Low-Pressure Spray Foam Composition With CO2 Shelf-Life Stability
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Solution Overview
Problem
Existing two-component polyurethane or polyisocyanurate spray foam compositions using hydrohaloolefin blowing agents suffer from poor shelf life stability due to side reactions with conventional catalysts, leading to instability and reduced reactivity, which is exacerbated by the use of hydrofluorocarbons, and there is a need for compositions with low global warming potential and improved stability.
Innovation Solution
Incorporating pressurized gaseous carbon dioxide (CO2) as a blowing agent in both the A-side and B-side components, along with one or more liquid blowing agents, to stabilize the foam composition and minimize fluoride ion generation, thereby enhancing shelf life stability and reducing global warming potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrohaloolefin blowing agents are used to reduce global warming potential, then global warming potential is reduced, but shelf life stability deteriorates due to side reactions with conventional catalysts
Solution Approach 1:
The patent changes the chemical parameters of the blowing agent system by switching from hydrohaloolefin to carbon dioxide, fundamentally altering the chemical reactivity profile to eliminate catalyst-induced degradation while maintaining low GWP characteristics
Solution Approach 2:
The patent introduces water as an intermediary substance that reacts with isocyanate to generate carbon dioxide in-situ, serving as a stable alternative to conventional blowing agents and eliminating the need for reactive hydrohaloolefin compounds that cause shelf-life instability
2Productivity
If conventional catalysts are used with hydrohaloolefin blowing agents, then foam generation is efficient, but fluoride ion generation increases leading to poor shelf life stability
Solution Approach 1:
The patent converts the potentially harmful interaction between catalysts and hydrohaloolefin into a beneficial in-situ generation of carbon dioxide through water-isocyanate reaction, eliminating fluoride ion generation while maintaining efficient foam generation
Solution Approach 2:
The patent replaces expensive and reactive hydrohaloolefin blowing agents with carbon dioxide generated in-situ from stable, non-harmful water and isocyanate reactants, eliminating the need for costly catalysts that generate harmful fluoride ions
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 use of CO2 as a blowing agent stabilizes the foam composition, achieving shelf life stability and low global warming potential, with both components generating less than 300 ppm of fluoride ions after one week of aging at 50°C, suitable for applications like air sealing and gap filling.
Implementation Method 1
a gaseous blowing agent comprising pressurized gaseous carbon dioxide (CO2)
Implementation Method 2
The use of CO2 as a blowing agent stabilizes the foam composition, achieving shelf life stability
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 blowing agent; and (b) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent; wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.