Patent ID: 11905707
Assignee: COVESTRO LLC
Field: Macromolecular chemistry, polymers (Chemistry)
Classification: CPC E  B  C | IPC C  E

Claim 10:
11. A method of manufacturing the wall structure of claim 1 comprising:
depositing a polyurethane foam-forming composition into a cavity of the wall structure to form a polyurethane foam layer in the cavity that adheres to a rear surface of at least one of: (i) a foam panel that abuts a front frame surface, the front frame surface being formed by a front surface of a first member, a front surface of a second member that is spaced apart from the first member, and a front surface of connecting members extending between the first member and the second member, wherein the foam panel, the first member, the second member, and the connecting members define the cavity; or (ii) a non-foam sheathing that abuts the front frame surface and is between the front frame surface and the foam panel so that the front frame surface such that the non-foam sheathing, the first member, the second member, and the connecting members define the cavity,
wherein the polyurethane foam layer deposited in the cavity has a density, as determined by ASTM D1622-14, of 44 kg/m3 (2.75 lb/ft3) to 160 kg/m3 (10.0 lb/ft3) and exhibits a Class A rating according to ASTM E84-16 and is a cured reaction product of the polyurethane foam-forming composition, and
wherein the polyurethane foam-forming composition comprises:
(a) a polyisocyanate present in an amount by weight,
(b) an aromatic polyester polyol having a functionality of greater than 2.5 and an OH number of 300 to 400 mg KOH/g, which is present in an amount of at least 50% by weight, based on total weight of the polyurethane foam-forming composition less the weight of the polyisocyanate;
(c) a catalyst, and
(d) a blowing agent composition comprising water and a hydrofluoroolefin,

wherein the hydrofluoroolefin is present in an amount of 1 to 6% by weight, based on the total weight of the polyurethane foam-forming composition, less the weight of the polyisocyanate.