Insulation boards and methods for their manufacture

1. A method for producing polyisocyanurate insulation foams, the method comprising:

(i.) providing a blowing agent including isopentane and n-pentane in the substantial absence of cyclopentane, where the isopentane to n-pentane weight ratio of from 1.5:1 to 1:1;

(ii.) providing a polyol stream;

(iii.) combining the polyol stream and the blowing agent to form a B-side stream, where the B-side stream includes about 10 to about 40 parts by weight blowing agent per 100 parts by weight polyol, and where said step of combining takes place under a pressure in excess of 80 psi and at a temperature in excess of about 10° C.;

(iv.) after said step of combining, increasing the pressure of the B-side stream to a pressure of about 1800 to about 2400 psi;

(v.) providing an A-side stream including an isocyanate;

(vi.) increasing the pressure of the A-side stream to a pressure of about 1800 to about 2400 psi; and

(vii.) mixing the A-side stream with the B-side stream within a mix head.

2. The method of claim 1 , where said step of combining includes combining said polyol and said blowing agent within a dynamic pin mixer.

3. The method of claim 1 , where the blowing agent includes at least about 90% by weight of the mixture of isopentane and n-pentane.

4. The method of claim 1 , where the blowing agent consists essentially of isopentane, n-pentane, and optionally at least one other blowing agent having a zero ozone depletion potential.

5. The method of claim 1 , where the B-side stream includes at least one of a surfactant, water, a flame retardant, and a catalyst.

6. The method of claim 1 , where said step of mixing the A-side stream and the B-side stream forms a mixture of polyisocyanurate ingredients, and further comprising depositing the mixture of polyisocyanurate ingredients onto a laminator and allowing the mixture of polyisocyanurate ingredients to form a developing foam.

7. The method of claim 2 , wherein, after said step of combining the B-side stream within a dynamic pin mixer, the method further includes the step of heating the B-side stream to a temperature of about 16° C. to about 29° C.

8. The method of claim 7 , further comprising the step of delivering the B-side stream to the mix head at a temperature of about 27° C. to about 35° C.

9. A method for producing polyisocyanurate insulation foams, the method comprising:

(i.) mixing a polyol and a blowing agent to form a B-side stream, where said step of mixing takes place under a pressure in excess of about 80 psi and at a temperature in excess of about 10° C., wherein the blowing agent agent includes isopentane and n-pentane in a substantial absence of cyclopentane, and wherein the blowing agent has an isopentane to n-pentane weight ratio of from 1.5:1 to 1:1, and wherein the amount of blowing agent employed is from about 10 to about 40 parts by weight blowing agent per 100 parts by weight polyol;

(ii.) increasing the pressure of the B-side stream to about 1,800 to about 2,400 psi and heating the B-side stream of reactants to a temperature of about 16° C. to about 29° C.;

(iii.) after said steps of increasing the pressure and heating, delivering the B-side stream to a mix head;

(iv.) delivering an A-side stream that includes an isocyanate at a pressure of about 1,800 to about 2,400 psi to a mix head; and

(v.) contacting the A-side stream and the B-side stream within the mix head.

10. The method of claim 9 , where the B-side stream of reactants further includes water in an amount from about 0.1 to about 2.0 parts by weight per 100 parts polyol.

11. The method of claim 9 , where the blowing agent includes less than 1.0 weight % cyclopentane.

12. The method of claim 9 , where the blowing agent includes less than 0.5 weight % cyclopentane.

13. The method of claim 9 , where the step of contacting mixes the A-side and B-side streams forms a mixture of polyisocyanurate ingredients, and further comprising depositing the mixture of polyisocyanurate ingredients onto a laminator and allowing the mixture of polyisocyanurate ingredients to form a developing foam.