Process for making low density spray polyurethane foam for thermal insulation, sound reduction, and airtightness of building enclosures

Abstract

The present disclosure provides novel low density open cell polyurethane (PUR) foams that can be prepared using a combination of precursors and conditions, such as an off-ratio A-side:B-side volume ratio (v:v) that includes a higher A-side volume than B-side volume, an aromatic polyisocyanate component having an isocyanate functionality of about 2.5 to about 3.0, and an isocyanate index of about 20 percent to about 40 percent. Using the processes and precursors disclosed herein, PUR foams with a density of about 0.25 lb / ft 3 ~approx. 0.45 lb / ft 3 A polyurethane foam having a density of

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 069,968, filed August 25, 2020, which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to low density polyurethane foams having good thermal insulation, airtightness, and sound attenuation properties, and compositions and processes for making them. [Background technology]

[0003] The need to develop more energy-efficient buildings is becoming increasingly important in light of environmental demands, and this need is reflected in updates to national and international building codes for energy efficiency. Revisions to the International Energy Conservation Code (IECC), the International Residential Code (IRC), and the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) all demonstrate the growing demand for improved energy efficiency. Requirements include improved thermal resistance and more effective air sealing, emphasizing the need for innovation in building materials and construction.

[0004] While traditional fibrous insulation provides the necessary thermal resistance, it lacks the ability to meet more stringent airtightness requirements. To compensate for this deficiency, builders and insulation contractors must utilize additional techniques, such as single-component construction foams and caulking, to pass airtightness requirements. This complex problem requires the mobilization of different laborers and the risk of not meeting airtightness standards, which requires multiple mobilizations and increases costs. Therefore, there is a need to address these issues and the added costs of using traditional fibrous insulation. If technologies such as spray polyurethane (PUR) foams could provide the required performance, it would be useful, at least because these foams are convenient and cost-effective to apply and because the foams can be used to form multiple control layers within the building envelope. In particular, it would be useful if low-density foams could be developed that could address the insulation and airtightness requirements for energy efficiency and provide good sound-reducing properties. Summary of the Invention

[0005] In one aspect, the present disclosure provides novel low-density spray polyurethane (PUR) foams and methods for preparation, which can provide a combination of good thermal insulation properties, airtightness qualities, and sound reduction. Spray polyurethane foams are fluid-applied, intumescent insulation materials that can provide a viable alternative to traditional fibrous insulation. With the disclosed low-density open-cell foams providing airtightness and thermal insulation functions, additional benefits can include enhanced sound reduction, for example, at sound transmission coefficient levels approximately 2-3 STC units higher than that of traditional fibrous insulation. Additional benefits include flame retardant properties when the foam composition is combined with a flame retardant, as disclosed.

[0006] In one embodiment, for example, about 0.25 lb / ft 3 (pounds per cubic foot) ~ approximately 0.45 lb / ft 3 It has been found that very low density polyurethane foams in the range can be prepared using a combination of precursors and conditions including: [1] an "off ratio" A-side:B-side volume ratio (v:v) that includes a higher A-side volume than B-side volume, thereby differing from the approximately 1:1 (v:v) ratio common in conventional commercial spray polyurethane foams, and [2] an aromatic polyisocyanate component having an isocyanate functionality of about 2.5 to about 3.0, and [3] an isocyanate index (expressed as a percentage) of about 20 to about 40.

[0007] Thus, in one aspect, the present disclosure provides a low density polyurethane (PUR) foam, the foam comprising: (a) a first reaction composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of about 20 to about 45; a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in a second reaction composition (side B); A flame retardant; A surfactant, and a second reaction composition (side B) comprising: a first reaction composition (A-side) and a second reaction composition (B-side) are contacted in amounts to provide: [1] a volume ratio (v:v) of A-side to B-side of 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of 20 to 40; Low density PUR foam, approximately 0.25 lb / ft 3 ~approx. 0.45 lb / ft 3 It has a density of

[0008] Accordingly, a process for making low density polyurethane (PUR) foam is also provided, the process comprising: (a) a first reaction composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; and (b) a second reaction composition (side B) having a hydroxyl number (mg

[0013] The method may include contacting a polyether polyol characterized by a % by weight (V / g) of KOH with a second reaction composition (B-side) comprising: [2] water (an aqueous blowing agent); [3] a polyurethane-forming catalyst at a concentration of 6% to 11% by weight in the second reaction composition (B-side); [4] a flame retardant; and [5] a surfactant, wherein the first reaction composition (A-side) and the second reaction composition (B-side) are contacted in amounts to provide: [a] a volume ratio (v:v) of A-side to B-side of 1.2:1 to 2:1; and [a] an Isocyanate Index (expressed as a percentage) of 20 to 40; and wherein the low density PUR foam has a viscosity of about 0.25 lb / ft. 3 ~approx. 0.45 lb / ft 3 It has a density of

[0009] These and other embodiments and aspects of the processes, methods, and compositions are more fully described in the detailed description and claims and further disclosure, including the examples provided herein. DETAILED DESCRIPTION OF THE INVENTION

[0010] definition

[0013] In order to more clearly define the terms used herein, the following definitions are provided and are applicable throughout this disclosure unless otherwise indicated or the context otherwise requires. When a term is used in this disclosure but is not specifically defined herein, the definition shall be in accordance with the IUPAC Compendium of Chemical Terminology, 2002, unless that definition contradicts any other disclosure or definition applicable herein or renders indefinite or invalid any claim to which that definition applies. ndDefinitions from Ed (1997) may be applied. To the extent that any definition or usage provided by any document incorporated herein by reference conflicts with the definition or usage provided herein, the definition or usage provided herein controls.

[0011] With respect to transitional terms or phrases in a claim, the transitional term "comprising," which is synonymous with "including," "containing," or "characterized by," is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. The transitional term "consisting of" excludes any element, step, or ingredient not specified in the claim. The transitional term "consisting essentially of" limits the claim to the materials or steps specified and those that do not materially affect the basic and novel characteristics of the claimed invention. Unless specified to the contrary, reciting a compound or composition "consisting essentially of" should not be construed as "comprising," but is intended to describe the recited ingredients, including materials that do not significantly alter the composition or method to which the term is applied. For example, a feedstock consisting of material A may contain impurities typically present in commercially produced or commercially available samples of the recited compound or composition. When a claim includes different features and / or classes of features (e.g., process steps, feedstock characteristics, and / or product characteristics, among other possibilities), the transitional terms comprising, consisting essentially of, and consisting of apply only to the class of features that are utilized, and different transitional terms or phrases may be utilized for different features within the claim. For example, a method may include several recited steps (and other unrecited steps), but utilize a catalyst composition preparation that consists of certain steps, but utilizes a catalyst composition that includes recited components and other unrecited components. While compositions and methods are described in terms of "comprising" various components or steps, the compositions and methods may also "consist essentially of" or "consist of" the various components or methods.

[0012] The terms "a," "an," and "the" are intended to include plural alternatives, e.g., at least one, unless specifically indicated. For example, disclosure of a "polyol" is meant to encompass one polyol compound, or a mixture or combination of two or more polyol compounds, unless otherwise specified.

[0013] The terms "configured for use" or "adapted for use," and similar language, are used herein to reflect that a particular recited structure or procedure is used in a polyurethane spray foam system or process, including for use with a high-pressure proportioner used in a polyurethane spray foam system. For example, unless otherwise specified, a particular structure "configured for use" means that it is "configured for use in a polyurethane spray foam system," and thus is designed, shaped, arranged, constructed, and / or adjusted to result in the combination of an A-side composition and a B-side composition, resulting in polymerization, as understood by one of ordinary skill in the art.

[0014] The terms "flame retardant chemical," "fire retardant chemical," or simply "flame retardant," or "fire retardant," as used herein to refer to additives or treatments used to treat or condition materials such as PUR foam, refer to an element, chemical compound, agent, or composition that has the ability to reduce or eliminate the tendency of a material or substrate to which it is added to burn when the material or substrate is exposed to a flame or fire. The flame retardant chemical selected will be suitable for combination with or use with one or more materials or substrates to which it is treated or to which it is added, and this can be determined by one of ordinary skill in the art.

[0015] Terms such as "flame retardant," "fire retardant," "flame resistant," and "fire resistant" may also be used to refer to a substance to which a flame-retardant chemical has been added or a substrate treated or coated with a flame-retardant chemical. For example, the present disclosure provides a flame-retardant polyurethane (PUR) foam, one component of which is a flame-retardant chemical. In one aspect, these terms may be used herein to refer to a substance or material that (a) does not support flame, fire, and / or combustion, either during the presence of a flame or fire or after the heat or ignition source has been removed, and / or (b) is flame-retardant or unable to burn (essentially fire-resistant, i.e., remains substantially unchanged when exposed to a flame, fire, and / or combustion process). A flame-resistant substance, material, or substrate may scorch and / or melt.

[0016] As used herein, the terms "open cell" or "open cell foam" refer to foam having at least 70 percent open cells as measured in accordance with ASTM D6226.

[0017] The term "functionality," and similar terms such as "isocyanate functionality," "polyisocyanate functionality," or "MDI functionality," when used to describe polyisocyanates, refers to the number-average isocyanate functionality, i.e., NCO moieties, of all isocyanates per mole used in the polyisocyanate component to prepare polyurethane foam. Isocyanate functionality may be abbreviated as Fn.

[0018] Similar terms such as "isocyanate content" and "NCO content" can be expressed as a weight percentage (%), which is the weight of all isocyanate (NCO) moieties in the polyisocyanate component (equivalent weight of 42.017 g per NCO functional group) divided by the weight of the polyisocyanate component, expressed as a percentage (wt%). Isocyanate content can also be expressed as a fraction.

[0019] Isocyanate "functionality" is the number of reactive NCO groups per molecule in an isocyanate molecule or in a polymeric isocyanate, such as MDI or polymeric MDI. For example, most MDI samples contain a blend of monomeric and polymeric MDI, and the isocyanate "functionality" is the average functionality across the different molecular and polymeric species.

[0020] As used herein, "MDI" refers to methylene diphenyl diisocyanate, also known as diphenylmethane diisocyanate, and its isomers. MDI (methylene diphenyl diisocyanate) exists as one of three isomers (4,4'MDI, 2,4'MDI, and 2,2'MDI) or as a mixture of two or more of these isomers. As used herein, unless specifically stated otherwise, "MDI" can also refer to and include polymeric MDI (sometimes referred to as "PMDI"). Polymeric MDI is a compound having a chain of three or more benzene rings connected to each other by methylene bridges, with an isocyanate group attached to each benzene ring. For example, one conventional MDI may have an average functionality of about 2.1 to about 3 (inclusive), with a typical viscosity of about 200 mPa to 1,000 mPa at 25°C.

[0021] The terms "Isocyanate Index," "NCO Index," "ISO Index," and the like, as understood by those skilled in the art, are used to refer to the ratio of the number or equivalent of NCO groups (from the A-side) to the number or equivalent of isocyanate-reactive hydrogen atoms (from the B-side) used in a formulation. Isocyanate Index can be reported as either a fraction or a percent; therefore, Isocyanate Index reported as a percent is calculated according to the following formula:

number

[0022] In other words, NCO Index represents the amount of isocyanate actually used in a formulation relative to the amount of isocyanate theoretically required to stoichiometrically react with the amount of isocyanate-reactive hydrogens used in the formulation. An Isocyanate Index of 100 (percent) reflects a 1:1 ratio (moles or numbers) of NCO groups to active hydrogens. In the examples, NCO Index is reported both as a decimal and as a percentage.

[0023] The term "hydroxyl number" (abbreviated as OHM) or "hydroxyl value" (abbreviated as OHV), or simply "hydroxyl number" or "hydroxyl value" of a chemical, is a characteristic of a chemical that contains free hydroxyl groups. The "hydroxyl number" is defined as the number of milligrams of potassium hydroxide (KOH) equivalent to the hydroxyl content in one gram of polyol or other compound containing free hydroxyl groups. For example, the hydroxyl number can be defined as the number of milligrams of potassium hydroxide (KOH) required to neutralize the acetic acid incorporated during the acetylation of one gram of a chemical that contains free hydroxyl groups. Thus, the hydroxyl number unit is expressed as mg KOH / g chemical. Based on this definition, the hydroxyl number of a chemical can be calculated according to the following formula:

number

[0024] The numerator of the fraction, 56,100, arises from the molecular weight of potassium hydroxide, 56.1 g / mol, of which 1,000 mg is present in a 1 g sample.

[0025] The term "optional" or "optionally" is used to mean that the subsequently described component, event, or circumstance may be used, may occur, or may even be used or may not occur, and that the description includes instances in which the component, event, or circumstance occurs and instances in which it does not occur. For example, the phrase "optionally substituted" means that the referenced compound may or may not be substituted, and that the description includes both unsubstituted compounds and compounds in which substitution is present.

[0026] Various numerical ranges are disclosed herein. When Applicant discloses or claims any type of range, Applicant's intent is to individually disclose or claim each possible numerical value that such range may reasonably encompass, including the endpoints of the range, and any subranges and combinations of subranges subsumed within that range, unless otherwise specified. For example, by disclosing a temperature of 70°C to 80°C, Applicant's intent is to individually recite 70°C, 71°C, 72°C, 73°C, 74°C, 75°C, 76°C, 77°C, 78°C, 79°C, and 80°C, including any ranges and combinations therebetween, and these methods of describing such ranges are interchangeable. Furthermore, all numerical endpoints of ranges disclosed herein are approximations unless excluded by disclaimer. As a representative example, if applicants state that one or more steps in a process disclosed herein may be carried out at a temperature in the range of 10°C to 75°C, this range should be interpreted as encompassing temperatures in the range of "about" 10°C to "about" 75°C.

[0027] Values ​​or ranges may be expressed herein as "about" from one particular value and / or to another particular value. When such values ​​or ranges are expressed, other disclosed embodiments include the recited particular values ​​from the one particular value and / or to the other particular value. Similarly, when values ​​are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that there are several values ​​disclosed therein, and that each value, in addition to the value itself, is also disclosed herein as "about" that particular value. In alternative aspects, use of the term "about" can mean ±15% of the stated value, ±10% of the stated value, ±5% of the stated value, ±3% of the stated value, or ±2% of the stated value.

[0028] Applicant reserves the right to qualify or exclude any individual members of any such value or range group, including any subrange or combination of subranges within a group, which may be claimed according to a range or in any similar manner if, for any reason, Applicant chooses to claim less than the full measure of the disclosure to take into account literature that Applicant may not be aware of at the time of filing. Applicant further reserves the right to qualify or exclude any individual substituents, analogs, compounds, coordinates, structures, or groups thereof, or any members of a claimed group, if, for any reason, Applicant chooses to claim less than the full measure of the disclosure to take into account literature or prior disclosure that Applicant may not be aware of at the time of filing.

[0029] All publications and patents mentioned herein are incorporated by reference for the purpose of describing and disclosing, for example, the constructs and methodology described in the publications, which may be used in connection with the invention described herein. Publications discussed throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein should be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

[0030] Summary of the Invention Spray polyurethane foam is a flow-applied, expanding insulation material that has proven itself as a viable alternative to traditional fibrous insulation. It forms multiple control layers in the building envelope. For low-density, open-cell foams, its primary functions are airtightness and thermal insulation. Sound reduction is a secondary feature of polyurethane foam, which can provide sound transmission coefficient levels approximately two to three times higher than traditional fibrous insulation. This disclosure provides a procedure for producing low-density spray foam insulation using unique chemicals and processes, as well as novel foams obtained therefrom.

[0031] Thus, the present disclosure provides novel low-density polyurethane (PUR) foams with good thermal insulation, airtightness, and sound-reducing properties that can be prepared using a combination of precursors and conditions, including: [1] an "off-ratio" A-side:B-side volume ratio (v:v), which differs from the approximately 1:1 (v:v) ratio common in conventional polyurethanes due to the inclusion of a higher A-side volume than the B-side volume; [2] an aromatic polyisocyanate component having an isocyanate functionality of about 2.5 to about 3.0; and [3] an isocyanate index (expressed as a percentage) of about 20 to about 40. In one aspect, these novel low-density foams are open-cell foams that can incorporate flame retardants. The disclosed combination of foam properties and process parameters provides low-density foams that are capable of meeting standards related to flame retardant, thermal barrier, and ignition barrier properties, enabling these foams to pass certain thermal barrier tests in the absence of standard-specified protective coverings, such as those specified in model building codes.

[0032] Thus, in one aspect, the present disclosure provides a low density polyurethane (PUR) foam, the foam comprising: (a) a first reaction composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of about 20 to about 45; Water (aqueous foaming agent), a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in a second reaction composition (side B); A flame retardant; a surfactant; and a second reactive composition (side B) comprising: a first reactive composition (A-side) and a second reactive composition (B-side) are contacted in amounts to provide: [1] an A-side:B-side volume ratio (v:v) of 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of 20 to 40; Low density PUR foam, approximately 0.25 lb / ft 3 ~approx. 0.45 lb / ft 3 It has a density of

[0033] Related processes for making polyurethane foams are also disclosed herein. According to one embodiment, the ingredients used to make the foams of the present disclosure can be used in conjunction with a high-pressure system, and the resulting foams can be referred to as high-pressure foams. For example, spray foam systems that can be used to produce the disclosed foams include those equipped with a proportioner operating at about 500 psi (pounds per square inch) to about 2,000 psi to pressurize the reactant composition.

[0034] These and other aspects of the present disclosure are described in additional detail herein, as follows.

[0035] Polyisocyanate Component. As noted above, the first reaction composition, referred to as Side A, can include a polyisocyanate component comprising an aromatic polyisocyanate. The polyisocyanate component can be a polyisocyanate compound or a mixture of polyisocyanate compounds. In one aspect, the polyisocyanate component can include methylene diphenyl diisocyanate (MDI), including any or all isomers, polymeric methylene diphenyl diisocyanate (PMDI), or any combination thereof. According to a further aspect, the polyisocyanate component can include 2,2'-methylene diphenyl diisocyanate (2,2,2'-MDI), 4,4'-methylene diphenyl diisocyanate (4,4'-MDI), polymeric methylene diphenyl diphenyl diisocyanate (PMDI), or any combination thereof. Examples of polyisocyanates useful in the foams and processes disclosed herein include: These include, but are not limited to, WANNATE® PM-700 and WANNATE® PM-200 manufactured by Wanhau USA.

[0036] In another embodiment, the polyisocyanate component can include about 20% to about 80% by weight of methylene diphenyl diisocyanate (MDI) and about 80% to about 20% by weight of polymeric methylene diphenyl diisocyanate (polymeric MDI or "PMDI"). Alternatively, the polyisocyanate component can include about 25% to about 75% by weight of methylene diphenyl diisocyanate (MDI) and about 75% to about 25% by weight of polymeric methylene diphenyl diisocyanate (polymeric MDI or "PMDI"), for example, according to product specification information. Alternatively, the polyisocyanate component can include from about 30% or about 35% to about 65% or about 70% by weight polymeric methylene diphenyl diisocyanate (polymeric MDI or "PMDI"), and from about 70% or about 65% to about 35% or about 30% by weight methylene diphenyl diisocyanate MDI.

[0037] In one embodiment, the first reactive composition (side A) can include an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0. In a further embodiment, as used herein, the polyisocyanate component can have an isocyanate functionality of from about 2.5 to about 2.9, alternatively from about 2.6 to about 2.9, alternatively from about 2.6 to about 2.8, alternatively from about 2.7 to about 2.8. Furthermore, as used herein, the polyisocyanate component can have an isocyanate functionality of about 2.5, about 2.6, about 2.7, about 2.8, about 2.9, or about 3.0, or any range or combination of ranges between any of these values.

[0038] In yet another aspect, the polyisocyanate component as used herein can have an NCO content (wt%) of 25% to about 35%, alternatively about 26% to about 33%, or alternatively even about 27% to about 30%. Alternatively, the polyisocyanate component as used herein can have an NCO content (wt%) of about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, or about 35%, or any range or combination of ranges between any of these values.

[0039] In one aspect, the polyisocyanate component used herein can have a viscosity (25° C., mPa·S) of from about 100 mPa·S (cP) to about 1,050 mPa·S (cP), or alternatively, the polyisocyanate component can have a viscosity (25° C., mPa·S) of from about 125 mPa·S (150 cP) up to about 950 mPa·S (1050 cP). For example, in one aspect, the polyisocyanate component can have a viscosity (25° C., mPa·S) of from about 125 cP to about 400 cP, alternatively from about 125 cP to about 350 cP, or alternatively from about 150 cP to about 300 cP. In a further example, the polyisocyanate component can also have a viscosity of about 575 cP to about 1,000 cP, alternatively 600 cP to about 950 cP, or alternatively about 650 cP to about 900 cP. The polyisocyanate component can also have a viscosity of about 100 cP, about 125 cP, about 150 cP, about 175 cP, about 200 cP, about 225 cP, about 250 cP, about 275 cP, about 300 cP, about 325 cP, about 350 cP, about 375 cP, about 400 cP, about 425 cP, about 450 cP, about 475 cP, about 500 cP, about 525 cP, about 550 cP, about 5 The viscosity may also be about 75 cP, about 600 cP, about 625 cP, about 650 cP, about 675 cP, about 700 cP, about 750 cP, about 800 cP, about 850 cP, about 900 cP, about 950 cP, about 1,000 cP, or about 1,050 cP, or any range or combination of ranges between any of these values ​​(at 25°C, mPa·S). The SI unit of dynamic viscosity in mPa·S is 1 cP = 10 -3 It will be understood by those skilled in the art that Pa·S=1 mPa·S is equivalent to the cgs unit of centipoise.

[0040] An example of a polyisocyanate component useful in the foams and processes disclosed herein is WANNATE® PM-700 from Wanhau USA, which may contain about 30% to about 70% by weight of polymeric methylene diphenyl diisocyanate (polymeric MDI or "PMDI") and about 70% to about 30% by weight of methylene diphenyl diisocyanate MDI, according to product specification information. The PM-700 may have a viscosity (at 25°C, mPaS) of about 600 cP to about 850 cP, e.g., about 700 cP. The NCO content of the PM-700 may be about 30.0 to about 32.0, and its density may be about 1.22 gm / cm. 3 ~Approx. 1.25gm / cm 3 is.

[0041] In some embodiments, the polyisocyanate component used in the contact product to make the polyisocyanate foam may have an isocyanate functionality of from about 3.0 to about 3.1, an NCO content (wt %) of from about 29 wt % to about 33 wt %, and a viscosity (25° C., mPaS) of from about 650 cP to about 750 cP.

[0042] Another example of a polyisocyanate component useful in the foams and processes disclosed herein is WANNATE® PM-200 from Wanhau USA, which may contain about 30% to about 70% by weight of polymeric methylene diphenyl diisocyanate (polymeric MDI or "PMDI") and about 70% to about 30% by weight of methylene diphenyl diisocyanate MDI, according to product specification information. The PM-200 may have a viscosity (at 25°C, mPa·S) of about 150 cP to about 250 cP, e.g., about 200 cP. The NCO content (wt%) of the PM-200 may be about 30.5% to about 32.0% by weight, and its density may be about 1.22 gm / cm to about 1.25 gm / cm. 3 and the NCO functionality may be from about 2.6 to about 2.7.

[0043] In some embodiments, the polyisocyanate component used in the contact product to make polyurethane foam may have an isocyanate functionality of from about 2.5 to about 2.7, an NCO content (wt %) of from about 30 wt % to about 32.5 wt %, and a viscosity (mPa·S at 25° C.) of from about 150 cP to about 300 cP.

[0044] In one aspect of polyurethane foams and processes for making polyurethane foams, the first reaction composition (side A) can include a polyisocyanate, alternatively the first reaction composition (side A) can consist essentially of a polyisocyanate, or alternatively the first reaction composition (side A) can consist of a polyisocyanate, i.e., side A can include only a sample of a polyisocyanate and only impurities typically present in commercially produced or commercially available samples of polyisocyanate.

[0045] In further embodiments, the first reaction composition (A-side) may comprise at least about 95% polyisocyanate by weight of the first reaction composition, hi some embodiments, the remainder of the A-side composition may comprise, for example, a surfactant, a plasticizer, or a combination thereof.

[0046] Polyether Polyol. As noted above, the second reaction composition, referred to as the B-side, can include a polyether polyol, which can be a polyether polyol compound or a mixture of polyether polyol compounds. According to embodiments of the present disclosure, the polyether polyol can be characterized by a hydroxyl number (mg KOH / g) of about 20 to about 45. The polyether polyol can be characterized by a hydroxyl number (mg KOH / g) of about 25 to about 42, or alternatively, about 28 to about 38. All ranges between these high and low hydroxyl values, and combinations of ranges, are encompassed by the present disclosure. In another aspect, the polyether polyol can be characterized by a hydroxyl value (mg KOH / g) of about 20, about 21, about 22, about 23, about 24, about 26, about 27, about 28, about 29, about 30, about 31, about 32, about 33, about 34, about 35, about 36, about 37, about 38, about 39, about 40, about 41, about 42, about 43, about 44, or about 45, or any range therebetween or combination of ranges therebetween.

[0047] In some embodiments, the second reaction composition (side B) may include other polyether polyols that may function as crosslinkers, stabilizers, etc., and may have very different properties, such as hydroxyl numbers, molecular weights, etc., compared to the polyether polyols described above having hydroxyl numbers (mg KOH / g) of from about 25 to about 42. These latter polyether polyols having hydroxyl numbers of from about 25 to about 42 may be characterized by molecular weights, hydroxyl functionality, etc., as disclosed herein.

[0048] According to further aspects of the present disclosure, polyether polyols characterized by the hydroxyl numbers disclosed above can also be characterized by a molecular weight (weight average or number average) of from about 250 g / mol to about 6,000 g / mol, alternatively from about 1,000 g / mol to about 5,500 g / mol, alternatively from about 2,000 g / mol to about 5,250 g / mol, or alternatively from about 4,000 g / mol to about 5,000 g / mol. In one embodiment, the polyether polyol has a viscosity of about 250 g / mol, about 300 g / mol, about 350 g / mol, about 400 g / mol, about 450 g / mol, about 500 g / mol, about 600 g / mol, about 700 g / mol, about 800 g / mol, about 900 g / mol, about 1,000 g / mol, about 1,250 g / mol, about 1,750 g / mol, about 2,000 g / mol, about 2,250 g / mol, about 2,500 g / mol, about 2,750 g / mol, about 3,000 g / mol mol, about 3,250 g / mol, about 3,500 g / mol, about 3,750 g / mol, about 4,000 g / mol, about 4,250 g / mol, about 4,500 g / mol, about 4,750 g / mol, about 5,000 g / mol, about 5,250 g / mol, about 5,500 g / mol, about 5,750 g / mol, or about 6,000 g / mol, or any range therebetween or combination of ranges.

[0049] In yet another aspect of the present disclosure, polyether polyols characterized by the hydroxyl numbers disclosed above can also be characterized by a hydroxyl functionality of from 2 to 8, alternatively from 2 to 6, alternatively from 2 to 4, or alternatively from 2 to 3. In one aspect, the polyether polyols can also be characterized by a hydroxyl functionality of about 2, about 3, about 4, about 5, about 6, about 7, or about 8, or any range or combination of ranges between any of these values.

[0050] According to another embodiment, the second reaction component (side B) can include a polyether polyol having the disclosed hydroxyl numbers in a concentration of from about 10% to about 50% by weight in the second reaction component, alternatively from about 12% to about 40% by weight, alternatively from about 15% to about 30% by weight, or alternatively from about 18% to about 28% by weight, including any subranges and combinations of subranges subsumed within these ranges. In one aspect, the second reaction composition can include a polyether polyol having a disclosed hydroxyl number at a concentration of about 10 wt%, about 12 wt%, about 13 wt%, about 15 wt%, about 18 wt%, about 20 wt%, about 22 wt%, about 25 wt%, about 28 wt%, about 30 wt%, about 32 wt%, about 35 wt%, about 38 wt%, about 40 wt%, about 42 wt%, about 45 wt%, about 48 wt%, or about 50 wt%, or any range or combination of ranges between any of these values.

[0051] In one aspect, the polyether polyol of the second reaction composition can comprise or be selected from polyoxyethylene diols (glycols), polyoxyethylene triols, polyoxyethylene tetrols, polyoxyethylene pentols, polyoxyethylene hexols, polyoxypropylene diols (glycols), polyoxypropylene triols, polyoxypropylene tetrols, polyoxypropylene pentols, polyoxypropylene hexols, or any combination thereof. The polyether polyol can also comprise or be selected from polypropylene glycol, polyethylene glycol, polytetramethylene glycol, glycerol triol, polyether tetrols, polyether pentols, aliphatic amine tetrols, aromatic amine tetrols, sorbitol, trimethylolpropane (TMP), or pentaerythritol. The polyether polyol can also be formed from the addition of ethylene oxide, propylene oxide, or other (C4-C8) alkylene oxides, or any combination thereof, to any of these polyols.

[0052] In embodiments, the polyether polyol of the second reaction composition may be formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to at least one polyol, at least one polyether polyol, at least one other type of compound having multiple active hydrogens, such as a polyamine, or any combination thereof. In one aspect, the polyether polyol may be formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to an active hydrogen component selected from ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, tripropylene glycol, trimethylpropane (TMP), glycerin, pentalitol, sorbitol, ethylose, diamethylene glycol ...

[0053] In one aspect, the polyether polyol can be formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to an active hydrogen component in the presence of a catalyst. For example, the catalyst can include or be selected from a metal hydroxide, a double metal cyanide catalyst, or a combination thereof. The polyether polyol of the second reaction component can be ethylene oxide terminated to provide a high primary hydroxide content, propylene oxide terminated to provide a high secondary hydroxide content, or the polyether polyol can be a combination of ethylene oxide terminated and propylene oxide terminated.

[0054] In another aspect, the polyether polyols include alkylene oxide adducts of non-reducing sugars or sugar derivatives, alkylene oxide adducts of phosphoric and polyphosphoric acids, alkylene oxide adducts of polyphenols, polyols prepared from natural oils such as castor oil, C2-C 60 , C2~C 40 , or C2~C 20The polyhydroxyalkane may comprise or be selected from alkylene oxide adducts of polyhydroxyalkanes, or any combination thereof.

[0055] According to further aspects of the present disclosure, the polyether polyol of the second reaction composition can comprise or be selected from 1,3-dihydroxypropane, 1,3-dihydroxybutane, 1,4-dihydroxybutane, 1,4-dihydroxyhexane, 1,5-dihydroxyhexane, 1,6-dihydroxyhexane, 1,2-dihydroxyoctane, 1,3-dihydroxyoctane, 1,4-dihydroxyoctane, 1,6-dihydroxyoctane, 1,8-dihydroxyoctane, 1,10-dihydroxydecane, glycerol, 1,2,4-trihydroxybutane, 1,2,6-trihydroxyhexane, 1,1,1-trimethyloleane, 1,1,1-trimethylolpropane, pentaerythritol, caprolactone, polycaprolactone, xylitol, arabitol, sorbitol, mannitol, or any combination thereof.

[0056] Examples of useful commercial polyether polyols include, but are not limited to, Carpol® GP-4520 from Carpenter Company, which is a glycerin-initiated polyether polyol, the resulting material having a functionality of 3 and an average molecular weight of 4500 Da (Daltons). The triol is polymerized with propylene oxide and then capped with 20% ethylene oxide. Other examples of commercial polyether polyols that can be used in accordance with the present disclosure include, but are not limited to, Pluracol® 816, which is a high molecular weight triol with a nominal molecular weight of approximately 4800 Da. Further examples of commercial polyether polyols that can be used in accordance with the present disclosure include, but are not limited to, Arcol® 11-34, which is a high molecular weight polyether polyol, specifically a polyoxypropylene triol modified with ethylene oxide, with a nominal or average molecular weight of approximately 4800 Da.

[0057] In embodiments, the polyether polyol may also include an addition reaction product of an alkylene oxide with an active hydrogen initiator; The alkylene oxide includes ethylene oxide, propylene oxide, butylene oxide, isobutylene oxide, N-hexyl oxide, styrene oxide, trimethylene oxide, epichlorohydrin, or any combination thereof; The active hydrogen initiator includes glycerin, triethanolamine, trimethylolpropane (TMP), or any combination thereof.

[0058] Other polyether polyols that can be used in the second reactant composition are disclosed in U.S. Patent Application Publication No. 2018 / 0072846, which is incorporated herein by reference in its entirety.

[0059] Catalyst. The second reaction composition (side B) can also include a polyurethane-forming catalyst. The catalyst can be any suitable catalyst known in the art suitable for use in producing polyurethane foams from the disclosed components. For example, in one embodiment, the polyurethane-forming catalyst can include or be selected from an amine compound. In one embodiment, the polyurethane-forming catalyst can include or be selected from a primary amine compound, a secondary amine compound, a tertiary amine compound, a quaternary ammonium salt, or a radical former.

[0060] In embodiments, the polyurethane-forming catalyst may include or be selected from Polycat® 15, Polycat® 37, Jeffcat® ZF 20, Jeffcat® Z-130, Jeffcat® LE 30, Dabco® T, Tetramethylguanidine, Dimethylaminopropylamine, Polycat® 30, Polycat® 31, Polycat® 37, Diethanolamine, Triethanolamine, Polycat® 142, Polycat® 141, Dabco® NE300, Dabco® NE310, Toyocat® D60, Dimethylaminoethanol, Jeffcat® ZF-10, Jeffcat® ZR-50, Niax® A-99, or any combination thereof.

[0061] In one embodiment, the polyurethane-forming catalyst can be present in the second reaction composition (side B) at a concentration of about 4% to about 12% by weight. Thus, the catalyst concentration of polyurethane foams of the present disclosure can be higher, including outside the range of catalyst concentrations used for producing packaging foams. In another embodiment, the polyurethane-forming catalyst can be present in the second reaction composition (side B) at a concentration of about 5% to about 11% by weight, or alternatively about 6% to about 10% by weight, including any subranges and combinations of subranges subsumed within these ranges. In a further embodiment, the polyurethane-forming catalyst may be present in the second reaction composition (side B) at a concentration of about 4.0 wt%, about 4.5 wt%, about 5.0 wt%, about 5.5 wt%, about 6.0 wt%, about 6.5 wt%, about 7.0 wt%, about 7.5 wt%, about 8.0 wt%, about 8.5 wt%, about 9.0 wt%, about 9.5 wt%, about 10.0 wt%, about 10.5 wt%, about 11.0 wt%, about 11.5 wt%, or about 12.0 wt%, or any range between any of these values ​​or combinations of ranges.

[0062] Flame Retardant. The second reaction composition (side B) can also include a flame retardant, and any flame retardant suitable for use in polyurethane foams can be used. In one embodiment, for example, the flame retardant can include or be selected from a phosphate compound, a halogenated compound, a non-halogenated compound, or a combination thereof. For example, in one embodiment, the flame retardant can include or be selected from a chlorinated compound, a brominated compound, an iodinated compound, a non-halogenated compound, or a combination thereof.

[0063] In one aspect, the flame retardant can include or can be selected from a halogenated compound selected from tris(2-chloroisopropyl)phosphate (TCPP), tris(1,3-dichloroisopropyl)phosphate (TDCPP), tris(2-chloroethyl)phosphate (TCEP), PHT 4-Diol (tetrabromophthalate diol), PHT 4-Diol LV (tetrabromophthalate diol, low viscosity), Saytex® RB79, Saytex® RB7980, Ixol® B-251, Ixol® M-125, SaFRon® 6605, or any combination thereof. The flame retardant may also include or be selected from a non-halogenated compound selected from triethyl phosphate, melamine, ammonium polyphosphate, VeriQuel® R100, pentaerythritol, sorbitol, xylitol, magnesium hydroxide, aluminum hydroxide, or any combination thereof.

[0064] In another aspect, the flame retardant can include or be selected from brominated compounds such as aryl brominated polyester polyols, brominated aliphatic compounds, brominated benzoate compounds, brominated phthalate compounds, polybrominated diphenyl ethers, polybrominated biphenyls, or any combination thereof. The flame retardant component can also include or be selected from brominated compounds such as dibromomonopentyl glycol, tribromomonopentyl alcohol, n-propyl bromide, bis[dibromopropoxydibromophenyl]propane, hexabromodecane, bis(tribromophenoxy)ethane, or any combination thereof.

[0065] In one embodiment of the polyurethane foam, and method for making the polyurethane foam, the flame retardant may be present in the second reaction composition (side B) at a concentration of from about 4% to about 42% by weight, alternatively from about 10% to about 40% by weight, alternatively from about 20% to about 40% by weight, alternatively from about 15% to about 30% by weight, including any subranges and combinations of subranges subsumed within these ranges. In further embodiments, the flame retardant may be present in the second reactive composition at a concentration of about 4 wt%, about 5 wt%, about 6 wt%, about 8 wt%, about 10 wt%, about 12 wt%, about 14 wt%, about 16 wt%, about 18 wt%, about 20 wt%, about 22 wt%, about 24 wt%, about 25 wt%, about 26 wt%, about 28 wt%, about 30 wt%, about 32 wt%, about 34 wt%, about 36 wt%, about 38 wt%, about 40 wt%, or about 42 wt%, or any range or combination of ranges between any of these values.

[0066] Flame retardants may be used in amounts sufficient to meet or exceed the test standards set forth in ASTM E-84 Flame Spread and Smoke Index. The polyurethane foams disclosed herein may meet or exceed various other tests, such as flame retardancy tests, ignition barrier tests, and thermal barrier tests, as disclosed herein below.

[0067] Surfactants. The second reaction composition (side B) may also include one or more surfactants that are compatible with the ingredients used to make the disclosed foams. In one aspect, for example, the surfactant component may include or be selected from a nonionic surfactant, a silicone surfactant, a non-silicone nonionic surfactant, an organic surfactant, or a combination thereof.

[0068] In one embodiment of the polyurethane foam and process for making polyurethane foam, the surfactant component may be present in the second reaction composition (side B) at a concentration of from about 0.05% to about 6% by weight of the second reaction composition, alternatively from about 0.1% to about 5% by weight, alternatively from about 0.5% to about 4% by weight, alternatively from about 1% to about 3% by weight, including subranges and combinations of subranges subsumed within these ranges. In one embodiment, these concentration numbers do not include the compatibilizer surfactant component, considered below. If an optional compatibilizer is present in the second reaction composition with the surfactant component, the total concentration of surfactant and compatibilizer may be the additive concentration of the surfactant and compatibilizer listed herein, even if both the surfactant and the compatibilizer are, for example, nonionic surfactants.

[0069] In embodiments, the surfactant component may be present in the second reactive composition (side B) at a concentration of about 0.05 wt%, 0.1 wt%, about 0.25 wt%, about 0.5 wt%, about 0.75 wt%, about 1.0 wt%, about 1.5 wt%, about 2.0 wt%, about 2.5 wt%, about 3.0 wt%, about 3.5 wt%, about 4.0 wt%, about 4.5 wt%, about 5.0 wt%, about 5.5 wt%, or about 6.0 wt%, or any range between any of these values ​​or combinations of ranges.

[0070] In some aspects, the surfactant in the second reactive composition may comprise or be selected from alkoxylation products of fatty acids, fatty acid esters, fatty acid amides, fatty alcohols, fatty polyols, sugars, or sugar alcohols. In embodiments, the surfactant in the second reactive composition (side B) may comprise or be selected from sorbitan esters, polyethoxylated sorbitan esters, polyoxyethylene glycol alkyl ethers, polyoxypropylene glycol alkyl ethers, glucoside alkyl ethers, polyoxyethylene glycol octylphenol ethers, polyoxyethylene glycol alkylphenol ethers, polyoxyethylene glycol sorbitan alkyl ethers, sorbitan alkyl ethers, or combinations thereof. In other aspects, the surfactant in the second reactive composition (side B) may comprise or be selected from oxyethylated alkylphenols, oxyethylated fatty acid alcohols, paraffin oil, castor oil esters, ricinoleic acid esters, or fatty acid alcohols.

[0071] According to another aspect, the first reactive composition (side A) may further comprise a surfactant in addition to the polyisocyanate component. Thus, while the first reactive composition (side A) may consist of or consist essentially of the polyisocyanate component, in embodiments, the first reactive composition may comprise a surfactant at a concentration of up to about 5% by weight of the first reactive composition. In this aspect, the surfactant that can be used in the first reactive composition may be a nonionic surfactant, a silicone surfactant, a non-silicone nonionic surfactant, or a combination thereof. In this aspect, the surfactant that can be used in the first reactive composition may be any of the surfactants used in the second reactive composition (side B).

[0072] In one aspect, the surfactant in the second reactive composition (side B) can include or be selected from a non-ionic surfactant such as Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof. In another embodiment, the surfactant in the second reactive composition (side B) can include or be selected from a silicone surfactant such as Silstab® 2760, Silstab® 2780, Silstab® 2550, Niax® L-6189, Vorasurf™ DC198, Niax® L-5388, Niax® L-5345, Dabco® 198, Niax® Y16312, Niax® L-6186, Niax® L-6972, Niax® L-6884, Niax® L-5388, Silstab® 2755, Tegostab® B-8580, Tegostab® B-8870, or any combination thereof. According to a further embodiment, the surfactant in the second reaction composition (side B) may comprise or be selected from an organic surfactant such as Dabco® LK443, Dabco® LK221, Vorsurf® 504, or any combination thereof.

[0073] Compatibilizer. According to one aspect of the present disclosure, the second reactive composition (side B), in addition to the surfactant component described above, may further optionally include a "compatibilizer" or "compatibilizing agent." The compatibilizer may include or be selected from a nonionic surfactant, a non-silicone nonionic surfactant, or a combination thereof.

[0074] In one aspect, there is substantial overlap between the surfactants used in the surfactant component and the optional compatibilizing agent component of the second reaction mixture, and a surfactant selected for one function can serve both functions. In one aspect, the compatibilizing agent can function to "compatibilize" the mixture of chemicals in the first and second reaction components so that the polyurethane-forming reaction can proceed smoothly.

[0075] In embodiments, examples of compatibilizers that may be used in the second reactive composition include, but are not limited to, nonionic surfactants such as Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof.

[0076] In one embodiment of the polyurethane foam and process for making polyurethane foam, the compatibilizer component may be present in the second reaction composition (side B) at a concentration from 0 wt. % since it is an optional component. In another embodiment, the compatibilizer component may be present in the second reaction composition at a concentration from 0 wt. % to about 22 wt. %, alternatively from about 0 wt. % to about 20 wt. %, alternatively from about 2 wt. % to about 20 wt. %, alternatively from about 5 wt. % to about 20 wt. %, alternatively from about 10 wt. % to about 20 wt. %, or alternatively from about 12 wt. % to about 17 wt. %, including subranges and combinations of subranges subsumed within these ranges. In embodiments, the compatibilizer component may be present in the second reactive composition (side B) at a concentration of 0 wt%, or about 0 wt%, about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, about 5 wt%, about 6 wt%, about 7 wt%, about 8 wt%, about 9 wt%, about 10 wt%, about 11 wt%, about 12 wt%, about 13 wt%, about 14 wt%, about 15 wt%, about 16 wt%, about 17 wt%, about 18 wt%, about 19 wt%, about 20 wt%, about 21 wt%, or about 22 wt%, or a range between any of these values ​​or combinations of ranges.

[0077] In one aspect, these concentration numbers do not include the surfactant component described above. If an optional compatibilizer is present in the second reactive composition along with the surfactant component, the total concentration of surfactant and compatibilizer can be the additive concentration of the surfactant and compatibilizer listed herein. In this aspect, the combined concentration of surfactant and compatibilizer components that may be present in the second reactive composition (side B) can be the additive concentration of the surfactant and compatibilizer components listed herein, even if there is a single component, such as a single nonionic surfactant in the second reactive composition, that functions as both the surfactant component and the compatibilizer component.

[0078] Water. The second reaction composition (side B) may also include water as a blowing agent. In one embodiment of polyurethane foams and processes for making polyurethane foams, water may be present in the second reaction composition at a concentration of about 15% to about 55% by weight, alternatively about 20% to about 50% by weight, alternatively about 25% to about 45% by weight, or alternatively about 30% to about 40% by weight, including any subranges and combinations of subranges subsumed within these ranges. According to further embodiments, water may be present in the second reaction composition at a concentration of about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, or about 55% by weight, or any range or combination of ranges between any of these values.

[0079] Other Components. The second reaction composition (side B) may also include several other components that may be considered optional components, since embodiments are known in which any or all of these other components are absent, and embodiments are also known in which any or all of these other components are present. The various optional components are well understood by those skilled in the art.

[0080] In one aspect, for example, optional ingredients include, but are not limited to, plasticizers, emulsifiers, biocides, bacteriostats, fillers, dyes or colorants, scorch inhibitors, crosslinkers, antioxidants, antistatic agents, stabilizers, cell openers, or any combination thereof.

[0081] For example, the second reaction composition can include a stabilizer that imparts rigidity to the foam. For example, the stabilizer can include a glycerin / sucrose-initiated polyether polyol such as Carpol® GSP 520, where the high functionality of the initiator results in a resulting polyol having a nominal functionality of 5 and a typical hydroxyl number of 520. In another aspect, for example, the second reaction composition can include a stabilizer selected from an alkoxylated sucrose glycerin-based polyol, an alkoxylated sucrose glycerin amine-based polyol, an alkoxylated sucrose-diethylene glycol-based polyol, an alkoxylated sucrose-amine-based polyol, an alkoxylated amine-based polyol, a Mannich-based alkoxylated polyol, triethanolamine, diethanolamine, or 2-methyl-2,4-pentanediol.

[0082] In one aspect, for example, the second reaction composition (side B) used to make the polyurethane form can include a plasticizer. In another aspect, the plasticizer can include or be selected from a phthalate plasticizer, a phosphate or phosphorus-containing plasticizer, or a benzoate plasticizer. In some aspects, the flame retardant compound can include or be selected from a phosphate compound, which can exhibit plasticizing properties. In another aspect, for example, the first reaction composition (side A) used to make the polyurethane form can include a plasticizer. For example, the optional plasticizer that can be used in the first reaction composition can include or be selected from a phthalate plasticizer, a phosphate or phosphorus-containing plasticizer, or a benzoate plasticizer.

[0083] Process Parameters. In one embodiment of the present disclosure, the first reactive composition (A-side) and the second reactive composition (B-side) are used in an "off-ratio" A-side:B-side volumetric ratio (v:v), which differs from the approximately 1:1 (v:v) ratio common in conventional spray polyurethane foams due to the use of a higher volume of A-side than B-side. Thus, according to an embodiment, the first reactive composition (A-side) and the second reactive composition (B-side) are used in amounts that provide an A-side:B-side volumetric ratio (v:v) of from about 1.2:1 to about 2.0:1. In other embodiments, the first reactive composition (A-side) and the second reactive composition (B-side) are used in amounts of from about 1.2:1 to about 1.9:1, alternatively from about 1.25:1 to about 1.75:1, alternatively from about 1.3:1 to about 1.6:1, or alternatively from about 1.3:1 to about 1.55:1, including any subranges and combinations of subranges subsumed within these ranges. In one aspect, the volume ratio of side A to side B (v:v) can be about 1.2, about 1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about 1.9, or about 2.0, or any range between any of these values, or combination of ranges.

[0084] According to a further aspect, the process can be carried out using amounts of A-side and B-side components to provide an Isocyanate Index (ISO Index) that is from about 20 to about 40 (expressed as a percentage). According to another aspect, the disclosed process can be carried out using amounts of A-side and B-side components to provide an Isocyanate Index (ISO Index) of from about 20 to about 35, alternatively from about 22 to about 32, or alternatively from about 20 to about 30, or any subranges and combinations of subranges subsumed within these ranges, all expressed as a percentage. For example, in one aspect, the Isocyanate Index (expressed as a percentage) can be about 20, about 21, about 22, about 23, about 24, about 25, about 26, about 27, about 28, about 29, about 30, about 31, about 33, about 34, about 35, about 36, about 37, about 38, about 39, or about 40, or any range or combination of ranges between any of these values.

[0085] According to one embodiment, the ingredients used to make the foams of the present disclosure can be used with a high-pressure system, and the resulting foams can be referred to as high-pressure polyurethane foams. For example, spray foam systems that can be used to produce the disclosed foams include those equipped with proportioners that dispense at pressures of 500 psi (pounds per square inch) to 2,000 psi, alternatively 750 psi to 1,750 psi, or alternatively 1,000 psi to 1,500 psi, including any subranges and combinations of subranges subsumed within these ranges. Pressures outside these ranges are possible; for example, proportioners can be used at pressures up to about 2,500 psi. For example, the proportioner may be configured to provide pressures of about 500 psi, about 550 psi, about 600 psi, about 650 psi, about 700 psi, about 750 psi, about 800 psi, about 850 psi, about 900 psi, about 950 psi, about 1,000 psi, about 1,050 psi, about 1,100 psi, about 1,150 psi, about 1,200 psi, about 1,250 psi, about 1,300 psi, about 1,350 psi, about 1,400 psi, and about 1,450 psi. The pressure may be used for a reservoir dispensing at a pressure of about 0 psi, about 1,450 psi, about 1,500 psi, about 1,550 psi, about 1,600 psi, about 1,650 psi, about 1,700 psi, about 1,750 psi, about 1,800 psi, about 1,850 psi, about 1,900 psi, about 1,950 psi, or about 2,000 psi, or any range or combination of ranges between any of these values.

[0086] In a further embodiment, the contacting of the first reactive composition (side A) and the second reactive composition (side B) can occur at a temperature of from about 100°F to about 160°F, alternatively from about 110°F to about 150°F, or alternatively from about 120°F to about 140°F, including any subranges and combinations of subranges subsumed within these ranges. For example, the contacting of the first reactive composition (side A) and the second reactive composition (side B) can occur at about 100°F, about 110°F, about 120°F, about 130°F, about 140°F, about 150°F, or about 160°F, or any range or combination of ranges between any of these values.

[0087] Foam Properties. In addition to the resulting foam properties disclosed herein, the flame-retardant polyurethane (PUR) foams prepared as described herein exhibit a flame retardant strength of about 0.25 lb / ft. 3 ~approx. 0.45 lb / ft 3 , alternatively about 0.27 lb / ft 3 ~about 0.42lb / ft 3 , or alternatively about 0.28 lb / ft 3 ~approx. 0.40 lb / ft 3 In a further aspect, the flame-retardant polyurethane (PUR) foams prepared as described herein may have a density of about 0.25 lb / ft or less, including any subranges and combinations of subranges subsumed within these ranges. 3 , about 0.26lb / ft 3 , 0.27 lb / ft 3 , 0.28 lb / ft 3 , 0.29 lb / ft 3 , 0.30 lb / ft 3 , 0.31 lb / ft 3 , 0.32 lb / ft 3 , 0.33 lb / ft 3 , 0.34 lb / ft 3 , 0.35 lb / ft 3 , 0.36 lb / ft 3 , 0.37 lb / ft 3 , 0.38 lb / ft 3 , 0.39 lb / ft 3 , 0.40 lb / ft 3 , 0.41 lb / ft 3 , 0.42 lb / ft 3 , 0.43 lb / ft 3 , 0.44 lb / ft 3 , or 0.45 lb / ft 3 , or a range between any of these values, or a combination of ranges.

[0088] Polyurethane foams according to the present disclosure can exhibit good fire resistance, flame retardancy, and thermal insulation properties, as well as good airtightness and sound attenuation properties. For example, polyurethane foams according to the present disclosure can be molded to a thickness of about 3.2 ft according to ASTM C-518. 2 ·°F·h / BTU·in~approx. 4.2ft 2 °F·h / BTU·in, or alternatively, approximately 3.6 ft 2 ·°F·h / BTU·in~approx. 4.0ft 2 3.2 ft , and can be formed into a barrier layer having an R-value of ... 2 ·°F·h / BTU·in, approx. 3.3ft 2 ·°F·h / BTU·in, approx. 3.4ft 2 ·°F·h / BTU·in, approx. 3.5ft 2 ·°F·h / BTU·in, approx. 3.6ft 2 ·°F·h / BTU·in, approx. 3.7ft 2 ·°F·h / BTU·in, approx. 3.8ft 2 ·°F·h / BTU·in, approx. 3.9ft 2 ·°F·h / BTU·in, approx. 4.0ft 2 ·°F·h / BTU·in, approx. 4.1ft 2 ·°F·h / BTU·in, or approximately 4.2 ft 2 The barrier layer can be formed to have an R-value of 100°F·h / BTU·in, including any range between any of these values.

[0089] In one aspect, the polyurethane foams of the present disclosure may also meet or exceed the surface burning characteristics requirements according to ASTM E-84 of a Flame Spread Index of ≦75 and a Smoke Development Index of ≦450, or alternatively a Flame Spread Index of ≦25 and a Smoke Development Index of ≦450.

[0090] According to another aspect, the polyurethane foams of the present disclosure may comply with the International Code Council Evaluation Services Acceptance Criteria for Spray Polyurethane Foam, AC-377, and meet or exceed the requirements for omission of ignition barriers as set forth in the standard.

[0091] In a further aspect, the polyurethane foams of the present disclosure are capable of meeting or exceeding the requirements for the omission of ignition barriers set forth in the International Residential Code, Chapter 3, and the International Building Code, Chapter 26, with special end-use configuration testing. The polyurethane foams of the present disclosure are capable of meeting or exceeding the requirements for the omission of thermal barriers set forth in the International Residential Code, Chapter 3, and the International Building Code, Chapter 26, with special end-use configuration testing.

[0092] In yet another aspect, the polyurethane foams of the present disclosure can meet or exceed the requirements for air impermeable insulation in accordance with ASTM E-2178.

[0093] The polyurethane foams of the present disclosure may also meet or exceed physical property requirements in accordance with the International Code Council Evaluation Service Acceptance Standard for Spray Polyurethane Foam, AC-377, Table 1.

[0094] These and other aspects and embodiments are provided in the examples that follow. [Example]

[0095] These examples are not intended to be limiting, but rather are representative of various embodiments and aspects of the present disclosure. The foams produced in the examples are produced using different volume ratios of the first reaction composition (side A) to the second reaction composition (side B), and therefore provide different NCO indices, as indicated.

[0096] In addition to the component weight percentage ranges described above, variations are possible for each reported mass of each component in Tables 1-5 for each of the examples provided herein. For example, in Tables 1-5, the mass of flame-retardant tris(2-chloroisopropyl)phosphate (TCPP) in the B-side component (resin) can vary by 20% to 30% by weight relative to the other components of the B-side. In one embodiment, the relative mass of each component in the tables can independently vary by about ±1% of the reported relative mass, about ±3% of the reported relative mass, about ±5% of the reported relative mass, about ±10% of the reported relative mass, or about ±15% of the reported relative mass. As an example, if the TCPP relative mass in the B-side component is 20.00, this relative mass can vary by ±10% of the reported relative mass, independently of the other components. Thus, the TCPP relative mass can be 18.00 to 22.00 (20.00 ± 5.5). This variation in the relative mass of TCPP may be independent of the variation in the relative mass of the other components listed in these examples and tables, which is an additional way in which the examples may vary, in addition to the component weight percentage ranges set forth in the detailed description above.

[0097] In these examples, OHV is hydroxyl value, Eq.Wt. is equivalent weight, PBW is weight percent, and Eq. is number of equivalents. The "resin component" corresponds to the second reaction composition (side B) and the "isocyanate component" corresponds to the first reaction composition (side A).

[0098] Example 1 The following table provides a list of ingredients for the first reaction composition (side A) comprising a polyisocyanate and the second reaction composition (side B) comprising a polyether polyol for this example. In this example, a polyurethane (PUR) foam is produced using a side A:side B volume ratio of 1.20:1 and an NCO index of 30.03. [Table 1]

[0099] Example 2 The following table provides a list of ingredients for the first reaction composition (side A) comprising a polyisocyanate and the second reaction composition (side B) comprising a polyether polyol for this example. In this example, a polyurethane (PUR) foam is produced using a side A:side B volume ratio of 2.00:1 and an NCO index of 37.73%. [Table 2]

[0100] Example 3 The following table provides a list of ingredients for the first reaction composition (side A) comprising a polyisocyanate and the second reaction composition (side B) comprising a polyether polyol for the example, in which a polyurethane (PUR) foam is produced using a side A:side B volume ratio of 1.50:1 and an NCO index of 32.79%. [Table 3]

[0101] Example 4 The following table provides a list of ingredients for the first reaction composition (side A) comprising a polyisocyanate and the second reaction composition (side B) comprising a polyether polyol for the example, in which a polyurethane (PUR) foam is produced using a side A:side B volume ratio of 1.75:1 and an NCO index of 38.01%. [Table 4]

[0102] Example 5 The following table provides a list of ingredients for the first reaction composition (side A) comprising a polyisocyanate and the second reaction composition (side B) comprising a polyether polyol for this example. In this example, a polyurethane (PUR) foam is produced using a side A:side B volume ratio of 1.40:1 and an NCO index of 34.36%. [Table 5]

[0103] Example 6 Low density polyurethane foam (4 inches thick) according to embodiment 1 of the present disclosure was applied to 5 / 8 inch thick gypsum board and analyzed according to ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials. The tested specimens were placed in a conditioning room maintained at 70±5°F and 50±5% relative humidity for a minimum of 72 hours prior to testing. The ASTM E84 test results are shown in the table below. [Table 6]

[0104] These ASTM E84 results provide the following flame spread classifications: (1) NFPA Class A (National Fire Protection Association ANSI / NFPA No. 101, Life Safety Code classification); (2) IBC Class A (International Building Code, Chapter 8, Interior Finishes, Section 803 Classification), and (3) IRC Class A (International Residential Code).

[0105] Example 7 A series of test specimens of polyurethane foam according to embodiment 1 of the present disclosure were analyzed according to ASTM E2178-13 Standard Test Method for Air Permeability of Building Materials. To determine that the fiberboard substrate allowed air to pass freely, such that the resistance to air flow within the fiberboard did not affect airflow measurements taken on the test specimens, individual pieces of fiberboard were tested without a membrane applied, and the air permeability of the fiberboard was found to be 2.05 L / sm@2 at 75 Pa. 2 It was determined that:

[0106] Test specimens were conditioned at 21±1°C and 40±5% relative humidity for a minimum of 7 days prior to testing. Test specimens were individually mounted in the test chamber, and the airflow through each specimen was determined according to ASTM E2178-13. Initial air ingress and egress tests were performed at a test pressure of 75 Pa to determine the two larger results. Tests were performed on a total of five specimens, the nominal thicknesses of which are provided below. ASTM E2178 test results are shown in the table below. Table 7 compares the air ingress and egress tests, with ingress providing the larger value, averaging 0.01759 L / m. 2 The air permeability was [Table 7] Table 8 provides data on test results at 50 Pa, 75 Pa, and 100 Pa for air intrusion at standard conditions after remeasurement (L / s m 2 ). [Table 8]

[0107] Air-impermeable insulation has a permeability of 0.02 L / s m when tested with a pressure difference of 75 Pa. 2 (0.004ft 3 / min-ft 2) is defined as the insulation that allows a maximum total air leakage rate of 100 psi. Therefore, all samples in the table above are air-impermeable according to ASTM E2178. The percentage difference for verification was within 10% of the initial value, as specified in Section 8.2.8 of ASTM E2178. An error analysis was performed to correct for test procedure variability, as required by ASTM E2178-03. Readings were corrected for temperature and atmospheric pressure according to ASTM E283.

[0108] Example 8 Flammability testing of low-density, open-cell spray-applied polyurethane foam prepared in accordance with the present disclosure with a 6-mil wet mil FlameSeal IB™ fire-resistant coating (average 4-mil dry film thickness) was performed using a modified version of NFPA 286, Standard Methods of Fire Tests for Evaluating Contribution of Wall and Ceiling Interior Finish to Room Fire Growth—2019 Edition, in accordance with ICC-ES AC377 Appendix X, Acceptance Criteria for Spray-Applied Foam Plastic Insulation, approved in February 2020. Test chamber modules were placed in a conditioned room at 73°F and 64% relative humidity for a minimum of 48 hours prior to testing. The test chamber temperature during testing to ICC-ES AC 377 Appendix X was 65°F (18°C) at 45% relative humidity.

[0109] According to ICC-ES AC377 Appendix X, the mean time to failure must exceed 4 minutes 18 seconds for the following events: heat release rate exceeding 1 MW; average top temperature exceeding 600°C (1112°F); floor heat flow rate exceeding 20 kW / m 2and flames exit the doorway. The table below compares the standard definition of flashover with the actual test results. Therefore, the sample passed the ICC-ES AC377 Appendix X flammability test. [Table 9]

[0110] Therefore, it is concluded that FlameSeal IB fire-resistant coating applied at 6 wet film thickness (4 dry film thickness) complies with the requirements of AC377 Appendix X for use as an alternative ignition barrier when applied to open-cell spray-applied foam insulation in accordance with Aspect 1 at a nominal 0.35 density and 11 inches in a wall cavity and 16.5 inches in a ceiling cavity.

[0111] Example 9 Flammability testing of low-density, open-cell spray-applied polyurethane foam prepared in accordance with the present disclosure with a 4-mil wet IFTI DC315 fire-resistant coating (average 3-mil dry film thickness) was performed using a modified NFPA 286, Standard Methods of Fire Tests for Evaluating Contribution of Wall and Ceiling Interior Finish to Room Fire Growth—2019 Edition, in accordance with ICC-ES AC377 Appendix X, Acceptance Criteria for Spray-Applied Foam Plastic Insulation, approved in February 2020. Test chamber modules were placed in a conditioned room at 73°F and 64% relative humidity for a minimum of 48 hours prior to testing. The test chamber temperature during testing to ICC-ES AC 377 Appendix X was 65°F (18°C) at 45% relative humidity.

[0112] According to ICC-ES AC377 Appendix X, the mean time to failure must exceed 4 minutes 18 seconds for the following events: heat release rate exceeding 1 MW; average top temperature exceeding 600°C (1112°F); floor heat flow rate exceeding 20 kW / m 2 and flames exit the doorway. The table below compares the standard definition of flashover with the actual test results. Therefore, the sample passed the ICC-ES AC377 Appendix X flammability test. [Table 10]

[0113] Therefore, it is concluded that IFTI DC315 applied at 4 wet film thickness (3 dry film thickness) complies with the requirements of AC377 Appendix X for use as an alternative ignition barrier when applied to open cell spray-applied foam insulation in accordance with aspect 1 at a nominal 0.35 density in 11 inches of wall cavities and 16.5 inches of ceiling cavities.

[0114] Example 10 Tests were conducted to determine the R-value of nominally 1-inch thick foam prepared in accordance with the present disclosure. Five samples of 1-inch thick spray foam aged for 90 days in accordance with Embodiment 1 were examined to determine the R-value. The samples were tested at an average temperature of 75°F and had an R-3.8 / inch, or 3.8 / hr-ft 2 The data are summarized in the table below. [Table 11] Aspects of the invention

[0115] The features of the invention described above may further include various aspects, statements, embodiments, and features presented below, which for purposes of this disclosure will be referred to as aspects.

[0116] Aspect 1. A low density polyurethane (PUR) foam, comprising: (a) a first reaction composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of about 20 to about 45; a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in a second reaction composition (side B); A flame retardant; A surfactant, and a second reaction composition (side B) comprising: a first reaction composition (A-side) and a second reaction composition (B-side) are contacted in amounts to provide: [1] a volume ratio (v:v) of A-side to B-side of 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of 20 to 40; Low density PUR foam, approximately 0.25 lb / ft 3 ~approx. 0.45 lb / ft 3 Low density polyurethane (PUR) foam having a density of

[0117] Embodiment 2. A process for making a low density polyurethane (PUR) foam, the process comprising: (a) a first reaction composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of about 20 to about 45; a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in a second reaction composition (side B); A flame retardant; A surfactant, and a second reaction product (side B) comprising water; a first reaction composition (A-side) and a second reaction composition (B-side) are contacted in amounts to provide: [1] a volume ratio (v:v) of A-side to B-side of 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of 20 to 40; Low density PUR foam, approximately 0.25 lb / ft 3 ~approx. 0.45 lb / ft 3 A process for making low density polyurethane (PUR) foam having a density of

[0118] Embodiment 3. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyisocyanate component comprises methylene diphenyl diisocyanate (MDI), polymeric methylene diphenyl diisocyanate (pMDI), or any combination thereof.

[0119] Embodiment 4. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyisocyanate component comprises 2,2'-methylene diphenyl diisocyanate (2,2'-MDI), 4,4'-methylene diphenyl diisocyanate (4,4'-MDI), polymeric methylene diphenyl diisocyanate (PMDI), or any combination thereof.

[0120] Embodiment 5. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyisocyanate component comprises about 20% to about 80% by weight methylene diphenyl diisocyanate (MDI) and about 80% to about 20% by weight polymeric methylene diphenyl diisocyanate (polymeric MDI), or alternatively about 25% to about 75% by weight methylene diphenyl diisocyanate (MDI) and about 75% to about 25% by weight polymeric methylene diphenyl diisocyanate (polymeric MDI).

[0121] Aspect 6. The polyurethane foam or process for making a polyurethane foam of any one of the preceding aspects, wherein the polyisocyanate component has an isocyanate functionality of from about 2.6 to about 2.9.

[0122] Aspect 7. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol is characterized by a hydroxyl number (mg KOH / g) of from about 25 to about 42, or alternatively, from about 28 to about 38.

[0123] Aspect 8. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol is characterized by a molecular weight (weight average or number average) of from about 250 g / mol to about 6,000 g / mol; alternatively, from about 1,000 g / mol to about 5,500 g / mol; alternatively, from about 2,000 g / mol to about 5,250 g / mol; or alternatively, from about 4,000 g / mol to about 5,000 g / mol.

[0124] Aspect 9. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol has a hydroxyl functionality of from 2 to 8, alternatively from 2 to 6, alternatively from 2 to 4, or alternatively from 2 to 3.

[0125] Aspect 10. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol is present in the second reaction composition in a concentration from about 10% to about 50% by weight, alternatively from about 12% to about 40% by weight, alternatively from about 15% to about 30% by weight, or alternatively from about 18% to about 28% by weight in the second reaction composition.

[0126] Aspect 11. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol comprises, or is selected from, polyoxyethylene diols (glycols), polyoxyethylene triols, polyoxyethylene tetrols, polyoxyethylene pentols, polyoxyethylene hexols, polyoxypropylene diols (glycols), polyoxypropylene triols, polyoxypropylene tetrols, polyoxypropylene pentols, polyoxypropylene hexols, or any combination thereof, or alkylene oxide addition products to any one or more of these polyols.

[0127] Aspect 12. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol comprises, or is selected from, polypropylene glycol, polyethylene glycol, polytetramethylene glycol, glycerol triol, polyether tetrol, polyether pentol, aliphatic amine tetrol, aromatic amine tetrol, sorbitol, trimethylolpropane (TMP), or pentaerythritol, or an alkylene oxide addition product to any one or more of these polyols.

[0128] Aspect 13. The polyurethane foam or process for making a polyurethane foam of any one of the preceding aspects, wherein the polyether polyol is formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to at least one polyol, at least one polyether polyol, at least one polyamine, or a combination thereof.

[0129] Aspect 14. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol is formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to an active hydrogen component selected from ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, tripropylene glycol, trimethylolpropane (TMP), glycerol, pentaerythritol, sorbitol, sucrose, ethylenediamine, toluenediamine, or any combination thereof.

[0130] Embodiment 15. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyether polyol is ethylene oxide terminated (high primary hydroxyl content), propylene oxide terminated (high secondary hydroxyl content), or a combination of ethylene oxide terminated and propylene oxide terminated.

[0131] Aspect 16. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol is formed from adding ethylene oxide, propylene oxide, or a combination thereof, added simultaneously or sequentially, to an active hydrogen component in the presence of a catalyst comprising a metal hydroxide, a double metal cyanide catalyst, or a combination thereof.

[0132] Aspect 17. The polyether polyol is an alkylene oxide adduct of a non-reducing sugar or sugar derivative, an alkylene oxide adduct of phosphoric acid and polyphosphoric acid, an alkylene oxide adduct of a polyphenol, a polyol prepared from a natural oil such as castor oil, a C2-C6 60 , C2~C 40 , or C2~C 20

[0023] Aspect 11. The polyurethane foam or process for making a polyurethane foam of any one of the preceding aspects, comprising, or selected from, an alkylene oxide adduct of a polyhydroxyalkane, or any combination thereof.

[0133] Aspect 18. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyether polyol comprises or can be selected from 1,3-dihydroxypropane, 1,3-dihydroxybutane, 1,4-dihydroxybutane, 1,4-dihydroxyhexane, 1,5-dihydroxyhexane, 1,6-dihydroxyhexane, 1,2-dihydroxyoctane, 1,3-dihydroxyoctane, 1,4-dihydroxyoctane, 1,6-dihydroxyoctane, 1,8-dihydroxyoctane, 1,10-dihydroxydecane, glycerol, 1,2,4-trihydroxybutane, 1,2,6-trihydroxyhexane, 1,1,1-trimethyloletane, 1,1,1-trimethylolpropane, pentaerythritol, caprolactone, polycaprolactone, xylitol, arabitol, sorbitol, mannitol, or any combination thereof.

[0134] Embodiment 19. The polyether polyol comprises an addition reaction product of an alkylene oxide with an active hydrogen initiator; the alkylene oxide comprises ethylene oxide, propylene oxide, butylene oxide, isobutylene oxide, N-hexyl oxide, styrene oxide, trimethylene oxide, epichlorohydrin, or any combination thereof;

[0023] Aspect 11. The polyurethane foam or process for making a polyurethane foam of any one of the preceding aspects, wherein the active hydrogen initiator comprises glycerin, triethanolamine, trimethylolpropane (TMP), or any combination thereof.

[0135] Aspect 20: The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane-forming catalyst comprises a primary amine compound, a secondary amine compound, a tertiary amine compound, a quaternary ammonium salt, or a radical former.

[0136] Aspect 21: The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane-forming catalyst comprises Polycat® 15, Polycat® 37, Jeffcat® ZF 20, Jeffcat® Z-130, Jeffcat® LE 30, Dabco® T, tetramethylguanidine, dimethylaminopropylamine, Polycat® 30, Polycat® 31, Polycat® 37, diethanolamine, triethanolamine, Polycat® 142, Polycat® 141, Dabco® NE300, Dabco® NE310, Toyocat® D60, dimethylaminoethanol, Jeffcat® ZF-10, Jeffcat® ZR-50, Niax® A-99, or any combination thereof.

[0137] Embodiment 22. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyurethane-forming catalyst is present in the second reaction composition (side B) at a concentration of from about 4% to about 12% by weight, alternatively from about 5% to about 11% by weight, or alternatively from about 6% to about 10% by weight.

[0138] Embodiment 23. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the flame retardant comprises a phosphate compound, a halogenated compound, a non-halogenated compound, or a combination thereof.

[0139] Aspect 24. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the flame retardant comprises a halogenated compound selected from tris(2-chloroisopropyl)phosphate (TCPP), tris(1,3-dichloroisopropyl)phosphate (TDCPP), tris(2-chloroethyl)phosphate (TCEP), PHT 4-Diol (tetrabromophthalate diol), PHT 4-Diol LV (tetrabromophthalate diol, low viscosity), Saytex® RB79, Saytex® RB7980, Ixol® B-251, Ixol® M-125, SaFRon® 6605, or any combination thereof.

[0140] Aspect 25. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the flame retardant comprises a non-halogenated compound selected from triethyl phosphate, melamine, ammonium polyphosphate, VeriQuel® R100, pentaerythritol, sorbitol, xylitol, magnesium hydroxide, aluminum hydroxide, or any combination thereof.

[0141] Aspect 26. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the flame retardant comprises a brominated compound selected from an aryl brominated polyester polyol, a brominated aliphatic compound, a brominated benzoate compound, a brominated phthalate compound, a polybrominated diphenyl ether, a polybrominated biphenyl, or any combination thereof.

[0142] Aspect 27. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the flame retardant comprises a brominated compound selected from dibromonopentyl glycol, tribromonopentyl alcohol, n-propyl bromide, bis[dibromopropoxydibromophenyl]propane, hexabromodecane, bis(tribromophenoxy)ethane, or any combination thereof.

[0143] Embodiment 28. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the flame retardant is present in the second reaction composition in a concentration from about 4% to about 42% by weight, alternatively from about 10% to about 40% by weight, alternatively from about 20% to about 40% by weight, or alternatively from about 15% to about 30% by weight.

[0144] Embodiment 29. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the surfactant in the second reaction composition (side B) comprises a nonionic surfactant, a silicone surfactant, a non-silicone nonionic surfactant, an organic surfactant, or a combination thereof.

[0145] Aspect 30. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the surfactant in the second reaction composition (side B) comprises a nonionic surfactant selected from Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof.

[0146] Aspect 31. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the surfactant in the second reaction composition (side B) comprises a silicone surfactant selected from Silstab® 2760, Silstab® 2780, Silstab® 2550, Niax® L-6189, Vorasurf™ DC198, Niax® L-5388, Niax® L-5345, Dabco® 198, Niax® Y16312, Niax® L-6186, Niax® L-6972, Niax® L-6884, Niax® L-5388, Silstab® 2755, Tegostab® B-8580, Tegostab® B-8870, or any combination thereof.

[0147] Embodiment 32. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the surfactant in the second reaction composition (side B) comprises an organic surfactant selected from Dabco® LK443, Dabco® LK221, Vorsurf® 504, or any combination thereof.

[0148] Embodiment 33. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the surfactant in the second reaction composition (side B) comprises an alkoxylation product of a fatty acid, a fatty acid ester, a fatty acid amide, a fatty alcohol, an aliphatic polyol, a sugar, or a sugar alcohol.

[0149] Aspect 34. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the surfactant of the second reaction composition (side B) comprises a sorbitan ester, a polyethoxylated sorbitan ester, a polyoxyethylene glycol alkyl ether, a polyoxypropylene glycol alkyl ether, a glucoside alkyl ether, a polyoxyethylene glycol octylphenol ether, a polyoxyethylene glycol alkylphenol ether, a polyoxyethylene glycol sorbitan alkyl ester, a sorbitan alkyl ether, or a combination thereof.

[0150] Embodiment 35. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the surfactant in the second reaction composition (side B) comprises an oxyethylated alkylphenol, an oxyethylated fatty alcohol, paraffin oil, a castor oil ester, a ricinoleic acid ester, or a fatty alcohol.

[0151] Embodiment 36. The polyurethane foam, or the process for making a polyurethane foam, of any one of the preceding embodiments, wherein the surfactant is present in the second reactant composition in a concentration from about 0.05% to about 6% by weight of the second reactant composition; alternatively, from about 0.1% to about 5% by weight; alternatively, from about 0.5% to about 4% by weight; or alternatively, from about 1% to about 3% by weight.

[0152] Embodiment 37. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition (side A) further comprises a surfactant.

[0153] Embodiment 38. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition (side A) comprises a nonionic surfactant, a silicone surfactant, a non-silicone nonionic surfactant, or a combination thereof.

[0154] Aspect 39. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the first reaction composition (side A) further comprises a nonionic surfactant selected from Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof.

[0155] Aspect 40. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the surfactant in the first reaction composition (side A) comprises a silicone surfactant selected from Silstab® 2760, Silstab® 2780, Silstab® 2550, Niax® L-6189, Vorasurf™ DC198, Niax® L-5388, Niax® L-5345, Dabco® 198, Niax® Y16312, Niax® L-6186, Niax® L-6972, Niax® L-6884, Niax® L-5388, Silstab® 2755, Tegostab® B-8580, Tegostab® B-8870, or any combination thereof.

[0156] Embodiment 41. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition (side A) consists essentially of a polyisocyanate component.

[0157] Embodiment 42. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition (side A) comprises a polyisocyanate component at a concentration of at least about 95% by weight of the first reaction composition.

[0158] Embodiment 43. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the second reaction composition (side B) further comprises a compatibilizing agent.

[0159] Embodiment 44. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the second reaction composition (side B) further comprises a compatibilizing agent selected from a nonionic surfactant, a non-silicone nonionic surfactant, or a combination thereof.

[0160] Aspect 45. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the second reaction composition (side B) further comprises a compatibilizer selected from Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof.

[0161] Embodiment 46. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the compatibilizer is present in the second reaction composition (side B) at a concentration of from about 2% to about 20% by weight, alternatively from about 5% to about 20% by weight, alternatively from about 10% to about 20% by weight, or alternatively from about 12% to about 17% by weight.

[0162] Embodiment 47. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein water is present in the second reaction composition (side B) at a concentration of from about 15% to about 55% by weight, alternatively from about 20% to about 50% by weight, alternatively from about 25% to about 45% by weight, or alternatively from about 30% to about 40% by weight.

[0163] Embodiment 48. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the second reaction composition further comprises any one or more of a plasticizer, an emulsifier, a biocide, a bacteriostat, a filler, a dye or colorant, a scorch inhibitor, a crosslinking agent, an antioxidant, an antistatic agent, or a cell opener.

[0164] Embodiment 49. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the second reaction composition further comprises a plasticizer selected from a phthalate plasticizer, a phosphate or phosphorus-containing plasticizer, or a benzoate plasticizer.

[0165] Aspect 50. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the second reaction composition further comprises a stabilizer comprising a glycerin / sucrose-initiated polyether polyol, an alkoxylated sucrose-glycerin-based polyol, an alkoxylated sucrose-glycerin amine-based polyol, an alkoxylated sucrose-diethylene glycol-based polyol, an alkoxylated sucrose-amine-based polyol, an alkoxylated amine-based polyol, a Mannich-based alkoxylated polyol, triethanolamine, diethanolamine, or 2-methyl-2,4-pentanediol.

[0166] Embodiment 51. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition further comprises a plasticizer selected from a phthalate plasticizer, a phosphate or phosphorus-containing plasticizer, or a benzoate plasticizer.

[0167] Embodiment 52. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the second reactant composition further comprises a crosslinker selected from a propoxylated sucrose-glycerin-based polyol.

[0168] Embodiment 53. The polyurethane foam or process for making a polyurethane foam of any one of the preceding embodiments, wherein the contacting occurs at high pressure by dispensing the components at a pressure of from 500 psi (pounds per square inch) to 2,000 psi, alternatively from 750 psi to 1,750 psi, or alternatively from 1,000 psi to 1,500 psi.

[0169] Embodiment 54. The polyurethane foam or process for making a polyurethane foam of any one of the preceding embodiments, wherein the contacting occurs by dispensing the plurality of components at a temperature of from 100°F to 160°F, alternatively from 110°F to 150°F, or alternatively from 120°F to 140°F.

[0170] Embodiment 55. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reaction composition (A-side) and the second reaction composition (B-side) are used in amounts to provide a volume ratio (v:v) of A-side:B-side from about 1.2:1 to about 1.9:1, alternatively from about 1.25:1 to about 1.75:1, alternatively from about 1.3:1 to about 1.6:1, or alternatively from about 1.3:1 to about 1.55:1.

[0171] Embodiment 56. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the first reactant composition and the second reactant composition are used in amounts to provide an Isocyanate Index (as a percentage) of from 20 to 35, alternatively from 22 to 32, or alternatively from 20 to 30.

[0172] Embodiment 57. The polyurethane foam has a viscosity of about 0.27 lb / ft 3 ~about 0.42lb / ft 3 , or approximately 0.28 lb / ft 3 ~approx. 0.40 lb / ft 3 10. The polyurethane foam or process for making a polyurethane foam of any one of the preceding aspects, having a density of

[0173] Aspect 58. A polyurethane foam is formed according to ASTM C-518 into a 3.2 ft 2 ·°F·h / BTU·in~4.2ft 2 °F·h / BTU·in, or alternatively 3.6 ft 2 ·°F·h / BTU·in~4.0ft 2 10. The polyurethane foam or process for making a polyurethane foam of any one of the preceding embodiments, formed into a barrier layer having an R-value of .degree. F. h / BTU in.

[0174] Aspect 59. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane foam meets or exceeds the surface flammability characteristics requirements in accordance with ASTM E-84 of ≦75 Flame Spread Index and ≦450 Smoke Development Index, or alternatively, ≦25 Flame Spread Index and ≦450 Smoke Development Index.

[0175] Aspect 60. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane foam meets or exceeds the requirements for omission of an ignition barrier as set forth in the International Code Council Evaluation Services Acceptance Criteria for Spray Polyurethane Foam, AC-377, as defined in the International Code Council Evaluation Services Acceptance Criteria for Spray Polyurethane Foam.

[0176] Aspect 61. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane foam meets or exceeds the requirements for omission of ignition barriers set forth in Chapter 3 of the International Residential Code and Chapter 26 of the International Building Code, via special end-use configuration testing.

[0177] Aspect 62. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane foam, in accordance with Chapter 3 of the International Residential Code and Chapter 26 of the International Building Code, meets or exceeds the requirements for omission of a thermal barrier as set forth in the code through special end-use configuration testing.

[0178] Embodiment 63. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding embodiments, wherein the polyurethane foam meets or exceeds the requirements for air impermeable insulation according to ASTM E-2178.

[0179] Aspect 64. The polyurethane foam, or process for making a polyurethane foam, of any one of the preceding aspects, wherein the polyurethane foam meets or exceeds physical property requirements according to International Code Council Evaluation Service Acceptance Criteria for Spray Polyurethane Foam, AC-377, Table 1, for low density insulation.

Claims

1. 1. A low density polyurethane (PUR) foam, said foam comprising: (a) a first reactive composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of from about 20 to about 45; a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in said second reaction composition (side B); A flame retardant; A surfactant, and a second reaction composition (side B) comprising water, the first reaction composition (A-side) and the second reaction composition (B-side) are contacted in amounts to provide: [1] an A-side:B-side volume ratio (v:v) of from 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of from 20 to 40; The low density PUR foam has a density of about 0.25 lb / ft ３ (4.0kg / m 3 ) ~ approx. 0.45lb / ft ３ (7.2 kg / m 3 ).

2. 10. The low density polyurethane (PUR) foam according to claim 1, wherein the polyisocyanate component comprises methylene diphenyl diisocyanate (MDI), polymeric methylene diphenyl diisocyanate (PMDI), or any combination thereof.

3. The low density polyurethane (PUR) foam of claim 1 , wherein the polyisocyanate component has an isocyanate functionality of from about 2.6 to about 2.

9.

4. The polyether polyol a hydroxyl number (mg KOH / g) of about 25 to about 42; a weight average molecular weight or number average molecular weight of about 250 g / mol to about 6,000 g / mol, and 10. The low density polyurethane (PUR) foam of claim 1, characterized by any one of a hydroxyl functionality from 2 to 8, or any combination thereof.

5. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyether polyol is present in the second reaction composition at a concentration of from about 10% to about 50% by weight.

6. The polyether polyol polyoxyethylene diols (glycols), polyoxyethylene triols, polyoxyethylene tetrols, polyoxyethylene pentols, polyoxyethylene hexols, polyoxypropylene diols (glycols), polyoxypropylene triols, polyoxypropylene tetrols, polyoxypropylene pentols, polyoxypropylene hexols, or any combination thereof, or alkylene oxide addition products to any one or more of these polyols; or 10. The low density polyurethane (PUR) foam of claim 1, comprising polypropylene glycol, polyethylene glycol, polytetramethylene glycol, glycerol triol, polyether tetrol, polyether pentol, aliphatic amine tetrol, aromatic amine tetrol, sorbitol, trimethylolpropane (TMP), or pentaerythritol, or alkylene oxide addition products to any one or more of these polyols.

7. The polyether polyol is prepared by adding ethylene oxide, propylene oxide, or a combination thereof, either simultaneously or sequentially, at least one polyol, at least one polyether polyol, at least one polyamine, or a combination thereof; or 10. The low density polyurethane (PUR) foam of claim 1 formed from adding to it an active hydrogen component selected from ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, tripropylene glycol, trimethylolpropane (TMP), glycerol, pentaerythritol, sorbitol, sucrose, ethylenediamine, toluenediamine, or any combination thereof.

8. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyether polyol is ethylene oxide terminated (high primary hydroxyl content), propylene oxide terminated (high secondary hydroxyl content), or a combination of ethylene oxide terminated and propylene oxide terminated.

9. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyether polyol is formed from adding ethylene oxide, propylene oxide, or a combination thereof added simultaneously or sequentially, to an active hydrogen component in the presence of a catalyst comprising a metal hydroxide, a double metal cyanide catalyst, or a combination thereof.

10. The polyether polyol Alkylene oxide adducts of non-reducing sugars or sugar derivatives, alkylene oxide adducts of phosphoric acid and polyphosphoric acid, alkylene oxide adducts of polyphenols, polyols prepared from natural oils, C ２ ~C ６０ , C ２ ~C ４０ , or C ２ ~C ２０ alkylene oxide adducts of polyhydroxyalkanes, or any combination thereof; or 10. The low-density polyurethane (PUR) foam of claim 1, comprising an alkylene oxide adduct of 1,3-dihydroxypropane, 1,3-dihydroxybutane, 1,4-dihydroxybutane, 1,4-dihydroxyhexane, 1,5-dihydroxyhexane, 1,6-dihydroxyhexane, 1,2-dihydroxyoctane, 1,3-dihydroxyoctane, 1,4-dihydroxyoctane, 1,6-dihydroxyoctane, 1,8-dihydroxyoctane, 1,10-dihydroxydecane, glycerol, 1,2,4-trihydroxybutane, 1,2,6-trihydroxyhexane, 1,1,1-trimethylolethane, 1,1-trimethylolpropane, pentaerythritol, caprolactone, polycaprolactone, xylitol, arabitol, sorbitol, mannitol, or combinations thereof.

11. the polyether polyol comprises an addition reaction product of an alkylene oxide with an active hydrogen initiator; the alkylene oxide comprises ethylene oxide, propylene oxide, butylene oxide, isobutylene oxide, N-hexyl oxide, styrene oxide, trimethylene oxide, epichlorohydrin, or any combination thereof; 10. The low density polyurethane (PUR) foam of claim 1, wherein the active hydrogen initiator comprises glycerin, triethanolamine, trimethylolpropane (TMP), or any combination thereof.

12. The polyurethane-forming catalyst is 10. The low density polyurethane (PUR) foam of claim 1, comprising a primary amine compound, a secondary amine compound, a tertiary amine compound, a quaternary ammonium salt, or a radical former.

13. The polyurethane-forming catalyst is Polycat® 15, Polycat® 37, Jeffcat® ZF 20, Jeffcat® Z-130, Jeffcat® LE 30, Dabco® T, tetramethylguanidine, dimethylaminopropylamine, Polycat® 30, Polycat® 31, Polycat® 37, diethanolamine, triethanolamine, Polycat® 142, Polycat® 141, Dabco® NE300, Dabco® NE310, Toyocat® D60, dimethylaminoethanol, Jeffcat® ZF-10, Jeffcat® ZR-50, Niax® A-99, or any combination thereof.

14. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane-forming catalyst is present in the second reaction composition (B-side) at a concentration of from about 4% to about 12% by weight.

15. 10. The low density polyurethane (PUR) foam according to claim 1, wherein the flame retardant comprises a phosphate compound, a halogenated compound, a non-halogenated compound, or a combination thereof.

16. The flame retardant is a halogenated compound selected from tris(2-chloroisopropyl)phosphate (TCPP), tris(1,3-dichloroisopropyl)phosphate (TDCPP), tris(2-chloroethyl)phosphate (TCEP), PHT 4-diol (tetrabromophthalate diol), PHT 4-diol LV (tetrabromophthalate diol, low viscosity), Saytex® RB79, Saytex® RB7980, Ixol® B-251, Ixol® M-125, SaFron® 6605, or any combination thereof; 10. The low density polyurethane (PUR) foam of claim 1, comprising a non-halogenated compound selected from triethyl phosphate, melamine, ammonium polyphosphate, VeriQuel® R100, pentaerythritol, sorbitol, xylitol, magnesium hydroxide, aluminum hydroxide, or any combination thereof.

17. The flame retardant is aryl brominated polyester polyols, brominated aliphatic compounds, brominated benzoate compounds, brominated phthalate compounds, polybrominated diphenyl ethers, polybrominated biphenyls, or any combination thereof; or 10. The low density polyurethane (PUR) foam of claim 1, comprising a brominated compound selected from dibromoneopentyl glycol, tribromoneopentyl alcohol, n-propyl bromide, bis[dibromopropoxydibromophenyl]propane, hexabromodecane, bis(tribromophenoxy)ethane, or any combination thereof.

18. 10. The low density polyurethane (PUR) foam of claim 1, wherein the flame retardant is present in the second reactant composition at a concentration of from about 4% to about 42% by weight.

19. 10. The low density polyurethane (PUR) foam of claim 1, wherein the surfactant in the second reaction composition (side B) comprises a nonionic surfactant, a silicone surfactant, a non-silicone nonionic surfactant, an organic surfactant, or a combination thereof.

20. the non-ionic surfactant is selected from Surfonic® N95, Tergitol® NP9, Ecosurf® SA9, Surfonic® CO-25, Surfonic® ME400-CO, Surfonic® N120, Ecosurf® SA7, Ecosurf® SA4, Surfonic® ME550, or any combination thereof; the silicone surfactant is selected from Silstab® 2760, Silstab® 2780, Silstab® 2550, Niax® L-6189, Vorasurf™ DC198, Niax® L-5388, Niax® L-5345, Dabco® 198, Niax® Y16312, Niax® L-6186, Niax® L-6972, Niax® L-6884, Niax® L-5388, Silstab® 2755, Tegostab® B-8580, Tegostab® B-8870, or any combination thereof; 20. The low density polyurethane (PUR) foam of claim 19, wherein the organic surfactant is selected from Dabco® LK443, Dabco® LK221, Vorsurf® 504, or any combination thereof.

21. 10. The low density polyurethane (PUR) foam of claim 1, wherein the surfactant in the second reaction composition (side B) comprises an alkoxylation product of a fatty acid, a fatty acid ester, a fatty acid amide, a fatty alcohol, an aliphatic polyol, a sugar, or a sugar alcohol.

22. The surfactant in the second reaction composition (side B) is Sorbitan esters, polyethoxylated sorbitan esters, polyoxyethylene glycol alkyl ethers, polyoxypropylene glycol alkyl ethers, glucoside alkyl ethers, polyoxyethylene glycol octylphenol ethers, polyoxyethylene glycol alkylphenol ethers, polyoxyethylene glycol sorbitan alkyl esters, sorbitan alkyl esters, or combinations thereof; or 10. The low density polyurethane (PUR) foam of claim 1 comprising an oxyethylated alkylphenol, an oxyethylated fatty alcohol, a paraffin oil, a castor oil ester, a ricinoleic acid ester, or a fatty alcohol.

23. 10. The low density polyurethane (PUR) foam of claim 1, wherein the surfactant is present in the second reactant composition at a concentration of from about 0.05% to about 6% by weight.

24. 10. The low density polyurethane (PUR) foam of claim 1, wherein the first reaction composition (A-side) further comprises a surfactant.

25. 10. The low density polyurethane (PUR) foam of claim 1, wherein said first reaction composition (A-side) consists essentially of said polyisocyanate component.

26. 10. The low density polyurethane (PUR) foam of claim 1, wherein said first reaction composition (side A) comprises said polyisocyanate component at a concentration of at least about 95% by weight of said first reaction composition.

27. 10. The low density polyurethane (PUR) foam of claim 1, wherein the second reaction composition (B-side) further comprises a compatibilizing agent selected from a nonionic surfactant, a non-silicone nonionic surfactant, or a combination thereof, and the compatibilizing agent is present in the second reaction composition (B-side) at a concentration of about 2% to about 20% by weight of the second reaction composition.

28. 10. The low density polyurethane (PUR) foam of claim 1, wherein the water is present in the second reaction composition (B-side) at a concentration of about 15% to about 55% by weight.

29. 10. The low density polyurethane (PUR) foam of claim 1, wherein the second reaction composition further comprises a plasticizer, an emulsifier, a biocide, a bacteriostat, a filler, a dye or colorant, a scorch inhibitor, a crosslinker, an antioxidant, an antistatic agent, a stabilizer, a cell opener, or any combination thereof.

30. 10. The low-density polyurethane (PUR) foam of claim 1, wherein the second reaction composition further comprises a stabilizer comprising a glycerin / sucrose-initiated polyether polyol, an alkoxylated sucrose-glycerin-based polyol, an alkoxylated sucrose-glycerin amine-based polyol, an alkoxylated sucrose-diethylene glycol-based polyol, an alkoxylated sucrose-amine-based polyol, an alkoxylated amine-based polyol, a Mannich-based alkoxylated polyol, triethanolamine, diethanolamine, or 2-methyl-2,4-pentanediol.

31. 10. The low density polyurethane (PUR) foam of claim 1, wherein the first reactive composition, the second reactive composition, or both the first reactive composition and the second reactive composition further comprise a plasticizer selected from a phthalate plasticizer, a phosphate or phosphorus-containing plasticizer, or a benzoate plasticizer.

32. 10. The low density polyurethane (PUR) foam of claim 1, wherein the second reaction composition further comprises a crosslinker selected from propoxylated sucrose-glycerin-based polyols.

33. the first reaction composition (A-side) and the second reaction composition (B-side) are used in amounts to provide an A-side:B-side volume ratio (v:v) of from 1.25:1 to 1.75:1, and an isocyanate index (as a percentage) of from 20 to 35; The polyurethane foam has a viscosity of about 0.27 lb / ft. ３ (4.3kg / m 3 ) ~ approx. 0.42lb / ft ３ 10. The low density polyurethane (PUR) foam of claim 1 having a density of (6.7 kg / m<3>).

34. The polyurethane foam is 3.2 ft. ２ ・°F・h / BTU・in (22.2m・K / W) ~ 4.2ft ２ 10. The low density polyurethane (PUR) foam of claim 1 formed into a barrier layer having an R-value of 29.1 m K / W.

35. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane foam meets or exceeds the surface burning characteristics requirements according to ASTM E-84 of ≦75 flame spread index and ≦450 smoke development index.

36. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane foam, in accordance with International Code Council Evaluation Services Acceptance Criteria for Spray Polyurethane Foam, AC-377, meets or exceeds the requirements for omission of the ignition barrier set forth in the code.

37. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane foam meets or exceeds the requirements for omission of ignition barriers set forth in the International Residential Code, Chapter 3, and the International Building Code, Chapter 26, through special end-use configuration testing.

38. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane foam meets or exceeds the requirements for omission of thermal barriers set forth in the International Residential Code, Chapter 3, and the International Building Code, Chapter 26, through special end-use construction testing.

39. A low density polyurethane (PUR) foam as described in claim 1, wherein the polyurethane foam meets or exceeds the requirements for air impermeable insulation in accordance with ASTM E-2178.

40. 10. The low density polyurethane (PUR) foam of claim 1, wherein the polyurethane foam meets or exceeds the physical property requirements according to International Code Council Evaluation Services Acceptance Criteria for Spray Polyurethane Foam, AC-377, Table 1 for low density thermal insulation.

41. 1. A process for making low density polyurethane (PUR) foam, said process comprising: (a) a first reactive composition (side A) comprising an aromatic polyisocyanate component having an isocyanate functionality of from about 2.5 to about 3.0; (b) a second reaction composition (side B), a polyether polyol characterized by a hydroxyl number (mg KOH / g) of from about 20 to about 45; a polyurethane-forming catalyst in a concentration of 5% to 12% by weight in said second reaction composition (side B); A flame retardant; A surfactant, and a second reaction product (side B) comprising water; the first reaction composition (A-side) and the second reaction composition (B-side) are contacted in amounts to provide: [1] an A-side:B-side volume ratio (v:v) of from 1.2:1 to 2:1; and [2] an isocyanate index (expressed as a percentage) of from 20 to 40; The low-density PUR foam has a density of about 0.25 lb / ft ３ (4.0 kg / m3) to about 0.45 lb / ft ３ (7.2 kg / m3), a process for producing a low-density polyurethane (PUR) foam.

42. 42. The process for making low density polyurethane (PUR) foam of claim 41, wherein said contacting occurs at high pressure with multiple components dispensing at a pressure of 500 psi (pounds per square inch) (3.45 MPa) to 2,000 psi (13.8 MPa).

43. 42. The process for making low density polyurethane (PUR) foam of claim 41, wherein said contacting occurs by dispensing multiple components at a temperature of from 100°F (37.8°C) to 160°F (71.1°C).

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