Ortho-cyclohexanediamine-initiated polyols and rigid polyurethane foam made therefrom

1. A process for preparing a rigid polyurethane foam, comprising

a) forming a reactive mixture containing at least

1) a polyol mixture having an average of 3.5 to 7 hydroxyl groups/molecule and an average hydroxyl equivalent weight of 90 to 175, wherein the polyol mixture contains from 5 to 75% by weight of an amine-initiated polyol having an average functionality of greater than 3.0 up to 4.0, the polyol being a reaction product of at least one C 2 -C 4 alkylene oxide with at least one orthocyclohexanediamine initiator compound and having an average functionality of from 3.3 to 4.0 and a hydroxyl equivalent weight of from 90 to 175;

2) at least one blowing agent and

3) at least one polyisocyanate; and

b) subjecting the reactive mixture to conditions such that the reactive mixture expands and cures to form a rigid polyurethane foam, wherein the reactive mixture has a flow index of 1.2 to 1.5 and the rigid polyurethane foam has a 10° C. k-factor no greater than 19.5 mW/m-° K.

2. The process of claim 1 , wherein the reactive mixture includes water.

3. The process of claim 2 , wherein the orthocyclohexanediamine compound is represented by the structure:

wherein each R is independently hydrogen or C 1 -C 4 alkyl.

4. The process of claim 3 wherein the orthocyclohexanediamine compound contains from 90 to 100% of a trans-orthocyclohexanediamine isomer and from 0 to 10% of a cis-orthocyclohexanediamine isomer, based on the weight of the orthocyclohexanediamine compounds.

5. The process of claim 4 , wherein the orthocyclohexanediamine compound contains from 98 to 100% of trans-1,2-cyclohexanediamine and from 0 to 2% of cis-1,2-cyclohexanediamine, based on the combined weight of cyclohexanediamine compounds.

6. The process of claim 1 , wherein the amine-initiated polyol is a reaction product of cis- or trans 1,2-diaminocyclohexane, or a mixture thereof, with a C 2 -C 4 alkylene oxide.

7. The process of claim 6 wherein the amine-initiated polyol has a hydroxyl functionality of 3.7 to 4.0.

8. The process of claim 7 , wherein the alkylene oxide is ethylene oxide, propylene oxide or a mixture of ethylene oxide and propylene oxide.

9. The process of claim 1 , wherein the polyol mixture contains at least one polyether polyol having a hydroxyl functionality of from 4.5 to 7 and a hydroxyl equivalent weight of 100 to 175.

10. The process of claim 9 , wherein the polyol mixture further contains at least one different amine-initiated polyol having an average hydroxyl functionality of from 2.0 to 4.0 and a hydroxyl equivalent weight of from 100 to 225.

11. The process of claim 10 , wherein the polyol mixture further contains a non-amine-initiated polyol having a hydroxyl functionality of from 2.0 to 3.0 and a hydroxyl equivalent weight of from 90 to 500.

12. The process of claim 1 , wherein the polyol mixture contains a mixture of the amine-initiated polyol and at least one at least one polyester polyol having a hydroxyl equivalent weight of 100 to 175.

13. The process of claim 5 , wherein step (b) is conducted in a closed mold, and the pressure in the mold is reduced to from 300 to 950 mbar prior to or immediately after introducing the reaction mixture into the mold.

14. The process of claim 1 , wherein step (b) is conducted in a closed mold, and the pressure in the mold is reduced to from 300 to 950 mbar prior to or immediately after introducing the reaction mixture into the mold.

15. A rigid polyurethane foam made in accordance with claim 1 .

16. The foam of claim 15 , which is an appliance insulation foam, a layer of a laminated board, pipe insulation or a vehicle dampening member.