HCFO Blowing Agents for Low-Density Foam Insulation
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Solution Overview
Problem
Current blowing agents, such as hydrofluorocarbons (HFCs), while non-ozone depleting, still have significant global warming potential (GWP) and are not effective in producing low-density, closed-cell foams with improved thermal insulation properties for thermoplastic foams.
Innovation Solution
The use of hydrochlorofluoroolefins (HCFOs), specifically 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd) and 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), in combination with other blowing agents like HFCs, HFOs, and carbon dioxide, to produce foams with decreased density, enlarged cell size, and improved k-factor for thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrofluorocarbons (HFCs) are used as blowing agents, then ozone depletion is eliminated, but global warming potential remains significant and foam density cannot be sufficiently reduced
Solution Approach 1:
The invention changes the chemical composition parameters by introducing HCFOs (hydrochlorofluoroolefins) with specific molecular structures that have both negligible ozone depletion potential and lower global warming potential compared to conventional HFCs. This parameter change in the blowing agent composition enables production of foams with reduced GWP while maintaining foam quality
Solution Approach 2:
The invention uses composite blowing agent compositions combining HCFOs with other blowing agents (HFOs, HFCs, CO2, alkanes) to achieve optimal foam properties. This composite approach allows the mixture to deliver both environmental benefits (reduced GWP and ODP) and performance benefits (lower foam density and improved cell structure) that single agents cannot achieve alone
2Quantity of substance
If conventional blowing agents are used, then foam production is achieved, but foam density remains high and cell size is not enlarged
Solution Approach 1:
The invention changes physical parameters of the blowing agent system by using HCFOs with specific boiling points and vapor pressures that facilitate formation of larger cells at lower densities. The unique properties of HCFO-1233zd and HCFO-1233xf enable controlled cell enlargement while maintaining closed-cell structure and low overall foam density
Solution Approach 2:
The invention applies partial action by using specific proportions of HCFOs in combination with other blowing agents, where the HCFO component specifically targets cell size enlargement and density reduction, while coblowing agents maintain foam stability and closed-cell structure. This partial specialization of function within the mixture achieves superior foam morphology
3Manufacturing precision
If HCFOs are used as blowing agents, then low density and enlarged cell size are achieved, but the combination with coblowing agents must be optimized
Solution Approach 1:
The invention optimizes parameters by establishing specific concentration ranges for HCFOs (1-50 wt%, preferably 5-30 wt%) and coblowing agents in the mixture. These parameter specifications enable consistent production of foams with controlled cell sizes and densities while simplifying the formulation process through defined composition windows
Solution Approach 2:
The invention uses coblowing agents as intermediaries that work synergistically with HCFOs. The coblowing agents (HFOs, HFCs, CO2, alkanes) mediate between the HCFOs and the polymer matrix, facilitating proper cell formation, stabilizing the foam structure, and enabling the HCFOs to achieve their density-reducing and cell-enlarging effects without causing structural defects
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
This combination allows for the production of low-density, closed-cell foams with improved thermal insulation properties and reduced GWP, overcoming the limitations of existing blowing agents in terms of density and cell size, while maintaining negligible ozone-depletion potential.
Implementation Method 1
blowing agent compositions comprising a hydrochlorofluoroolefin... can permit the production of lower density, closed-cell foam and good k-factor
Implementation Method 2
production of low density insulating foams with improved k-factor
Data Source
AI summary
The present invention relates to foam products made with blowing agent compositions comprising at least one hydrochlorofluoroolefin (HCFO) used in the preparation of Namable thermoplastic compositions. The HCFOs of the present invention include, but are not limited to, 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd), particularly the trans-isomer, 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), dichloro-fluorinated propenes, and mixtures thereof. The blowing agent compositions of the present invention are used with coblowing agents including carbon dioxide, atmospheric gases, hydrofluorocarbons (HFC), hydrofluoroolefins (HFO), alkanes, hydrofluoroethers (HFE), and mixtures thereof. Preferred HFCs used as coblowing agents in the present invention include, but are not limited too, 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1-difluoroethane (HFC-152a), 1,1,1-trifluoroethane (HFC-143a), pentafluorethane (HFC-125), difluoromethane (HFC-32). The blowing agent compositions are useful in the production of low density insulating foams with improved k-factor.