The invention generally pertains to the use of polyurethane foam blown by at least one blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C., including miscible blends thereof, which passes all United States Coast Guard Title 33, Part 183 specifications wherein the buoyant force of the froth polyurethane or polyisocyanurate foam is not reduced more than 5% after exposure to being immersed in a fully saturated gasoline vapor atmosphere, in reference fuel B, in reference oil No. 2, and in a 5% solution of Na 3 PO 4 .
1. A two component polyurethane or polyisocyanurate foam blown by at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof, which passes all United States Coast Guard Title 33, Part 183 specifications wherein the buoyant force of the foam is not reduced more than 5% after exposure to all of the conditions identified in the United States Coast Guard Title 33, Part 183 specifications, namely:
the two component polyurethane foam synthesized from two sets of pressurized reactant components which comprise an A-side and a B-side:
the B-side reactant components comprising a polyol blend:
25-45 wt. % of at least one polyether polyol in the polyol blend present in a major amount;
10-30 wt. % of at least one phthalic anhydride based aromatic polyester polyol present in a minor amount in the polyol blend, the at least one phthalic anhydride based aromatic polyester polyol comprising at least 35% of the polyol blend;
30-65 wt. % of at least one other additive selected from the group comprising at least one flame retardant and at least one plasticizer;
1-5 wt. % of at least one surfactant;
1-5 wt. % of at least one catalyst;
0.5-3 wt. % of water;
the at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof; and
the weight percentages of all of the B-side reactant components combining to total 100%;
the A-side reactive components comprising:
a poly- or diisocyanate; and
the at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof.
2. The polyurethane foam of claim 1 wherein
the at least one phthalic anhydride based aromatic polyester is
wherein
R 1 is selected from the group consisting of an alkylene group of from 2 to 10 carbon atoms, —CH 2 —R 3 —CH 2 —, and —(R 4 O) m —R 4 —;
R 2 and R 5 are independently —[CH 2 CH 2 O] x —, [CH 2 CH(CH 3 )O] x —, —[CH 2 CH 2 CH(CH 3 )O] x —, or a random combination thereof;
R 3 is selected from the group consisting of
each R 4 is independently an alkylene group of from 2 to 4 carbon atoms; and
x, m, and n are independently from 1-200.
3. The polyurethane foam of claim 2 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
and further wherein
an hydroxyl number in mg KOH/g is between 230-250 inclusive;
a viscosity value at 25° C. is between 2,000-4,500 cP inclusive;
an equivalent average weight is approximately 234; and
an average molecular weight is approximately 468.
4. The polyurethane foam of claim 2 wherein
the at least one polyether polyol is
and further wherein
an hydroxyl number in mg KOH/g is approximately 600;
a viscosity value at 25° C. is approximately 380 cP; and
an average molecular weight is approximately 280.
5. The polyurethane foam of claim 4 wherein
the at least one other additive is selected from the group comprising
6. The polyurethane foam of claim 5 wherein
the at least one catalyst is at least two catalysts selected from the group comprising
7. The polyurethane foam of claim 6 wherein
the water is added in an amount of approximately 1% by weight.
8. The polyurethane foam of claim 7 wherein
the at least one blowing agent has a boiling point at atmospheric pressure of between ˜10° C. to ˜40° C.
9. The polyurethane foam of claim 8 wherein
the at least one blowing agent is 1,1,1,3,3-pentafluoropropane.
10. A process of synthesizing a two-component polyurethane or polyisocyanurate foam blown by at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C., and miscible blends thereof, which passes all United States Coast Guard Title 33, Part 183 specifications wherein the buoyant force of the foam is not reduced more than 5% after testing pursuant to the United States Coast Guard Title 33, Part 183 specifications:
the two-component polyurethane foam synthesized from two sets of pressurized reactant components which comprise an A-side and a B-side:
the B-side reactant components comprising a polyol blend:
25-45 wt. % of at least one polyether polyol in the polyol blend present in a major amount;
10-30 wt. % of at least one phthalic anhydride based aromatic polyester polyol present in a minor amount in the polyol blend;
30-65 wt. % of at least one other additive selected from the group comprising at least one flame retardant and at least one plasticizer;
1-5 wt. % of at least one surfactant;
1-5 wt. % of at least one catalyst;
0.5-3 wt. % of water;
the at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof; and
the weight percentages of all of the B-side reactant components combining to total 100%;
the A-side reactive components comprising:
a poly- or diisocyanate; and
the at least one hydrofluorocarbon blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof,
the process comprising the step of adding at least one phthalic anhydride based aromatic polyester polyol comprising at least 35% of the polyol blend, the ortho substitution on the phenyl ring providing additional thermal, hydrolytic and chemical stability to a polyurethane without the added amount of the at least one phthalic anhydride based aromatic polyester polyol.
11. The process of claim 10 wherein
The at least one phthalic anhydride based aromatic polyester polyol is
wherein
R 1 is selected from the group consisting of an alkylene group of from 2 to 10 carbon atoms, —CH 2 —R 3 —CH 2 —, and —(R 4 O) m —R 4 —;
R 2 and R 5 are independently —[CH 2 CH 2 O] x —, [CH 2 CH(CH 3 )O] x —, —[CH 2 CH 2 CH(CH 3 )O] x —, or a random combination thereof;
R 3 is selected from the group consisting of
each R 4 is independently an alkylene group of from 2 to 4 carbon atoms; and
x, m, and n are independently from 1-200.
12. The process of claim 11 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
and further wherein
an hydroxyl number in mg KOH/g is between 230-250 inclusive;
a viscosity value at 25° C. is between 2,000-4,500 cP inclusive;
an equivalent average weight is approximately 234; and
an average molecular weight is approximately 468.
13. The process of claim 11 wherein
the at least one polyether polyol is
and further wherein
an hydroxyl number in mg KOH/g is approximately 600;
a viscosity value at 25° C. is approximately 380 cP; and
an average molecular weight is approximately 280.
14. The process of claim 13 wherein
the at least one other additive is selected from the group comprising
15. The polyurethane foam of claim 14 wherein
the at least one catalyst is at least two catalysts selected from the group comprising
16. The process of claim 15 wherein
the water is added in an amount of approximately 1% by weight.
17. The process of claim 16 wherein
the at least one blowing agent has a boiling point at atmospheric pressure of between ˜10° C. to ˜40° C.
18. The process of claim 17 wherein
the at least one blowing agent is 1,1,1,3,3-pentafluoropropane.
19. A two-component polyurethane or polyisocyanurate foam blown by at least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof, which passes all United States Coast Guard Title 33, Part 183 specifications wherein the buoyant force of the foam is not reduced more than 5% after testing pursuant to the United States Coast Guard Title 33, Part 183 specifications:
the two-component polyurethane foam synthesized from two sets of pressurized reactant components which comprises an A-side and a B-side:
the B-side reactant components comprising a polyol blend:
25-45 wt. % of at least one polyether polyol in the polyol blend present in a major amount;
10-30 wt. % of at least one phthalic anhydride based aromatic polyester polyol present in a minor amount in the polyol blend, the at least one phthalic anhydride based aromatic polyester polyol comprising at least 35% of the polyol blend;
30-65 wt. % of at least one other additive selected from the group comprising at least one flame retardant and at least one plasticizer;
1-5 wt. % of at least one surfactant;
1-5 wt. % of at least two catalysts, one of which is a tin-based catalyst;
essentially no water;
the least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof; and
the weight percentages of all of the B-side reactant components combining to total 100%;
the A-side reactive components comprising:
a poly- or diisocyanate; and
the least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C. and miscible blends thereof.
20. The polyurethane foam of claim 19 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
wherein
R 1 is selected from the group consisting of an alkylene group of from 2 to 10 carbon atoms, —CH 2 —R 3 —CH 2 —, and —(R 4 O) m —R 4 —;
R 2 and R 5 are independently —[CH 2 CH 2 O] x —, [CH 2 CH(CH 3 )O] x —, —[CH 2 CH 2 CH(CH 3 )O] x —, or a random combination thereof;
R 3 is selected from the group consisting of
each R 4 is independently an alkylene group of from 2 to 4 carbon atoms; and
x, m, and n are independently from 1-200.
21. The polyurethane foam of claim 20 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
and further wherein
an hydroxyl number in mg KOH/g is between 230-250 inclusive;
a viscosity value at 25° C. is between 2,000-4,500 cP inclusive;
an equivalent average weight is approximately 234; and
an average molecular weight is approximately 468.
22. The polyurethane foam of claim 20 wherein
the at least one polyether polyol is
and further wherein
an hydroxyl number in mg KOH/g is approximately 600;
a viscosity value at 25° C. is approximately 380 cP; and
an average molecular weight is approximately 280.
23. The polyurethane foam of claim 22 wherein
the at least one other additive is selected from the group comprising
24. The polyurethane foam of claim 23 wherein
the at least two catalysts comprise
and at least one of
25. The polyurethane foam of claim 24 wherein
the at least one blowing agent has a boiling point at atmospheric pressure of between ˜10° C. to ˜40° C.
26. The polyurethane foam of claim 25 wherein
the at least one blowing agent is 1,1,1,4,4,4 hexafluoro-2-butene.
27. A process of synthesizing a two-component polyurethane or polyisocyanurate foam blown by at least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C., and miscible blends thereof, which passes all United States Coast Guard Title 33, Part 183 specifications wherein the buoyant force of the foam is not reduced more than 5% after testing pursuant to the United States Coast Guard Title 33, Part 183 specifications:
the two-component polyurethane foam synthesized from two sets of pressurized reactant components which comprises an A-side and a B-side:
the B-side reactant components comprising a polyol blend:
25-45 wt. % of at least one polyether polyol in the polyol blend present in a major amount;
10-30 wt. % of at least one phthalic anhydride based aromatic polyester polyol present in a minor amount in the polyol blend;
25-45 wt. % of at least one plasticizer;
30-65 wt. % of at least one other additive selected from the group comprising at least one flame retardant and at least one plasticizer;
1-5 wt. % of at least two catalysts, one of which is a tin-based catalyst;
no added water;
the at least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C., and miscible blends thereof; and
the weight percentages of all of the B-side reactant components combining to total 100%;
the A-side reactive components comprising:
a poly- or diisocyanate; and
the at least one hydrofluoroolefin blowing agent having a boiling point at atmospheric pressure of between ˜5° C. to ˜50° C., and miscible blends thereof,
the process comprising the step of adding at least one phthalic anhydride based aromatic polyester polyol comprising at least 35% of the polyol blend, the ortho substitution on the phenyl ring providing additional thermal, hydrolytic and chemical stability to a polyurethane without the added amount of the at least one phthalic anhydride based aromatic polyester polyol.
28. The process of claim 27 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
wherein
R 1 is selected from the group consisting of an alkylene group of from 2 to 10 carbon atoms, —CH 2 —R 3 —CH 2 —, and —(R 4 O) m —R 4 —;
R 2 and R 5 are independently —[CH 2 CH 2 O] x —, [CH 2 CH(CH 3 )O] x —, —[CH 2 CH 2 CH(CH 3 )O] x —, or a random combination thereof;
R 3 is selected from the group consisting of
each R 4 is independently an alkylene group of from 2 to 4 carbon atoms; and
x, m, and n are independently from 1-200.
29. The process of claim 28 wherein
the at least one phthalic anhydride based aromatic polyester polyol is
and further wherein
an hydroxyl number in mg KOH/g is between 230-250 inclusive;
a viscosity value at 25° C. is between 2,000-4,500 cP inclusive;
an equivalent average weight is approximately 234; and
an average molecular weight is approximately 468.
30. The process of claim 28 wherein
the at least one polyether polyol is
and further wherein
an hydroxyl number in mg KOH/g is approximately 600;
a viscosity value at 25° C. is approximately 380 cP; and
an average molecular weight is approximately 280.
31. The process of claim 30 wherein
the at least one other additive is selected from the group comprising
32. The process of claim 31 wherein
the at least two catalysts comprise
and at least one of
33. The process of claim 32 wherein
the at least one blowing agent has a boiling point at atmospheric pressure of between ˜10° C. to ˜40° C.
34. The process of claim 33 wherein
the at least one blowing agent is 1,1,1,4,4,4 hexafluoro-2-butene.