Polyisocyanurate Foam Composition for Stable Formic Acid Blowing
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Solution Overview
Problem
Existing processes for producing rigid polyisocyanurate foams using formic acid as a blowing agent suffer from limited storage stability and require physical blowing agents, which can consume significant amounts of isocyanate and affect foam properties.
Innovation Solution
A process involving a composition comprising polyesterol, formic acid as the sole blowing agent or a mixture with water, a trimerization catalyst, and polyether alcohol prepared by adding alkylene oxides to toluenediamine, which improves storage stability and enhances mechanical and thermal insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If physical blowing agents are used in the production of rigid polyisocyanurate foams, then the foam expansion and cell structure are improved, but significant amounts of isocyanate are consumed and foam properties are adversely affected
Solution Approach 1:
The invention extracts and eliminates physical blowing agents from the foam composition, relying instead on formic acid as a chemical blowing agent. This removes the source of excessive isocyanate consumption while maintaining foam expansion through alternative chemical mechanisms.
Solution Approach 2:
The invention changes the blowing mechanism from physical (vaporization of physical blowing agents) to chemical (decomposition of formic acid). This parameter change in the blowing agent type fundamentally alters the isocyanate consumption profile while achieving adequate foam expansion.
2Loss of substance
If formic acid is used as the sole blowing agent, then isocyanate consumption is reduced, but storage stability of the composition is limited
Solution Approach 1:
The invention introduces a specific catalyst system comprising a trimerization catalyst and polyether alcohol as intermediary components. These intermediaries mediate between formic acid and isocyanate, controlling the timing and rate of reaction to improve storage stability while maintaining reduced isocyanate consumption.
Solution Approach 2:
The invention changes the chemical environment by introducing specific catalysts and polyether alcohols, which alter the reactivity parameters of formic acid. This enables formic acid to function as an effective blowing agent with improved storage stability through controlled reaction kinetics.
3Device complexity
If polyesterols and formic acid are used without additional polyether alcohols, then the composition is simpler, but storage stability is limited
Solution Approach 1:
The invention changes the compositional parameters by adding polyether alcohol, which modifies the chemical environment and reaction kinetics. This single parameter change significantly improves storage stability without substantially increasing overall composition complexity.
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 process results in rigid polyisocyanurate foams with improved storage stability, good mechanical properties, and excellent thermal insulation, achieving a flame height of less than 15 cm and classifying as class E according to EN ISO 11925-2.
Implementation Method 1
chemical blowing agents are compounds which form gaseous products by reaction with isocyanate
Implementation Method 2
at least one polyether alcohol prepared by addition of alkylene oxides to toluenediamine
Implementation Method 3
catalyst system comprising at least one trimerization catalyst
Implementation Method 4
excellent properties as thermal insulation material
Data Source
AI summary
The present invention relates to a process for preparing a rigid polyisocyanurate foam comprising reacting a composition (A) comprising a polyesterol, a blowing agent comprising formic acid, a catalyst system comprising at least one trimerization catalyst and at least one polyisocyanate as component (B), wherein composition (A) further comprises at least one polyether alcohol prepared by addition of alkylene oxides to toluenediamine. The present invention further relates to a rigid polyisocyanurate foam obtained or obtainable by the process of the present invention and the use of said rigid polyisocyanurate foam as insulating material.