HFO HCFO Blowing Agent Composition for Low-GWP Thermoplastic Foams
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Solution Overview
Problem
Current blowing agents for thermoplastic foams, such as hydrofluorocarbons, have significant global warming potential (GWP) despite being non-ozone depleting, and existing combinations of hydrofluoroolefins (HFOs) and hydrochlorofluoroolefins (HCFOs are not disclosed for producing low-density, closed-cell foams with improved thermal insulation properties.
Innovation Solution
A blowing agent composition comprising at least one hydrofluoroolefin (HFO) and one hydrochlorofluoroolefin (HCFO), specifically using HFOs like 3,3,3-trifluoropropene and HCFOs like trans-1-chloro-3,3,3-trifluoropropene, to produce low-density, closed-cell foams with enhanced k-factor for thermal insulation, employing a process that involves blending these agents with a polymer resin and controlling the foaming process through heat plasticization and specific additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrofluorocarbons (HFCs) are used as blowing agents, then ozone depletion potential is eliminated, but global warming potential remains significant
Solution Approach 1:
The patent changes the chemical composition parameters by transitioning from HFCs to a blend of HFOs and HCFOs, which have different molecular structures and environmental properties. This parameter change achieves both low GWP and acceptable ODP while maintaining foaming performance
Solution Approach 2:
The patent uses a composite blowing agent system combining HFOs and HCFOs in specific ratios. This composite approach allows optimization of environmental properties while maintaining the physical and chemical characteristics needed for effective thermoplastic foaming
2Ease of manufacture
If conventional blowing agents are used, then foaming process is straightforward, but foam density and cell structure control are limited
Solution Approach 1:
The patent utilizes the specific boiling point range and molecular characteristics of HFOs and HCFOs to control cell nucleation and growth rates. By selecting blowing agents with appropriate volatility and solubility parameters, the invention achieves precise cell size control while maintaining processability
3Strength
If higher density foam is produced, then structural strength is improved, but thermal insulation efficiency decreases
Solution Approach 1:
The patent creates uniform cell distribution and consistent cell wall thickness through controlled foaming with HFO/HCFO blends. This local quality control ensures optimal insulation performance throughout the foam structure while maintaining adequate mechanical strength
Solution Approach 2:
The patent optimizes the porous structure by controlling cell size, cell density, and cell wall characteristics through the use of HFO and HCFO blowing agents. The resulting foam structure maximizes thermal insulation efficiency while maintaining structural integrity
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 composition enables the production of low-density, closed-cell foams with enlarged cell sizes and improved thermal insulation properties, reducing GWP and ozone depletion potential while maintaining effective plasticization and foaming processes.
Implementation Method 1
blowing agent composition comprising (1) at least one hydrofluoroolefin (HFO) and (2) at least one hydrochlorofluoroolefin (HCFO) in the preparation of foamable thermoplastic compositions
Implementation Method 2
employing a process that involves blending these agents with a polymer resin and controlling the foaming process through heat plasticization
Data Source
AI summary
The present invention relates to blowing agent compositions comprising the unsaturated halogenated hydroolefin 3,3,3-trifluoropropene (HFO 1243zf) and combinations including primarily 3,3,3-trifluoropropene (HFO 1243zf). The blowing agent compositions are useful in that they provide sufficient plasticization to permit the production of low density insulating thermoplastic foams with improved k-factor.