POLYOL COMPOSITIONS FOR FOAM INSULATION
The present invention relates to emulsion compositions of modified polyester polyols and a method of preparing such modified polyester polyol emulsions that are useful in the formulation of polyurethane and polyisocyanurate cellular polymers for use in making foam articles.
1 . A foam precursor comprising:
a. polyol;
b. R-value enhancing additive comprising a compound selected from aryl diols, substituted aryl diols, aryl triols, substituted aryl triols and combinations thereof; and
c. surfactant, wherein the HLB number of the surfactant is from 5 to 20 on Griffin's scale.
2 . The foam precursor of claim 1 wherein the polyol comprises a polyester polyol.
3 . The foam precursor of claim 2 wherein the polyester polyol comprises an aromatic polyester polyol.
4 . The foam precursor of claim 1 wherein the R-value enhancing additive comprises resorcinol.
5 . The foam precursor of claim 1 wherein the R-value enhancing additive comprises from 80 to 100 wt % resorcinol.
6 . The foam precursor of claim 1 wherein the HLB number of the surfactant is from 10 to 20 on Griffin's scale.
7 . The foam precursor of claim 1 wherein it is a homogeneous mixture with viscosity in the range of 500 to 10,000 centipoise, determined at 25° C. according to ASTM D-4878.
8 . An emulsion comprising a reaction product of the foam precursor of claim 7 .
9 . A foam composition comprising a reaction product of the foam precursor of claim 1 with organic isocyanate, the reaction product having a weight per unit volume of at least 1.4 lb/ft 3 and insulation R-value of greater than 6.
10 . The foam composition of claim 9 wherein the reaction product has a weight per unit volume of from 1.4 to 1.6 lb/ft 3 .
11 . The foam composition of claim 9 wherein the reaction product has a weight per unit volume of 1.5 lb/ft 3 .
12 . The foam composition of claim 9 comprising a blowing agent.
13 . The foam composition of claim 12 wherein the blowing agent contains less than 1 wt % fully halogenated alkanes.
14 . A foam composition comprising:
a. aromatic polyester polyol;
b. R-value enhancing additive comprising a compound selected from aryl diols, substituted aryl diols, aryl triols, substituted aryl triols and combinations thereof;
c. surfactant, wherein the HLB number of the surfactant is from 5 to 20 on Griffin's scale;
d. an isocyanate; and
e. blowing agent.
15 . The foam composition of claim 14 wherein the R-value enhancing additive comprises resorcinol.
16 . The foam composition of claim 15 wherein the R-value enhancing additive comprises from 80 to 100 wt % resorcinol.
17 . The foam composition of claim 14 wherein the HLB number of the surfactant is from 10 to 20 on Griffin's scale.
18 . The foam composition of claim 14 wherein the blowing agent contains less than 1 wt % fully halogenated alkanes.
19 . The foam composition of claim 14 wherein the blowing agent contains from 0.1 to less than 1 wt % fully halogenated alkanes.
20 . The foam composition of claim 14 produced from an emulsion composition comprising a homogeneous mixture which comprises polyol, R-value enhancing additive and surfactant, with viscosity in the range of 500 to 10,000 centipoise, determined at 25° C. according to ASTM D-4878, wherein the emulsion composition is reacted with organic isocyanate at conditions sufficient to develop a cellular matrix substance having the weight per unit volume of at least 1.4 lb/ft′ and insulation R-value of greater than 6.
21 . The foam composition of claim 20 having more nearly spherical and more uniformly sized and distributed cell structure than the same composition formed in the absence of the R-value enhancing additive comprising a compound selected from aryl diols, substituted aryl diols, aryl triols, substituted aryl triols and combinations thereof.
22 . The foam composition of claim 20 having more nearly spherical and more uniformly sized and distributed cell structure than the same composition formed in the absence of the R-value enhancing additive comprising resorcinol.
23 . A closed-cell foam reaction product of polyester polyol, isocyanate, R-value enhancing additive and surfactant formed in the presence of blowing agent, wherein:
a. the R-value enhancing additive comprises a compound selected from aryl diols, substituted aryl diols, aryl triols, substituted aryl triols and combinations thereof; and
b. the concentration of the surfactant on the surfaces of the closed cells is greater than the concentration of the surfactant in the bulk of the cell walls.
24 . The closed-cell foam of claim 23 wherein the HLB number of the surfactant is from 5 to 20 on Griffin's scale.
25 . The closed-cell foam of claim 23 wherein the HLB number of the surfactant is from 10 to 20 on Griffin's scale.
26 . The closed-cell foam of claim 23 wherein the R-value enhancing additive comprises from 80 to 100 wt % resorcinol.