 40, wherein the foaming composition comprises a total foaming agent concentration of 3% by weight and 5.5% by weight.

42. The method according to any one of claims 37 to 41, wherein the barrier coating composition has a viscosity of 5000 cP or less with a 30% solid content.

43. The method according to any one of claims 37 to 42, 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.

44. The method according to any one of claims 37 to 43, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

45. The method according to any one of claims 37 to 44, wherein the barrier polymer has a minimum crystallinity of 30%.

46. The method according to any one of claims 37 to 45, wherein the additive comprises one or more of the following: wetting agents, rheological modifiers, defoaming agents, silicones, matting agents, pH adjusters, UV stabilizers, and flame retardants, antiblocking agents, hydrophobic silica, or mixtures thereof.

47. The method according to any one of claims 37 to 46, wherein the additive comprises a rheological modifier present in an amount of 0.01% to 20% by weight based on the total solid content of the barrier coating.

48. The method according to any one of claims 37 to 47, 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.

49. The method according to any one of claims 37 to 48, 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.

50. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solids 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, The method according to any one of claims 37 to 49, comprising at least one UV stabilizer with a solid content of 0.05% to 12% by weight.

51. The method according to any one of claims 37 to 50, wherein the barrier coating has a pH of 4 to 7.

52. The method according to any one of claims 37 to 51, wherein the barrier coating is present on each surface of the foamed product.

53. The method according to any one of claims 37 to 52, 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, vinyl halogenated 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.

54. A covering system, A structural portion having a first surface and an opposing second surface, At least one coated insulating product is bonded to one of the first surface or the second surface of the structural portion, wherein the coated insulating product is A foamed product having a first main surface, an opposing second main surface, and four secondary surfaces extending between them, wherein the foamed product is formed from a foaming composition, and the foaming composition is a) Matrix composition, and b) A foamed product comprising a foaming agent composition containing less than 3.5% by weight of a fluorinated alkene based on the total weight of the foaming composition, 3 g / m ２ ~225g / m ２ A barrier coating present on at least one surface of the foamed product in total amount, wherein the barrier coating is formed from a barrier coating composition, and the barrier coating composition is A barrier polymer comprising 40% to 99.9% by weight based on the total solid content of the barrier coating composition, having a minimum crystallinity of 10%, and A coating system comprising a barrier coating comprising at least one additive in an amount of 0.1% to 60% by weight, 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 insulating product has a 180-day R / in value of at least 4.

8.

55. The foaming agent composition contains at least 2% by weight of CO based on the total weight of the foaming composition. ２ and the coating system according to claim 54, comprising less than 3% by weight of a fluorinated alkene.

56. The foaming agent composition contains at least 2.5% by weight of CO2 based on the total weight of the foaming composition. ２ and the coating system according to claim 54 or 55, comprising less than 2% by weight of a fluorinated alkene.

57. The coating system according to any one of claims 54 to 56, wherein the foaming agent further comprises methyl formate.

58. The coating system according to any one of claims 54 to 57, wherein the foaming composition comprises a total foaming agent concentration of 3% by weight and 5.5% by weight.

59. The coating system according to any one of claims 54 to 58, wherein the barrier coating composition has a viscosity of 5000 cP or less with a solid content of 30%.

60. The coating system according to any one of claims 54 to 59, 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.

61. The coating system according to any one of claims 54 to 60, wherein the barrier polymer comprises one or more of poly(vinylidene chloride), polyvinyl alcohol, poly(ethylene-co-vinyl alcohol), and poly(vinylidene fluoride).

62. The coating system according to any one of claims 54 to 61, wherein the barrier polymer has a minimum crystallinity of 30%.

63. The coating system according to any one of claims 54 to 62, wherein the additive comprises one or more of the following: a wetting agent, a rheological modifier, an antifoaming agent, a silicone, a matting agent, a polydimethylsiloxane, a pH adjuster, a UV stabilizer, and hydrophobic silica.

64. The coating system according to any one of claims 54 to 63, wherein the additive comprises a rheological modifier present in an amount of 0.01% to 20% by weight, based on the total solid content of the barrier coating.

65. The coating system according to any one of claims 54 to 64, 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.

66. The coating system according to any one of claims 54 to 65, 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.

67. The barrier coating is determined based on the total solid content of the barrier coating. A barrier polymer with a solids 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 coating system according to any one of claims 54 to 66, comprising at least one UV stabilizer with a solid content of 0.05% to 12% by weight.

68. The coating system according to any one of claims 54 to 67, wherein the barrier coating has a pH of 4 to 7.

69. The coating system according to any one of claims 54 to 68, wherein the barrier coating is present on each surface of the foam product.

70. The coating system according to any one of claims 54 to 69, 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, vinyl halogenated 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.

Images