Polyurethane Foam with Particulate Poly(Phenylene Ether)

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Solution Overview

Problem

Polyurethane and polyisocyanurate foams exhibit high flammability and moisture absorption, which compromise their physical properties and safety in insulation applications.

Innovation Solution

Incorporating particulate poly(phenylene ether) into the foams, specifically poly(2,6-dimethyl-1,4-phenylene ether) with a mean particle size of 2 to 8 micrometers, to enhance flame retardancy and reduce moisture absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by stationary object

If polyurethane and polyisocyanurate foams are used for thermal insulation, then thermal insulation performance is improved, but flammability increases and moisture absorption increases

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidflammability and moisture absorption

Core Design Contradiction:

Use of energy by stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates particulate poly(phenylene ether) as a filler within the polyurethane or polyisocyanurate foam matrix, creating a composite material that combines the thermal insulation properties of the foam with the flame-retardant and moisture-resistant characteristics of the poly(phenylene ether) particles. This composite structure allows simultaneous achievement of thermal insulation performance and reduced flammability/moisture absorption.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies particulate poly(phenylene ether) specifically to address localized issues of flammability and moisture absorption within the foam structure. The particulate filler is distributed throughout the foam matrix to provide localized protection against these harmful factors while maintaining the overall foam structure's thermal insulation functionality.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If flame retardants are added to polyurethane foams, then flammability is reduced, but physical properties deteriorate

Engineering Contradiction:

ImproveflammabilityVSAvoidphysical properties

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent specifies precise parameters for the particulate poly(phenylene ether) filler, including particle size (0.1 to 10 micrometers, preferably 0.5 to 5 micrometers) and concentration (1 to 50 weight percent, preferably 5 to 30 weight percent). By optimizing these parameters, the patent achieves flame retardancy while minimizing negative impacts on physical properties such as strength and foam structure integrity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3036288B1Rigid foam and associated article and method

Publication Date: 2020.02.19 SABIC GLOBAL TECHNOLOGIES BV

AI summary

A rigid polyurethane or polyisocyanurate foam includes 1 to 50 weight percent of a particulate poly(phenylene ether) having a mean particle size of 1 to 40 micrometers. The particulate poly(phenylene ether) imparts reduced flammability and reduced water absorption to the foam. The foam is useful as a thermally insulating material in articles including domestic appliances, building materials, tanks, pipelines, heating pipes, cooling pipes, cold stores, and refrigerated vehicles.