One-Component Spray Foam Composition for Low Post-Expansion Control
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Solution Overview
Problem
Conventional one-component polyurethane foam compositions exhibit high post-expansion rates, leading to difficulties in determining the initial dispensing amount, poor performance when under- or over-applied, and issues with dispensing control, while existing dispensers are either messy, disposable, or expensive and bulky, with poor fine flow control.
Innovation Solution
A one-component polyurethane spray foam composition comprising specific isocyanate-containing compounds, optionally polyols, propellants, flame retardants, plasticizers, and surfactants, along with a dispenser featuring a pressurized container and a mechanical applicator that allows for fine flow control and low post-expansion rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional one-component polyurethane foam formulations are used, then the foam provides basic insulation and sealing functions, but the foam exhibits high post-expansion rates causing poor performance and appearance
Solution Approach 1:
The patent modifies the chemical composition parameters of the foam formulation, specifically using polyols with functionality of 2.5 or higher and adjusting the isocyanate index to 80-120. These parameter changes result in reduced post-expansion rates and improved dispensing control, allowing the foam to maintain consistent performance and appearance.
2Ease of operation
If conventional dispensers are used, then the dispensing process is simple, but the dispensers lack fine flow control and cause messy application
Solution Approach 1:
The dispenser incorporates a dynamic control mechanism that allows the operator to adjust the flow rate of foam during dispensing. This dynamic adjustment capability enables fine flow control while maintaining ease of operation, preventing both under-application and over-application issues.
3Volume of moving object
If high post-expansion foam is used, then the foam can fill gaps effectively, but it requires labor-intensive trimming and creates waste
Solution Approach 1:
By changing the formulation parameters to achieve low post-expansion characteristics, the foam expands predictably to the desired volume without excessive growth. This eliminates the need for labor-intensive trimming operations and reduces material waste from over-application.
4Strength
If conventional foam formulations are used, then the foam provides basic insulation properties, but the foam shows poor appearance and performance when under- or over-applied
Solution Approach 1:
The modified foam formulation with specific polyol functionality (2.5 or higher) and controlled isocyanate index (80-120) provides consistent expansion characteristics that maintain proper application precision. This ensures optimal insulation performance and appearance whether the application is at, slightly under, or slightly over the target amount.
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 composition achieves low post-expansion rates and precise application, minimizing disparities between dispensed and fully cured foam, and the dispenser provides effective dispensing control, reducing labor-intensive trimming and improving appearance.
Implementation Method 1
a propellant; optionally a flame retardant; optionally a plasticizer; optionally a surfactant; and optionally a catalyst
Data Source
AI summary
Described herein are one-component spray foam compositions having a low post post-expansion rate. Also described herein are methods of making and using one-component spray foam compositions having a low post-expansion rate. Also described herein are dispensers for dispensing the one-component spray foam compositions having a low post-expansion rate. Compositions and methods in accordance with the present disclosure are useful in a wide variety of applications, and are particularly useful in construction applications.