Closed-Cell Spray Foam Composition for Immediate Thick Passes

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Solution Overview

Problem

Conventional high lift spray foams exhibit poor dimensional stability and non-uniform density when applied in thick single pass applications, requiring lengthy waiting periods between passes to prevent temperature buildup and fire risks, making multi-pass applications inefficient and impractical.

Innovation Solution

A closed cell spray foam insulation method using a B-side mixture with a high-functional polyester polyol and polyether polyol, allowing subsequent layers to be applied within minutes of the previous layer, reducing heat generation and enabling rapid multi-pass applications without sacrificing material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If multiple spray passes are used to achieve thick foam insulation, then the thermal resistance and insulation performance are improved, but the installation time increases due to required waiting periods between passes

Engineering Contradiction:

Improvethermal resistanceVSAvoidinstallation time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The patent modifies the chemical formulation parameters of the spray foam, specifically using a polyol blend with a lower exothermic reaction profile. This parameter change allows the foam to be applied in multiple thick passes without dangerous temperature buildup, eliminating the need for waiting periods between passes and significantly reducing installation time while maintaining high thermal resistance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention enables continuous spray foam application by eliminating the required waiting periods between passes. The modified foam formulation allows workers to continuously apply thick layers without interruption for temperature management, making the installation process more efficient and reducing overall installation time while achieving the desired insulation thickness.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If thick single pass spray foam application is used to reduce installation time, then productivity is improved, but dimensional stability and density uniformity deteriorate

Engineering Contradiction:

Improveinstallation efficiencyVSAvoiddimensional stability

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the chemical composition parameters of the spray foam to use a polyol blend that produces a more controlled exothermic reaction. This parameter modification allows the foam to expand and cure uniformly even when applied in thick single pass or multi-pass applications, maintaining dimensional stability and consistent density throughout the foam thickness without requiring multiple thin passes.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If multiple spray passes are applied with waiting periods to prevent heat buildup, then temperature control and fire safety are improved, but the application process complexity increases

Engineering Contradiction:

Improvefire riskVSAvoidapplication process complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent converts the potentially harmful exothermic reaction into a beneficial controlled reaction by selecting a polyol blend with specific properties. This modified formulation reduces the peak temperature and extends the time to reach self-ignition temperature, transforming the heat generation from a hazard requiring complex waiting protocols into a controlled process that allows continuous application with simplified procedures.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 method achieves dimensional stability and consistent density across the foam thickness, significantly reducing installation time while eliminating fire risks associated with heat buildup, resulting in a more efficient and practical spray foam application process.

Implementation Method 1

the exothermic chemical reaction that forms the foam insulation

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS11717848B2Multiple immediate pass application of high thickness spray foams

Publication Date: 2023.08.08 JOHNS MANVILLE CORP

AI summary

A method of applying a closed cell spray foam insulation may include spraying a first layer of a closed cell spray foam insulation into a wall cavity. A B-side mixture of the closed cell spray foam insulation may include a polyol blend having a polyester polyol having a functionality of at least about 3.0 and a polyether polyol. The method may include spraying at least one additional layer of the closed cell spray foam insulation against the first layer within 5 minutes of spraying the first layer.