PROCESS FOR PRODUCING ISOCYANATE-BASED FOAM CONSTRUCTION BOARDS
A process for producing a polyurethane or polyisocyanurate construction board, the process comprising: providing an A-side reactant stream that includes an isocyanate-containing compound; providing a B-side reactant stream that includes a polyol, wherein the B-side reactant stream includes a blowing agent mixture including isopentane and a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 15 MPa 0.5 ; and mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture.
1 . A process for producing a polyurethane or polyisocyanurate construction board, the process comprising:
(i) providing an A-side reactant stream that includes an isocyanate-containing compound;
(ii) providing a B-side reactant stream that includes a polyol, where the B-side reactant stream includes a blowing agent mixture including isopentane and a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 15 MPa 0.5 , where the blowing agent mixture includes at least 60 wt % isopentane, and
(iii) mixing the A-side reactant stream with the B-side reactant stream to produce a reaction mixture.
2 . The process of claim 1 , further comprising the step of exposing the reaction mixture to heat.
3 . The process of claim 2 , where the reaction mixture is deposited onto a facer.
4 . The process of claim 3 , where the reaction is formed into a foam construction board within a laminator.
5 . The process of claim 1 , where the B-side reactant stream includes at least 0.9 parts by weight blowing agent additive per 100 parts by weight polyol.
6 . The process of claim 5 , where the B-side reactant stream includes at least 2.0 parts by weight blowing agent additive per 100 parts by weight polyol.
7 . The process of claim 1 , where the B-side reactant stream includes at least 5.0 wt % blowing agent additive based upon the total weight of the blowing agent employed.
8 . The process of claim 7 , where the B-side reactant stream includes at least 10.0 wt % blowing agent additive based upon the total weight of the blowing agent employed.
9 . The process of claim 1 , where the process produces a construction board having an index of at least 220.
10 . The process of claim 9 , where the process produces a construction board having an index of at least 225.
11 . The process of claim 1 , where the blowing agent additive has a Hansen Solubility Parameter that is greater than 16 MPa 0.5 .
12 . The process of claim 1 , where the blowing agent additive has a Hansen Solubility Parameter of from 15.0 to 35.0 MPa 0.5 .
13 . The process of claim 12 , where the blowing agent additive has a Hansen Solubility Parameter of from 16.5 to 28.0 MPa 0.5 .
14 . The process of claim 13 , where the blowing agent additive has a Hansen Solubility Parameter that is greater than 17 MPa 0.5 .
15 . The process of claim 12 , where the blowing agent additive has a boiling point, at one atmosphere, of less than 150° C.
16 . The process of claim 15 , where the blowing agent additive has a boiling point, at one atmosphere, of from about 5° C. to about 150° C.
17 . The process of claim 16 , where the blowing agent mixture includes at least 70 wt % isopentane.
18 . The process of claim 17 , where the blowing agent mixture includes at least 80 wt % isopentane.
19 . The process of claim 18 , where the blowing agent mixture is substantially devoid of n-pentane and cyclopentane.
20 . A process for producing a polyurethane or polyisocyanurate construction board, the process comprising:
(i) combining polyol, isocyanate, isopentane, and a blowing agent additive that has a Hansen Solubility Parameter (δ t ) that is greater than 15 MPa 0.5 to form a foam-forming mixture, where the foam-forming mixture is substantially devoid of n-pentane and cyclopentane,
(ii) depositing the foam-forming mixture on a facer; and
(iii) heating the foam-forming mixture to form a closed-cell foam.
21 . A construction board prepared according to a process of claim 1 .
22 . A roof deck including the construction board of claim 21 .