Hydrohaloolefin Spray Foam Composition With Split Catalyst Stability
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Solution Overview
Problem
Two-component polyurethane or polyisocyanurate spray foam compositions containing hydrohaloolefin blowing agents face significant shelf-life stability issues due to side reactions with current catalysts, leading to poor reactivity and foaming characteristics, which have not been adequately addressed by existing solutions.
Innovation Solution
Incorporating a gelation catalyst, such as a metal complex or nucleophilic organic compound, into the B-side component and a blowing catalyst, like a morpholino compound, into the A-side component, while using a hydrohaloolefin blowing agent, to stabilize the reaction and improve shelf-life stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current catalysts are used with hydrohaloolefin blowing agents, then foaming characteristics are achieved, but shelf-life stability deteriorates due to side reactions
Solution Approach 1:
The patent divides the catalyst system into two separate components: Component A contains the polyol and gelation catalyst, while Component B contains the isocyanate and blowing catalyst. This segmentation prevents side reactions between catalysts and hydrohaloolefin blowing agents during storage, thereby improving shelf-life stability while maintaining foaming characteristics when components are mixed and applied.
Solution Approach 2:
The patent introduces a two-component system where each component contains specific catalysts that act as intermediaries to control the reaction sequence. The gelation catalyst in Component A and blowing catalyst in Component B are designed to work in sequence after mixing, mediating the reaction between polyol and isocyanate to produce foam while preventing premature side reactions with the hydrohaloolefin blowing agent during storage.
2Object-affected harmful factors
If hydrohaloolefin blowing agents are used, then environmental performance is improved, but shelf-life stability deteriorates due to catalyst interactions
Solution Approach 1:
The patent segments the formulation into two stable components for long-term storage: Component A (polyol + gelation catalyst) and Component B (isocyanate + blowing catalyst + hydrohaloolefin). This segmentation isolates the hydrohaloolefin blowing agent from catalysts during storage, preventing degradation while preserving its environmentally beneficial properties. Upon mixing, the catalysts activate to produce foam with improved environmental performance.
Solution Approach 2:
The patent changes the physical state and reactivity parameters of the catalyst system by separating them into two components. During storage, catalysts remain dormant in their respective components with the hydrohaloolefin. Upon mixing, parameters change as catalysts become active, initiating the foaming reaction. This parameter change enables long-term stability of hydrohaloolefin-containing formulations while maintaining reactivity when needed.
3Productivity
If catalysts are placed in the B-side component, then foaming reaction is initiated, but shelf-life deteriorates due to side reactions with hydrohaloolefin
Solution Approach 1:
The patent segments the catalyst placement: gelation catalyst goes in Component A (polyol side) and blowing catalyst goes in Component B (isocyanate side). This segmentation ensures that when components are mixed, both catalysts are present to initiate the foaming reaction efficiently, while during storage each catalyst remains isolated from the hydrohaloolefin blowing agent, preventing side reactions and preserving shelf-life.
Solution Approach 2:
The patent applies local quality by placing different catalysts in different components based on their specific functions. The gelation catalyst is locally placed in Component A to control polyol-isocyanate polymerization, while the blowing catalyst is locally placed in Component B to control foam expansion. This localized placement optimizes foaming reaction initiation while preventing unwanted catalyst-blowing agent interactions during storage.
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 approach significantly enhances the shelf-life of low pressure two-component polyurethane or polyisocyanurate spray foams, ensuring stable foam production and performance comparable to formulations using hydrofluorocarbon blowing agents.
Implementation Method 1
Incorporating a gelation catalyst, such as a metal complex or nucleophilic organic compound, into the B-side component and a blowing catalyst, like a morpholino compound, into the A-side component, while using a hydrohaloolefin blowing agent, to stabilize the reaction and improve shelf-life stability
Implementation Method 2
Two-component compositions are particularly advantageous for reactive systems that either generate a gas, or the exothermic reaction may convert a low boiling point liquid component into a gas, and where the products can form a foam that cures as a solid foam
Implementation Method 3
Two-component compositions are particularly advantageous for reactive systems that either generate a gas, or the exothermic reaction may convert a low boiling point liquid component into a gas, and where the products can form a foam that cures as a solid foam
Data Source
AI summary
Storage-stable two-component polyurethane or polyisocyanurate spray foam compositions are disclosed, said compositions comprising: (a) an A-side component comprising one or more polyisocyanate and one or more catalyst; and (b) a B-side component comprising one or more polyol; and further comprising one or more hydrohaloolefin blowing agent in either the A-side component or the B-side component, or in both; wherein both the A-side component and the B-side component, separately, generate less than 600 ppm of fluoride ion after two weeks of aging at 50 °C.