Bismuth Catalyst PUR Foam Faster Cure R-Value
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Solution Overview
Problem
Current methods for producing polyisocyanurate/polyurethane (PUR/PIR) foam face challenges in enhancing insulation efficiency without increasing foam thickness and in accelerating the production rate due to prolonged cure times.
Innovation Solution
A catalyst composition combining bismuth carboxylate salts with alkali metal-based or quaternary ammonium-based carboxylate salts is used to create a PUR/PIR foam, resulting in faster cure profiles, increased production rates, reduced foam cell size, and improved R-value, while maintaining thermal stability and eliminating amine odor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst compositions are used to make PUR/PIR foam, then the foam can be produced with standard cure times, but the insulation efficiency is insufficient and production rate is limited due to prolonged cure times
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by combining bismuth carboxylate salt with alkali metal or quaternary ammonium carboxylate salt in specific molar ratios (5:1 to 20:1). This parameter change in catalyst composition and stoichiometry enables simultaneous achievement of fast cure rates (improving productivity) and high insulation efficiency (improving reliability), resolving the contradiction between production rate and insulation performance.
2Reliability
If foam thickness is increased to improve insulation efficiency, then the R-value increases, but the product dimensions increase and material usage increases
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst system to achieve faster cure kinetics and smaller cell structure. This enables the foam to achieve higher R-values per inch of thickness, allowing improved insulation efficiency without increasing the physical thickness of the foam product.
3Reliability
If conventional catalyst systems are used, then the foam cures at standard rates, but the cure time is prolonged which limits commercial output
Solution Approach 1:
The patent modifies the catalyst system parameters by using bismuth carboxylate salt combined with alkali metal or quaternary ammonium carboxylate salt in optimized molar ratios. This chemical parameter change accelerates the trimerization and polymerization reactions, reducing cure time from conventional extended periods to faster cure profiles, thereby increasing commercial output while maintaining foam structure stability.
Solution Approach 2:
The patent creates a composite catalyst system combining bismuth carboxylate salt with alkali metal or quaternary ammonium carboxylate salt. This composite catalyst composition synergistically accelerates the foam formation and curing reactions, achieving both rapid cure rates and stable foam structure, thus reducing loss of time without compromising reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves faster reaction rates, smaller cell sizes, and higher R-values, leading to improved insulation performance and increased production efficiency without the drawbacks of conventional catalyst systems.
Implementation Method 1
a catalyst composition comprising a combination of at least one bismuth carboxylate salt and at least one or more of an alkali metal-based carboxylate salt and a quaternary ammonium-based carboxylate salt
Implementation Method 2
at least one blowing agent
Data Source
AI summary
A composition and process to make polyisocyanurate or polyurethane foam using a catalyst composition comprising at least one bismuth carboxylate catalyst and one or more co-catalysts selected from the group of alkali metal carboxylates and quaternary ammonium carboxylate salts, such that the resultant foam has improved insulation properties. The polyisocyanurate or polyurethane foams produced by this catalyst composition and method are useful for laminated boardstock, construction panels, appliance insulation, and spray-applied insulation.