Compositions for forming foams

Abstract

Embodiments of the present disclosure are directed towards compositions for forming foams including an isocyanate-reactive composition including a first aromatic polyester polyol, a second aromatic polyester polyol, a third aromatic polyester polyol, a phosphorous ionic liquid, and an isocyanate composition including an isocyanate.

Description

COMPOSITIONS FOR FORMING FOAMSField of Disclosure

[0001] This disclosure relates to compositions for forming foams and methods for making and using them.Background

[0002] Foam is used as thermal insulation material in buildings, vehicles, and appliances, among other applications. Foam is made by reacting one or more polyols and one or more isocyanates.Summary

[0003] The present disclosure provides various embodiments, including the following. A composition for forming foam including an isocyanate-reactive composition including a first aromatic polyester polyol, a second aromatic polyester polyol, a third aromatic polyester polyol, a phosphorous ionic liquid, and an isocyanate composition including an isocyanate.Detailed Description

[0004] Compositions for forming foams are disclosed herein. The compositions for forming foams, as disclosed herein, can provide a combination of desirable properties, as discussed further herein. The compositions for forming foams disclosed herein can advantageously be utilized to make a foam having desirable fire test properties, e.g., a B2 fire rating determined in accordance with EN 11925-2.

[0005] Previous foams have utilized flame retardants, such as tris(chloropropyl) phosphate and / or triethyl phosphate. However, tris(chloropropyl) phosphate is being phased out in a number of locations and / or for a number of applications and triethyl phosphate disadvantageously performs a plasticizer while being non-reactive in the foaming reaction. As such, formulations, which do not utilize tris(chloropropyl) phosphate or triethyl phosphate, that can make foams having desirable fire test properties are desirable.

[0006] Embodiments of the present disclosure adventitiously provide that the compositions for forming foams include a phosphorous ionic liquid. As mentioned, compositions for forming foams disclosed herein can advantageously be utilized to make a foam having desirable fire test properties. Further, these compositions for forming foams do not utilize tris(chloropropyl) phosphate or triethyl phosphate.

[0007] Further, the compositions for forming foams disclosed herein can provide foam having an improved, i.e. reduced, friability, as compared to other foam formulations thatinclude similar polyols. Reduced friability is desirable for a number of applications, such as insulation applications. A foam with reduced friability is less likely to break down and / or generate dust over time, thereby maintaining structural integrity and insulating properties, as compared to a foam with a relatively greater friability.

[0008] The compositions for forming foams disclosed herein include an isocyanatereactive composition and an isocyanate composition.

[0009] Embodiments provide that the isocyanate-reactive composition includes a first aromatic polyester polyol, a second aromatic polyester polyol, and a third aromatic polyester polyol. As used herein, “polyol” refers to a molecule having an average of greater than 1.0 hydroxyl groups per molecule, e.g., an average hydroxyl functionality of greater than 1.0.

[0010] Embodiments provide that the first aromatic polyester polyol is terephthalic acid initiated. The first aromatic polyester polyol can have a functionary from 2 to 4. As used herein, “functionality” refers to an average hydroxyl functionality, unless stated otherwise. One or more embodiments provide that the first aromatic polyester polyol has a functionality of 2.

[0011] Embodiments provide that the first aromatic polyester polyol has an average hydroxyl number from 205 to 240 mg KOH / g. All individual values and subranges from 205 to 240 mg KOH / g are included; for example, the first aromatic polyester polyol can have an average hydroxyl number from a lower limit of 205, 210, or 215 mg KOH / g to an upper limit of 240, 230, or 225 mg KOH / g. Hydroxyl number can be determined by ASTM D4274-21.

[0012] Embodiments provide that the first aromatic polyester polyol has a number average molecular weight from 400 to 600 g / mol. All individual values and subranges from 400 to 600 g / mol are included; for example, the first aromatic polyester polyol can have number average molecular weight from a lower limit of 400, 425, or 475 g / mol to an upper limit of 600, 575, or 550 g / mol. Number average molecular weight can be determined by GPC.

[0013] The first aromatic polyester polyol can be made with known equipment, known components, and known conditions. The first aromatic polyester polyol may be obtained commercially.

[0014] The first aromatic polyester polyol can be from 25 to 55 weight percent (wt%) of the isocyanate-reactive composition based upon a total weight (100 wt%) of the isocyanate-reactive composition. All individual values and subranges from 25 to 55 wt%are included; for example, the first aromatic polyester polyol can be from a lower limit of 25, 30, or 35 wt% to an upper limit of 55, 50 or 45 wt% of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

[0015] Embodiments provide that the second aromatic polyester polyol is terephthalic acid initiated. The second aromatic polyester polyol can have a functionary from 2 to 4. One or more embodiments provide that the second aromatic polyester polyol has a functionality of 2.4.

[0016] Embodiments provide that the second aromatic polyester polyol has an average hydroxyl number from 310 to 400 mg KOH / g. All individual values and subranges from 310 to 400 mg KOH / g are included; for example, the second aromatic polyester polyol can have an average hydroxyl number from a lower limit of 310 or 315 mg KOH / g to an upper limit of 400, 375, 350, or 325 mg KOH / g.

[0017] Embodiments provide that the second aromatic polyester polyol has a number average molecular weight from 300 to 550 g / mol. All individual values and subranges from 300 to 550 g / mol are included; for example, the second aromatic polyester polyol can have number average molecular weight from a lower limit of 300, 350, or 400 g / mol to an upper limit of 550, 500, or 450 g / mol.

[0018] The second aromatic polyester polyol can be made with known equipment, known components, and known conditions. The second aromatic polyester polyol may be obtained commercially.

[0019] The second aromatic polyester polyol can be from 5 to 25 wt% of the isocyanatereactive composition based upon a total weight of the isocyanate-reactive composition. All individual values and subranges from 5 to 25 wt% are included; for example, the second aromatic polyester polyol can be from a lower limit of 5, 8, or 10 wt% to an upper limit of 25, 20 or 15 wt% of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

[0020] Embodiments provide that the third aromatic polyester polyol is terephthalic acid initiated. The third aromatic polyester polyol can have a functionary from 2 to 4. One or more embodiments provide that the third aromatic polyester polyol has a functionality of 2.

[0021] Embodiments provide that the third aromatic polyester polyol has an average hydroxyl number from 250 to 305 mg KOH / g. All individual values and subranges from 250 to 305 mg KOH / g are included; for example, the third aromatic polyester polyol canhave an average hydroxyl number from a lower limit of 250, 275, or 285 mg KOH / g to an upper limit of 305 or 300 mg KOH / g.

[0022] Embodiments provide that the third aromatic polyester polyol has a number average molecular weight from 400 to 650 g / mol. All individual values and subranges from 400 to 650 g / mol are included; for example, the third aromatic polyester polyol can have number average molecular weight from a lower limit of 400, 450, or 500 g / mol to an upper limit of 650, 600, or 575 g / mol.

[0023] The third aromatic polyester polyol can be made with known equipment, known components, and known conditions. The third aromatic polyester polyol may be obtained commercially.

[0024] The third aromatic polyester polyol can be from 10 to 30 wt% of the isocyanatereactive composition based upon a total weight of the isocyanate-reactive composition. All individual values and subranges from 10 to 30 wt% are included; for example, the third aromatic polyester polyol can be from a lower limit of 10, 13, or 15 wt% to an upper limit of 30, 28 or 25 wt% of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

[0025] Embodiments provide that the isocyanate-reactive composition includes a phosphorous ionic liquid. As used herein, “phosphorous ionic liquid” refers to a phosphorous ionic composition that is liquid at Standard Ambient Temperature and Pressure (SATP: 25 °C; 101 .325 kPa). The phosphorous ionic liquid includes a compound having phosphorus. Embodiments provide that the phosphorous ionic liquid can be a phosphate ionic liquid. Embodiments provide that the phosphorous ionic liquid can be an imidazolium ionic liquid.

[0026] Embodiments provide that the phosphorous ionic liquid is reactive with one or components of the compositions for forming foams disclosed herein. As such, the phosphorous ionic liquid may be referred to as a reactive phosphorous ionic liquid. Advantageously, utilizing the reactive phosphorous ionic liquid can reduce plasticizing that may occur when utilizing non-reactive additives.

[0027] Embodiments provide that the phosphorous ionic liquid is 1 -Ethyl-3- methylimidazolium diethyl phosphate (CAS 848641 -69-0).

[0028] The phosphorous ionic liquid can be from 4 to 15 wt% of the isocyanate-reactive composition based upon a total weight of the isocyanate-reactive composition. All individual values and subranges from 4 to 15 wt% are included; for example, the phosphorous ionic liquid can be from a lower limit of 4, 5, or 6 wt% to an upper limit of15, 12, or 10 wt% of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

[0029] Embodiments provide that the isocyanate-reactive composition includes a catalyst. The catalyst may be a blowing catalyst, a gelling catalyst, a trimerization catalyst, or a combination thereof.

[0030] Examples of blowing catalysts, include, but are not limited to, short chain tertiary amines or tertiary amines containing an oxygen. The amine-based catalyst may not be sterically hindered. For instance, blowing catalysts include bis-(2- dimethylaminoethyl)ether, pentamethyldiethylene-triamine, triethylamine, tributyl amine, N,N-dimethylaminopropylamine, N,N-dimetilciclohexilamina, dimethylethanolamine, N,N,N',N'-tetra-methylethylenediamine, and combinations thereof, among others. Examples of commercial blowing catalysts are POLYCAT 5 and POLYCAT 8 from Evonik, among other commercially available blowing catalysts.

[0031] Examples of gelling catalysts include, but are not limited to, organometallic compounds, cyclic tertiary amines and / or long chain amines, e.g., that contain several nitrogen atoms, and combinations thereof. Organometallic compounds include organotin compounds, such as tin(ll) salts of organic carboxylic acids, e.g., tin(ll) diacetate, tin(ll) dioctanoate, tin(ll) diethylhexanoate, and tin(ll) dilaurate, and dialkyltin(IV) salts of organic carboxylic acids, e.g., dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate and dioctyltin diacetate. Bismuth salts of organic carboxylic acids may also be utilized as the gelling catalyst, such as, for example, bismuth octanoate. Cyclic tertiary amines and / or long chain amines include dimethylbenzylamine, triethylenediamine, and combinations thereof. Examples of a commercially available gelling catalysts are POLYCAT SA-2LE, DABCO 33 LV, DABCO BL-11 , DABCO EG, and DABCO T-12 from Evonik, among other commercially available gelling catalysts.

[0032] Examples of a commercially available trimerization catalysts are POLYCAT 41 , DABCO K 2097, and DABCO TMR 30, from Evonik, among other commercially available trimerization catalysts.

[0033] The catalyst can be from 0.1 to 4 wt% of the isocyanate-reactive composition based upon a total weight of the isocyanate-reactive composition. All individual values and subranges from 0.1 to 4 wt% are included; for example, the catalyst can be from a lower limit of 0.1 , 0.5, 0.75, or 1 .0 wt% to an upper limit of 4, 3.5, or 3 wt% based upon the total weight of the isocyanate-reactive composition.

[0034] Embodiments provide that the isocyanate-reactive composition includes a blowing agent. The blowing agent can be a chemical blowing agent, a physical blowing agent, or combinations thereof. Examples of chemical blowing agents include water and formic acid. Examples of physical blowing agents include methyl formate, low boiling hydrocarbons, e.g., heptane, hexane, n-pentane, iso-pentane, butane, cyclopentane, cyclohexane, and the like; and mixtures thereof, low boiling ketones such as acetone and methyl ethyl ketone, hydrochlorofluorocarbons (HCFCs) such as 1 , 1 -dichloro- 1 - fluoroethane, hydrofluorocarbons (HFCs) such as 1 ,1 ,1 ,3,3-pentafluoropropane, hydrofluoroolefins (HFOs) such as trans-1 ,3,3,3-tetrafluoroprop-1 -ene, 1 , 3,3,3- tetrafluoropropene, and the like; and mixtures thereof. Commercially available hydrofluoroolefin blowing agents include SOLSTICE LBA and SOLSTICE GBA, available from Honeywell; and OPTEON 1100 and OPTEON 1150, available from Chemours. Linear, branched and / or cyclic C4-C6 alkanes such as cyclopentane, isopentane, n- pentane and neopentane can be utilized. One or more embodiments provide that the blowing agent includes n-pentane and water. One or more embodiments provide that the blowing agent includes a cyclopentane / isopentane blend and water.

[0035] The blowing agent can be from 3 to 20 wt% of the isocyanate-reactive composition based a total weight of the isocyanate-reactive composition. All individual values and subranges from 3 to 20 wt% are included; for example, the blowing agent can be from a lower limit of 3, 5, or 10 wt% to an upper limit of 20, 18, or 16 wt% of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

[0036] Embodiments provide that the isocyanate-reactive composition includes a surfactant. Surfactants for use in the preparation of foams are known and many are commercially available. The surfactant may be a silicone surfactant. Examples of suitable silicone surfactants include, but are not limited to, TEGOSTAB B-8421 , B-8427, B-8454, B-8404, B-8407, B-8409, B-8715, and B-8462 from Evonik; NIAX L-2171 , L- 5130, L-5180, L-5340, L-5440, L-6100, L-6900, L-6980, and L-6988 from MOMENTIVE, and VORSSURF 5374, VORASURF DC 5164, from The Dow Chemical Company. The surfactant may be a non-hydrolysable polyether-polydimethyl-siloxane-copolymer.

[0037] The surfactant can be from 0.5 to 4 wt% of the isocyanate-reactive composition based upon a total weight of the isocyanate-reactive composition. All individual values and subranges from 0.5 to 4 wt% are included; for example, the surfactant can be from alower limit of 0.5, 0.75, or 1 .0 wt% to an upper limit of 4, 3.5, or 3 wt% of the isocyanatereactive composition based upon the total weight of the isocyanate-reactive composition.

[0038] One or more embodiments provide that the isocyanate-reactive compositions disclosed herein include an additive. Additives for use in the preparation of foams are known. Different additives and / or different amounts of the additive may be utilized for various applications. Examples of additives include pigments, colorants, antioxidants, bioretardant agents, and combinations thereof, among others.

[0039] One or more embodiments provide that the isocyanate-reactive compositions disclosed herein include one or more other polyols. “Other polyols” refers to polyols other than the first aromatic polyester polyol, the second aromatic polyester polyol, and the third aromatic polyester polyol discussed herein. One or more embodiments provide that one or more of the other polyols is utilized rather than the first aromatic polyester polyol, the second aromatic polyester polyol, and / or the third aromatic polyester polyol discussed herein. Examples of other polyols include other aromatic polyester polyols than the first aromatic polyester polyol, the second aromatic polyester polyol, and the third aromatic polyester polyol discussed herein, non-aromatic polyester polyols, polyether polyols, and combinations thereof. Different amounts of the one or more other polyols may be utilized for various applications.

[0040] One or more embodiments provide that the compositions for forming foams disclosed herein are halogen free. In other words, the compositions for forming foams do not include a halogen. Halogen free foam formulations are desirable for a number of applications.

[0041] As mentioned, the compositions for forming foams disclosed herein include an isocyanate-reactive composition and an isocyanate composition. The isocyanatereactive composition can be combined with an isocyanate composition to make a foam. The isocyanate-reactive composition and the isocyanate composition can be combined utilizing known equipment and known conditions.

[0042] The isocyanate composition includes an isocyanate. The isocyanate may be a polyisocyanate. As used herein, “polyisocyanate" refers to a molecule having an average of greater than 1.0 isocyanate groups per molecule, e.g., an average functionality of greater than 1 .0.

[0043] The isocyanate can be an aliphatic polyisocyanate, a cycloaliphatic polyisocyanate, an aromatic polyisocyanate, or combinations thereof, for example. Examples of isocyanates include, but are not limited to, polymethylenepolyphenylisocyanate, toluene 2,4- / 2,6-diisocyanate (TDI), methylenediphenyl diisocyanate (MDI), polymeric MDI, triisocyanatononane (TIN), naphthyl diisocyanate (NDI), 4,4'-diisocyanatodicyclohexylmethane, 3-isocyanatomethyl-3,3,5- trimethylcyclohexyl isocyanate (isophorone diisocyanate, IPDI), tetramethylene diisocyanate, hexamethylene diisocyanate (HDI), 2-methylpentamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate (THDI), dodecamethylene diisocyanate, 1 ,4- diisocyanatocyclohexane, 4,4'-diisocyanato-3,3'-dimethyldicyclohexylmethane, 4,4'- diisocyanato-2,2-dicyclohexylpropane, 3-isocyanatomethyl-1 -methyl-1 - isocyanatocyclohexane (MCI), 1 ,3 -diisooctylcyanato -4 -methylcyclohexane, 1 ,3 - diisocyanato-2-methylcyclohexane, and combinations thereof, among others. As well as the isocyanates mentioned above, partially modified polyisocyanates including uretdione, isocyanurate, carbodiimide, uretonimine, allophanate or biuret structure, and combinations thereof, among others, may be utilized.

[0044] The isocyanate can be polymeric. As used herein “polymeric”, in describing the isocyanate, refers to higher molecular weight homologues and / or isomers. For instance, polymeric methylene diphenyl isocyanate refers to a higher molecular weight homologue and / or an isomer of methylene diphenyl isocyanate.

[0045] As mentioned, the isocyanate can have an average functionality of greater than 1 .0 isocyanate groups per molecule. For instance, the isocyanate can have an average functionality from 1 .5 to 8.0. All individual values and subranges from 1.5 to 8.0 are included; for example, the isocyanate can have an average functionality from a lower limit of 1 .5, 1 .7, 2.0, 2.3, 2.5, 2.7, or 3.0 to an upper limit of 8.0, 7.5, 7.0, 6.7, 6.5, 6.3, 6.0, 5.7 or 5.5.

[0046] The isocyanate can have an isocyanate equivalent weight 80 g / eq to 500 g / eq. All individual values and subranges from 80 to 500 g / eq are included; for example, the isocyanate can have an isocyanate equivalent weight from a lower limit of 80, 82, 84, 90, or 100 to an upper limit of 500, 450, 400, 375, or 350 g / eq.

[0047] The isocyanate may be prepared by a known process. For instance, the polyisocyanate can be prepared by phosgenation of corresponding polyamines with formation of polycarbamoyl chlorides and thermolysis thereof to provide the polyisocyanate and hydrogen chloride, or by a phosgene-free process, such as by reacting the corresponding polyamines with urea and alcohol to give polycarbamates, and thermolysis thereof to give the polyisocyanate and alcohol, for example.

[0048] The isocyanate may be obtained commercially. Examples of commercial isocyanates include, but are not limited to, polyisocyanates under the trade names VORANATE, such as VORANATE M 600, VORACOR, such as VORACOR CL 100 and VORACOR CE 101 , and PAPI™, such as PAPI 27, available from The Dow Chemical Company, among other commercial isocyanates.

[0049] The isocyanate composition can be utilized such that the composition for forming foam has an isocyanate index from 250 to 600. Isocyanate index can be determined as a quotient, multiplied by one hundred, of an actual amount of isocyanate utilized and a theoretical amount of isocyanate for curing. All individual values and subranges from 250 to 600 are included; for example, the compositions for forming foams can have an isocyanate index from a lower limit of 250, 300, 350, 375, or 400 to an upper limit of 600, 550, or 500.

[0050] The isocyanate composition can be utilized such that the isocyanate composition is from 200 wt% to 350 wt% based upon 100 wt% of isocyanate-reactive composition. In other words, a greater mass of isocyanate composition is utilized as compared to a mass of isocyanate-reactive composition utilized. All individual values and subranges from 200 wt% to 350 wt% are included; for example, the isocyanate composition be from a lower limit of 200 or 205 wt% to an upper limit of 350, 325, 300, or 250 wt% based upon 100 wt% of isocyanate-reactive composition.

[0051] The compositions for forming foams disclosed herein can be utilized to make a foam. One or more embodiments provide that the foam is a polyisocyanurate foam. One or more embodiments provide that the foam is a polyurethane / polyisocyanurate (PUR / PIR) foam. The compositions for forming foams disclosed herein can be cured by utilizing known equipment and known conditions. The polyisocyanurate foam can have a number of desirable properties.

[0052] As mentioned, the foam can advantageously have desirable fire test properties. Embodiments provide that the foam has a B2 fire rating determined in accordance with EN 11925-2. This B2 fire rating is desirable for a number of applications.

[0053] As mentioned, the foam can advantageously provide an improved, i.e. reduced, friability, as compared to other foam formulations that include similar polyols. Reduced friability is desirable for a number of applications, such as insulation applications. A foam with reduced friability is less likely to break down and / or generate dust over time, thereby maintaining structural integrity and insulating properties, as compared to a foam with a relatively greater friability. Embodiments provide that the foam can provide a friabilityless than 10%. For instance, the foam can provide a friability from 1 to 9%. All individual values and subranges from 1 to 9% are included; for example, the foam can provide a friability from a lower limit of 1 , 2, or 3% to an upper limit of 9, 8, or 7%. Friability can be determined according to ASTM C 421 .

[0054] The foam can have a Free Rise Density from 20 to 100 kg / m3. All individual values and subranges from 20 to 100 kg / m3are included; for example, the foam be from a lower limit of 20, 25, 30, or 35 kg / m3to an upper limit of 100, 80, 60, or 50 kg / m3. Free Rise Density can be determined according to ASTM D 6226.

[0055] Foam, i.e. rigid foam, of the present disclosure is useful in various types of thermal insulation applications such as for building and construction use, walk-in cooler, refrigerated transport container, cryogenic storage, as well as other applications.

[0056] One or more embodiments provide that an insulated metal panel (IMP) can be made with the composition for forming disclosed herein, e.g., where the composition for forming foam has an isocyanate index from 250 to 600 or 350 to 600. Such insulated metal panels can be utilized for construction applications and / or cold storage applications, for instance.

[0057] The following examples are provided for illustration but are not intended to limit the scope. All parts and percentages are by weight unless otherwise indicated.EXAMPLES

[0058] In the Examples, various terms and designations for materials are used including, for instance, the following.

[0059] First aromatic polyester polyol (terephthalic acid initiated, average hydroxyl functionality 2.0, average hydroxyl number 220 mg KOH / g, number average molecular weight 510 g / mol, obtained from The Dow Chemical Company).

[0060] Second aromatic polyester polyol (terephthalic acid initiated, average hydroxyl functionality 2.4, average hydroxyl number 315 mg KOH / g, number average molecular weight 427 g / mol, obtained from The Dow Chemical Company).

[0061] Third aromatic polyester polyol (terephthalic acid initiated, average hydroxyl functionality 2.0, average hydroxyl number 300 mg KOH / g, number average molecular weight 561 g / mol, obtained from The Dow Chemical Company).

[0062] Catalyst 1 (blowing catalyst, pentamethyldiethylenetriamine, POLYCAT 5, obtained from Evonik).

[0063] Catalyst 2 (trimerization catalyst, 30% solution of potassium acetate in diethylene glycol, DABCO K2097, obtained from Evonik).

[0064] Surfactant (silicone surfactant, TEGOSTAB B 8421 , obtained from Evonik).

[0065] Non-reactive flame retardant (triethylphosphate, obtained from ICL-IP).

[0066] Reactive flame retardant (organic phosphonate, LEVAGARD 2100, obtained from ICL-IP).

[0067] Reactive phosphorous ionic liquid (1-Ethyl-3-methylimidazolium diethyl phosphate, obtained from lolitec).

[0068] Dicyanamide ionic liquid (1 -Benzyl-3-methylimidazolium dicyanamide, obtained from lolitec). 1 -Benzyl-3-methylimidazolium dicyanamide is a reactive ionic liquid.

[0069] Blowing agent 1 (70 wt% cyclopentane, 30 wt% isopentane).

[0070] Blowing agent 2 (water).

[0071] Isocyanate (PAPI 27, obtained from The Dow Chemical Company).

[0072] Example 1 , a composition for forming foam, was made as follows. Components shown in Table 1 , except the isocyanate, were added to a container and mixed with a high-speed mixer at 3,000 rpm for 15 seconds. Then a desired amount of isocyanate was added and the contents of the container were mixed with at 3,000 rpm for 5 seconds.

[0073] Then the mixed contents of the container were poured into a box (20 cm by 9 cm by 3 cm) lined with a polyethylene film for free rise foam formation. The foam was then cured for approximately 24 hours.

[0074] Comparative Examples A-D were made as Example 1 with any changes shown in Table 1.Table 1

[0075] A number of properties were determined for the respective foam products made from Example l and Comparative Examples A-D. The results are reported in Table 2.Table 2

[0076] The data of Table 2 illustrate that Example 1 provided a foam having an improved, i.e. reduced, friability percent, as compared to foams made from each of Comparative Examples A, B, and D.

[0077] The data of Table 2 illustrate that Example 1 provided a foam having a B2 fire rating.

[0078] Free Rise Density was determined according to ASTM D 6226.

[0079] Friability was determined according to ASTM C 421 .

[0080] B2 Fire Rating was determined one week after curing according to ignitability test EN 11925-2. Respective foam samples (20 cm by 9 cm by 3 cm) were impinged by a flame (25 mm high measured vertically prior to the test); then, the flame was rotated to impinge the edge of the foam sample. During flame impingement, lasting for 30 seconds, the height of the flame was observed. A flame height below 100 mm indicated passing B2 fire rating.

Claims

What is claimed is:1 . A composition for forming foam comprising: an isocyanate-reactive composition comprising: a first aromatic polyester polyol; a second aromatic polyester polyol; a third aromatic polyester polyol; a phosphorous ionic liquid; and an isocyanate composition comprising an isocyanate.

2. The composition for forming foam of claim 1 , wherein the phosphorous ionic liquid comprises 1 -ethyl-3-methylimidazolium diethyl phosphate.

3. The composition for forming foam of claim 2, wherein the phosphorous ionic liquid is 4 to 15 weight percent of the isocyanate-reactive composition based upon a total weight of the isocyanate-reactive composition.

4. The composition for forming foam of claim 3, wherein the first aromatic polyester polyol has an average hydroxyl number from 205 to 240 mg KOH / g, the second aromatic polyester polyol has an average hydroxyl number from 310 to 400 mg KOH / g, and the third aromatic polyester polyol has an average hydroxyl number from 250 to 305 mg KOH / g.

5. The composition for forming foam of claim 4, wherein the first aromatic polyester polyol is from 25 to 55 weight percent of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition, the second aromatic polyester polyol is from 5 to 25 weight percent of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition, and the third aromatic polyester polyol is from 10 to 30 weight percent of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

6. The composition for forming foam of claim 5, wherein the composition for forming foam includes a catalyst, a blowing agent, and a surfactant.

7. The composition for forming foam of claim 6, wherein the catalyst is from 0.1 to 4 weight percent of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition, the blowing agent is from 3 to 20 weight percent of the isocyanate-reactive composition based the total weight of the isocyanate-reactive composition, and the surfactant is from 0.5 to 4 weight percent of the isocyanate-reactive composition based upon the total weight of the isocyanate-reactive composition.

8. The composition for forming foam of claim 7, wherein the surfactant is a silicone surfactant.

9. A foam made with the composition for forming foam of any one of the preceding claims.

10. An insulated metal panel made with the composition for forming foam of any one of claims 1 -8, wherein the composition for forming foam has an isocyanate index from 250 to 600.

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