RIGID POLYURETHANE FOAMS

Abstract: Rigid polyurethane foams having a closed cell content higher than 85 %, a core density of below 32 kg/m<3> and a dimensional stability, expressed as the sum of the absolute values of the relative linear changes in the three dimensions after exposure to -20 DEG C for 14 days, of below 15 %.

Description: DESCRIPTION RIGID POLYURETHANE FOAMS This invention relates to rigid polyurethane or urethane-modified polyisocyanurate foams, to processes for their preparation, and to novel compositions useful in said processes. Rigid polyurethane and urethane-modified polyisocyanurate foams are in general prepared by reacting the appropriate polyisocyanate and isocyanate- reactive compound (usually a polyol) in the presence of a blowing agent. One use of such foams is as a thermal insulation medium in buildings, refrigerators and other domestic appliances. Industry is constantly looking for lower density rigid polyurethane foam not showing any detrimental effect on other foam properties such as the dimensional stability. Especially low density (cyclo) alkane blown foams are difficult to obtain. It is an object of the present invention to provide a stable low density rigid polyurethane foam, especially a (cyclo)alkane blown foam, showing satisfactory dimensional stability. According to the present invention a rigid polyurethane or urethane-modified polyisocyanurate foam is provided having a closed cell content of above 85 -, a core density of below 32 kg/m J and a dimensional stability expressed as the sum of the absolute values of the relative linear changes in the three dimensions after exposure to -20°C for 14 days, of below 15 *. The closed cell content is measured according to standard ISO DIS 4590. The core density is measured according to standard DIN 53420-78 or ISO 845. The relative linear changes in the three dimensions are measured according to standard ISO 2769 or ISC 1923. According to a preferred embodiment of tne present invention the said rigid polyurethane foam has a core density of below 28 kg/m , preferably below 27 kg/m , more preferably below 26 or even 25 kg/m and most preferably below 22 kg/m 3 . According to another preferred embodiment of the present invention the said rigid polyurethane foam has a dimensional stability of below 10 -, preferably below 7.5 ^ . Generally a rigid polyurethane foam of tnε present invention having a core density of below 20 kg/rr has a dimensional stability of below 15 ~, a rigiα polyurethane foam having a core density of below 25 kg/m 3 has a dimensional stability of below 10 % and a rigid polyurethane foam having a core density of below 28 kg/m 3 has a dimensional stability of below 7.5 %. The rigid polyurethane foam of the present invention is especially useful in low temperature applications (of below 5°C) . According to the present invention there is also provided a process for preparing such a rigid polyurethane foam by reacting a polyisocyanate composition with a polyfunctional isocyanate-reactive composition under foam-forming conditions in the presence of a mixture of physical blowing agents, each of said physical blowing agents having a boiling point in the range -40°C to 80°C, preferably in the range 15°C to 60°C. Preferably the physical blowing agents used in the process of the present invention do not contain halogen atoms. Preferably at least one of the physical blowing agents used in the process of the present invention has a gas thermal conductivity at the foam operational temperature lower than the gas thermal conductivity of carbon dioxide, more preferably lower than the gas thermal conductivity of n- pentane, most preferably lower than the gas thermal conductivity of cyclopentane. The foam operational temperature is defined as the lowest temperature to which the foam, during use, is exposed. For example the operational temperature for a foam to be used in a refrigerator is -10°C, in a freezer -25°C. Preferably the sum of the gas partial pressures of all the blowing agent components (including the physical blowing agents and any CO- generated by a chemical blowing agent such as water) is at least 0.3 bar, more preferably at least 0.45 bar and most preferably at least 0.6 bar. Preferably at the foam operational temperature at the most 40 of the physical blowing agent mixture is condensed, preferably at the most 20 *, more preferably at the most 10 s and most preferably at the most 2 . The physical blowing agent mixture for use in the process of the present invention generally comprises at least 3 components, preferably at least 4 components, especially if the foam is intended for use at low temperatures. Preferably at least one of the components of the physical blowing agent mixture to be used in the process of the present invention is an alkane or a cycloalkane and/or acetone. Suitable components for use in the present physical blowing agent mixture comprise 2-methylpentane, 3-methylpentane, 1-propιonaldehyde, trans-1,3- pentadiene, cιs-1, 3-pentadιene, l-pentene-4-yne, 4-methyl-cιs-2-pentene, 4- methyl-1-pentene, l-pentene-3-yne, trans-2-pentene, cιs-2-pentene, methyl isocyanate, 1, 5-hexadιene, 2, 3-pentadιene, 1,2-pentadιene, 1, 4-pentadιene, 2-methyl-l-butene, 3,3-dιmethyl-l-butene, cyclopentadiene, 1,3-propylene oxide, dimethylacetylene, cyclopentane, cyclopentene, 1-propanal, ethyl formate, glyoxal, 2,3-dιmethylbutane, methyl t-butyl ether, vinyl formate, 1-pentyne, methyl isobutyl ether, methyl isopropyl ether, 3-methyl-l,2- butadiene, 3-methyl-l-butyne, methyl n-propyl ether, 2-methyl-2-butene, ethylene irmne, furan, divinyl ether, diethyl amine, methylal, 1-pentene, n-pentane, methyl formate, n-propyl amine, acrolem, isopentane, 2,2- dimethylbutane, isopropylmercaptan, dimethylsulfide, tetramethylsilane, 1,2- propylene oxide, methylacetate, 2-methyl-l-butene-3-yne, carbondisulfide, acetaldehyde, acetone, ethylmercaptan, diethyl ether, cyclohexane, methyl cyclopentane, methyl ethyl ketone, sulfur dichloride, tetrachlorosilane, trichlorosilane, bromine, sulfur trioxide, 1, 1-dιchloro-l-fluoroethane, dimethylchlorosilane, 1, 1-dιfluoroethane, 2-chloropropene, n-propylchloride, t-butylchloride, 1,2-dιchloro-l, 1,2-trιfluoroethane, 1, l-dιchloro-2,2,2- trifluoroethane, trans-1,2-dιchloroethylene, cιs-1,2-dιchloroethylene, halothane, cyclobutane, n-hexane, dnsopropylether, propargylchloride, trimethylchlorosilane, 2-bromopropane, difluoroethane, ethylene oxide, ethylchloride, perfluoropropane, methyl vinyl ether, perfluorocyclobutane, perfluorobutene, perfluorobutane, chlorine pentafluoπde, ethylfluoride, dimethyl ether, cyclopropane, butadiene, cis-butene, trans-butene, methylpropene, cyclobutane, butane, methylpropane, chlorine trifluoride, 1, 1,1,2-tetrafluoroethane, 1, 1-dιfluoroethane, chloroprene, 1,2- dibromotetrafluoroethane, chloromethyl methyl ether, 3-chloropropene, 1,1,2- trichlorotrifluoroethane, tr chlorofluoromethane, dibromodifluoromethane, methyldichlorosilane, acetylchlo ide, 1, 1-dιchloroethylene, 1,1- dichloroethane, isopropylchloride, dichloromethane, bromoethane, methyliodide, bromochlorodifluoromethane, dichlorodifluoromethane, chlorodifluoromethane, dichlorofluoromethane, bromotπfluoroethylene, chlorotrifluoroethylene, chloropentafluoroethane, dichlorotetrafluoroethane, chlorodifluoroethylene, vmylbromide, vinylchloride, chlorodifluoroethane, hexafluoropropylene, hexafluoroacetone. Physical blowing agent mixtures for use in the process of the present invention preferably contain alkanes, optionally cycloalkanes, and/or alkenes, optionally cycloalkenes, and/or acetone and/or one or more of the following hydrofluorocarbons: 1, 1, 1, 3, 3-pentafluoropropane (HFC 245fa) , 1, 1, 1,2-tetrafluoroethane (HFC 134a), 1, 1, 1,2,2-pentafluoroethane (HFC 125) , 1, 1-dιfluoroethane (HFC 152a), 1, 1, 1, 4,4, 4-hexafluorobutane (HFC 356mffm) , 1,1, 1,2, 3-pentafluoropropane (HFC245eb), 1, 1,2,2, 3-pentafluoropropane (HFC 245ca), 1,1, 1,2,3, 3-hexafluoropropane (HFC 236ea), 1,1,1,3,3,3- hexafluoropropane (HFC 236fa), 1, 1, 1, 3,3-pentafluorobutane (HFC 365mfc) and/or perfluorinated alkanes and/or fluorinated ethers especially the isomers of E245 and E356. Most preferred are physical blowing agent mixtures containing one or more (cyclo)alkanes having 5 to 6 carbon atoms such as cyclopentane, n-pentane, isopentane, 2,2-dιmethylbutane, 2-methylpentane, 3-methylpentane, optionally acetone and optionally hydrofluorocarbons. The relative amounts of each component to be used in the present physical blowing agent mixture is to be determined so as to obtain a suitable level of internal gas pressure (preferably above 0.3 bar) and condensation (preferably at the most 40 « at the foam operational temperature) . Besides the physical blowing agent mixture as described above a chemical blowing agent generating CO such as water, may be used in the process of the present invention. The total quantity of blowing agent (physical and chemical blowing agents) to be used in the process of the present invention is to be determined so as to obtain a suitable core density (below 32 kg/m"), and will typically be from 2 to 25 z by weight based on the total reaction system. Particularly preferred blowing agent mixtures for use in the process of the present invention include (amounts are expressed as pbw on the lsocyanate- reactive component) : - cyclopentane (3.S), acetone (2.3), 2,2-dιmethylbutane (5.2), isopentane (10.5), n-pentane (7.1), 1, 1, 1,2-tetrafluoroethane (3.3), water (3.9) (referred to hereinafter as MIX 1); - cyclopentane (3.9), 2,2-dιmethylbutane (5.3), 2-methylpentane (3.0), 3- methylpentane (2.6), n-pentane (7.2), isopentane (10.8), water (4.0) (referred to hereinafter as MIX 2) ; - cyclopentane (3.31, acetone (2.0 ) , 2,2-dιmethylbutane ( 4.2), isopentane (7.0), water (1.5) (referred to hereinafter as MIX 3); - cyclopentane (3.2j , acetone (2.0), 2, 2-dιmethylbutane (4.2), isopentane (8.1), water (1.0), 3-methylpentane (1.0) (referred to hereinafter as MIX ) ; - cyclopentane ( 3 . 2 ) , acetone ( 2 . 0 ) , 2 , 2-dιmethylbutane ( 4 . 2 ) , isopentane ( 1 . 6 ) , wate r ( 2 . 2 ) , 3-methylpentane ( 3 . 0 ) ( re ferred to hereinafter as MIX 5 ) ; - cyclopentane (3.2), acetone (2.0), isopentane (7.7), water (2.2) (referred to hereinafter as MIX 6) ; - cyclopentane (3.5;, acetone (2.4), isopentane (9.8), n-pentane (12. C > , water (2.0) (referred to hereinafter as MIX 7). MIX 1 and MIX 2 are especially useful for preparing 25 kg/m 3 dense rigid polyurethane foams for use in construction, being exposed to -20 β C. MIX 3, MIX 4, MIX 5 and MIX 6 are especially useful for preparing 27-29 kg/m 3 dense rigid polyurethane foams for use in appliances, being exposed to -5°C. Another preferred blowing agent mixture for use in the process of the present invention is a mixture containing cyclopentane, isopentane, n- pentane, acetone and 2,2-dιmethylbutane in the following mole percentages: 13.8, 36.6, 24.7, 9.8 and 15.2 respectively. Suitable organic polyisocyanates for use in the process of the present invention include any of those known in the art for the preparation of rigid polyurethane or urethane-modified polyisocyanurate foams, and in particular the aromatic polyisocyanates such as diphenylmethane dnsocyanate in the form of its 2,4'-, 2,2'- and 4,4'-ιsomers and mixtures thereof, the mixtures of diphenylmethane dnsocyanates (MDI) and oligomers thereof known in the art as "crude" or polymeric MDI (polymethylene polyphenylene polyisocyanates) having an isocyanate functionality of greater than 2, toluene dnsocyanate in the form of its 2,4- and 2,6-ιsomers and mixtures thereof, 1, 5-naphthalene dnsocyanate and 1, -dιιsocyanatobenzene. Other organic polyisocyanates which may be mentioned include the aliphatic dnsocyanates such as isophorone dnsocyanate, 1, 6-dιιsocyanatohexane and 4,4'-dnsocyanatodicyclohexylmethane. Polyfunctional isocyanate-reactive compositions with which the polyisocyanate composition can be reacted to form rigid polyurethane or urethane-modified polyisocyanurate foams include any of those known in the art for that purpose. Of particular importance for the preparation of rigid foams are polyols and polyol mixtures having average hydroxyl numbers of from 300 to 1000, especially from 300 to 700 mg OH/g, and hydroxyl functionalities of from 2 to 8, especially from 3 to 8. Suitable polyols have been fully described in the prior art and include reaction products of alkylene oxides, for example ethylene oxide and/or propylene oxide, with initiators containing from 2 to 8 active hydrogen atoms per molecule. Suitable initiators include: polyols, for example glycerol, trimethylolpropane, triethanolamine, pentaerythritol, sorbitol and sucrose; polyamines, for example ethylene diamine, tolylene diamine, diammodiphenylmetnane and polymethylene polyphenylene polyamines; and aminoalcohols, for example ethanolamine and diethanolamine; and mixtures of such initiators. Other suitable polymeric po yols include polyesters (especially aromatic polyesters) obtained by the condensation of appropriate proportions of glycols and higher functionality polyols with dicarboxylic or polycarboxylic acids. Still further suitable polymeric polyols include hydroxyl terminated polythioethers, polyamides, poiyesteramides, polycarbonates, polyacetals, polyolefins and polysiloxanes. The quantities of the polyisocyanate compositions and the polyfunctional isocyanate-reactive compositions to be reacted will depend upon the nature of the rigid polyurethane or urethane-modified polyisocyanurate foam to be produced and will be readily determined by those skilled in the art. In addition to the polyisocyanate and polyfunctional isocyanate-reactive compositions and the blowing agent mixture of the present invention, the foam-forming reaction mixture will commonly contain one or more other auxiliaries or additives conventional to formulations for the production of rigid polyurethane and urethane-modified polyisocyanurate foams. Such optional additives include crosslinking agents, for examples low molecular weight polyols such as triethanolamme, foam-stabilising agents or surfactants, for example siloxane-oxyalkylene copolymers, urethane catalysts, for example tin compounds such as stannous octoate or dibutyltm dilaurate or tertiary amines such as dimethylcyclohexylamine or triethylene diamine, and fire retardants, for example halogenated alkyl phosphates such as tris chloropropyl phosphate. According to a particular embodiment of the present invention the process is carried out in the presence of an insoluble fluorinated compound yielding foams having smaller cell sizes and improved thermal insulation. A urethane-modified polyisocyanurate foam (NCO index above 150) made in the presence of such an insoluble fluorinated compound also has improved friability properties. The term insoluble as used herein with respect to the insoluble fluorinated compound is defined as showing a solubility in either the lsocyanate- reactive composition or the polyisocyanate composition with which it is to be blended of less than 500 ppm by weight at 25°C and atmospheric pressure Insoluble fluorinated compounds for use in the process of the invention include any of those disclosed in US Patent No 4,961,879, US Patent No. 5,034,424, US Patent No. 4,972,002, European Patent Applications Nos 0508649 and 0498628 and PCT Patent Application No. 95/18176. It is preferred to use an insoluble, substantially fluorinated or perfluorinated compound having a boiling point of at least 20°C at atmospheric pressure, and preferably at least 40°C and more preferably at least 60°C, or 80°C or 100°C. The term substantially fluorinated as used herein with reference to the insoluble, substantially fluorinated compound used in the process of the invention is to be understood to embrace compounds in which at least 50 % of the hydrogen atoms of the unfluorinated compounds are replaced by fluorine. Suitable compounds include substantially fluorinated or perfluorinated hydrocarbons, substantially fluorinated or perfluorinated ethers, substantially fluorinated or perfluorinated tertiary amines, substantially fluorinated or perfluorinated amino-ethers and substantially fluorinated or perfluorinated sulphones. Suitable examples of substantially fluorinated or perfluorinated hydrocarbons are those containing from 1 to 15 carbon atoms, which may be either cyclic or acyclic, either aromatic or aliphatic and either saturated or unsaturated, such as substantially fluorinated and perfluorinated methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, cyclobutane, cyclooctane, cyclohexane, cyclopentane, cycloheptane, norbornadiene, decaline, dimethylcyclobutane, methylcyclohexane, 1- methyldecaline, phenanthrene, dimethylcyclobutane, and isomers thereof. Particular mention may be made of the various isomers of perfluoropentane and perfluorohexane such as perfluoro-n-pentane and perfluoro-n-hexane and of hexafluoropropene dimers and trimers such as perfluoro(4-methylpent-2- ene) . Certain insoluble fluorinated compounds suitable for use in the process of the invention may themselves act as blowing agents under the conditions pertaining to the foam-forming reaction, particularly where their boiling point is lower than the exotherm temperature achieved by the reaction mixture. For the avoidance of doubt, such materials may, partly or completely, fulfil the function of blowing agent in addition to that of insoluble fluorinated compound. The amount of the insoluble fluorinated compound used in the process of the present invention ranges from 0.05 to 10 ϊ , preferably from 0.1 to 5 , most preferably from 0.6 to 2.3 % by weight based on the total foam-forming composition. The insoluble fluorinated compound will usually be incorporated in the foam- forming reaction mixture in the form of an emulsion or preferably a microemulsion in one of the major components, that is to say in the isocyanate-reactive component and/or the polyisocyanate component. Such emulsions or microemulsions may be prepared using conventional techniques and suitable emulsifying agents. Emulsifying agents suitable for preparing stable emulsions or microemulsions of fluorinated liquid compounds in organic polyisocyanates and/or isocyanate-reactive compounds include surfactants chosen from the group of nonionic, ionic (anionic or cationic) and amphoteric surfactants. Preferred surfactants are silicone surfactants, fluoro surfactants and/or alkoxylated alkanes. The amount of emulsifying agent used is between 0.02 and 5 pbw per 100 pbw of foam forming reaction system and between 0.05 and 10 pbw per 100 pbw of polyisocyanate or polyol composition. In operating the process for making rigid foams according to the invention, the known one-shot, prepolymer or semi-prepolymer techniques may be used together with conventional mixing methods and the rigid foam may be produced in the form of slabstock, mouldings, cavity fillings, sprayed foam, frothed foam or laminates with other materials such as hardboard, plasterboard, plastics, paper or metal. It is convenient in many applications to provide the components for polyurethane production in pre-blended formulations based on each of the primary polyisocyanate and isocyanate-reactive components. In particular, many reaction systems employ a polyisocyanate-reactive composition which contains the major additives such as the blowing agent and the catalyst in addition to the polyisocyanate-reactive component or components. Therefore the present invention also provides a polyisocyanate composition or a polyisocyanate-reactive composition comprising a physical blowing agent mixture as specified above. The various aspects of this invention are illustrated, but not limited by the following examples in which the following ingredients are used: Polyol A being a PET polyester polyol containing approximately 30 - recycled polyethylene terephthalate, having an approximate functionality of 2.3 and a hydroxyl value of 350 mg KOH/g. Tegostab B 8408 being a silicone surfactant available from Goldschmidt. Tegostab B 8406 being a silicone surfactant available from Goldschmidt. TEP being triethylphosphate. DMEA being N,N-dimethylammoethanol. NIAX Al being an amine catalyst available from Air Products. Dabco T 45 being a catalyst available from Air products. SUPRASEC 2085 being a polyisocyanate available from Imperial Chemical Industries PLC. DALTOLAC XR 159 being a polyether polyol available from Imperial Chemical Industries PLC. DALTOLAC XR 144 being a polyether polyol available from Imperial Chemical Industries PLC. DALTOLAC R 130 being a polyether polyol available from Imperial Chemical Industries PLC. DALTOLAC P744 being a polyester polyol available from Imperial Chemical Industries PLC. DALTOREZ XP 805 being a polyester polyol available from Imperial Chemical Industries PLC. DALTOLAC R 105 being a polyether polyol available from Imperial Chemical Industries PLC. Tegostab B 8423 being a silicone surfactant available from Goldschmidt. RS 201 being a silicone surfactant available from Union Carbide (Air Products) . RS 210 being a silicone surfactant available from Union Carbide (Air Products) . SR 234 being a silicone surfactant available from OSi. PFO being perfluoro(4-methylpent-2-ene) . Catalyst SFC being an amine catalyst available from Imperial Chemical Industries PLC. SUPRASEC DNR being a polyisocyanate available from Imperial Chemical Industries PLC. SUPRASEC, DALTOLAC and DALTOREZ are trademarks of Imperial Chemical Industries PLC. EXAMPLE 1 Construction type rigid polyurethane foams were prepared starting from the formulations indicated in Table 1 as follows. The polyol blends were mixed and vigorously agitated (by hand shaking or propellor mixing) until a uniform homogeneous blend was obtained or a uniform white emulsion produced. This blend was then mixed with the polyisocyanate using standard foam equipment. The initial temperature of the chemicals was 23°C ± 2°C. Foams were allowed to cure for at least 16 hours at room temperature before physical property measurements. Of the obtained foams free rise density, dimensional stability after 1 day at -20°C and after 14 days at -20°C and thermal conductivity (initial, after 1 week at 70°C and after 3 weeks at 70°C) were measured. The results are indicated in Table 1 below. These results show that for foams A and B according to the present invention, in addition to improvements in dimensional stability, thermal conductivity substantially improved compared to the Reference Foam. TABLE 1 Reference Foam Foam A Foam B Polyol A pbw 100 100 100 Tegostab B 8408 pbw 2 2 2 Triethylphosphate pbw 15 15 15 DMEA pbw 3.6 3.6 3.6 NIAX Al pbw 0.16 0.16 0.16 Dabco T 45 pbw 2.69 2.69 2.69 water pbw 4.1 n-pentane pbw 30 MIX 1 pbw 32.3 MIX 2 pbw 32.8 Suprasec 2085 pbw 385.87 378.14 385.87 Density kg/m 3 25.3 25.5 22.1 Dim.Stab. 1 day/-20°C Length * -13.3 -0.3 -1.2 Width z -8.9 -0.5 -1.8 Thickness % 0.7 -0.3 0.2 Sum absolute values 22.9 1.1 3.2 Dim.Stab. 14 days/-20°C Length Ϊ -12.4 -0.2 -5.0 Width 4 -9.8 0.5 -5.8 Thickness ft 2.4 5.1 0.7 Sum absolute values 24.6 5.8 11.5 Thermal conductivity Lambda Initial mW/mK 27.1 23.7 24.6 Lambda 1 week/70°C mW/mK 29.4 27.0 27.9 Lambda 3 week/70°C mW/mK 29.7 27.4 29.1 EXAMPLE 2 Construction type rigid polyurethane foams were prepared starting from the formulations indicated in Table 2 along the lines described in example 1. Of the obtained foams closed cell content (CCC) , dimensional stability after 1 day at -20°C and after 14 days at -20 C C and thermal conductivity (initial, after 1 week at 70°C, 3 weeks at 70°C and 5 weeks at 70°C) were measured. The results are indicated in Table 2 below. TABLE 2 Ref. Foam A Foam B Foam C Foam D Polyol A pbw 50 50 50 50 50 Daltolac XR 159 pbw 50 50 50 50 50 Tegostab B 8423 pbw 1.0 1.0 1.0 1.0 1.0 RS 210 pbw 1.0 1.0 1.0 1.0 1.0 Niax Al pbw 0.1 0.1 0.1 0.1 0.1 Catalyst SFC pbw 1.0 1.0 1.0 1.0 1.0 water pbw 2.0 cyclopentane pbw 15 MIX 3 pbw 18.0 MIX 4 pbw 19.5 MIX 5 pbw 16.2 MIX 6 pbw 15.1 Suprasec DNR pbw 140 132 124 143 143 1 Core density kg/m : 29.4 27.7 28.4 28.1 28.9 Free rise density kg/πr 23.8 23.3 24.5 24.6 24.8 Overall density kg/m : 29.7 29.4 29.4 29.4 29.0 CCC - 89 92 92 92 92 Dim.Stab. ld/-20°C Length % -0.32 -0.08 -0.11 0.11 0.17 Width a- 0.01 0.05 0.16 0.01 0.17 Thickness % 0.32 0.41 0.86 0.45 1.19 Sum abs . values 0.65 0.54 1.13 0.57 1.53 Dim.Stab.14d/-20°C Length % -0.91 0.05 -0.77 0.27 0.20 Width z 0.24 3.7 0.22 0.13 0.21 Thickness * 0.74 1.28 1.25 1.69 1.44 Sum abs. values 1.89 5.03 2.24 2.09 1.85 Lambda Initial mW/mK 20.6 22.2 24.5 22.7 21.1 Lambda 1 week/70°C mW/ k 23.0 24.3 26.3 25.2 23.1 Lambda 3 week/70°C mW/mK 24.5 25.9 27.9 26.9 24.4 Lambda 5 week/70°C mW/mK 25.8 26.5 28.4 27.0 25.4 EXAMPLE 3 Appliance type rigid polyurethane foams were prepared starting from the formulations indicated in Table 3 along the lines described in example 1 Of the obtained foams closed cell content (CCC) , dimensional stability after 1 day at -20°C and after 14 days at -20°C and thermal conductivity (initial, after 1 week at 70°C, 3 weeks at 70°C and 5 weeks at 70°C) were measured. The results are indicated in Table 3 below. TABLE 3 Ref. Foam E Daltolac XP 159 pbw 33 33 Daltolac XR 144 pbw 30 30 Daltolac R 130 pbw 31 31 Tegostab B 8423 pbw 1.15 1.15 RS 210 pbw 1.15 1.15 Niax Al pbw 0.1 0.1 Catalyst SFC pbw 4.0 5.0 water pbw 2.0 cyclopentane pbw 24.0 MIX 7 pbw 30.1 Suprasec DNR pbw 134.29 134.29 Core density kg/m J 26.3 26.0 Free rise density kg/m 3 17.5 16.6 Overall density kg/m" 25.1 25.1 CCC i 82 90 Dim.Stab. ld/-20°C Length % -0.47 -0.04 Width - -0.22 0.02 Thickness 0.40 0.00 Sum abs . values 1.09 0.06 Dim.Stab.14d/-20°C Length -0.31 0.15 Width z -0.11 0.14 Thickness - 0.85 0.36 Sum abs. values 1.27 0.65 Lambda Initial mW/mK 22.4 25.8 Lambda 1 week/70°C mW/mK 26.9 28.9 Lambda 3 week/70°C mW/mK 28.4 29.8 Lambda 5 week/70°C mW/mK 29.0 30.8 EXAMPLE 4 Appliance type rigid polyurethane foams were prepared starting from the formulations indicated in Table 4 along the lines described in example 1. Of the obtained foams closed cell content (CCC), dimensional stability after 1 day at -20°C and after 14 days at -20°C and thermal conductivity (initial, after 1 week at 70°C, 3 weeks at 70°C and 5 weeks at 70°C) were measured. The results are indicated in Table 4 below. TABLE 4 Ref.A Foam F Ref.B Foam G Daltolac XR 159 pbw 33 33 33 33 Daltolac XR 144 pbw 30 30 30 30 Daltolac R 130 pbw 31 31 31 31 Tegostab B 8423 pbw 1.15 1.15 1.15 1.15 RS 210 pbw 1.15 1.15 1.15 1.15 Niax Al pbw 0.1 0.1 0.1 0.1 Catalyst SFC pbw 4.0 5.0 4.0 5.0 water pbw 2.0 2.0 cyclopentane pbw 24.0 24.0 MIX 7 pbw 30.1 30.1 Suprasec DNR pbw 134.29 134.29 134.29 134.29 Core density kg/m 3 25 25 20 20 Free rise density kg/m 3 17.5 16.6 17.5 16.6 CCC 82 90 71 Dim.Stab. ld/-20°C Length % -0.47 -0.04 -1.68 Width ~ -0.22 0.02 -0.5 Thickness k 0.40 0 -0.95 Sum abs . values 1.09 0.06 3.13 Dim.Stab.14d/-20°C Length z -0.31 0.15 -5.23 Width % -0.11 0.14 -3.04 Thickness % 0.85 0.36 -7.36 Sum abs. values 1.27 0.65 15.63 Lambda Initial mW/mK 22.4 25.8 25.5 Lambda 1 week/70°C mW/mK 26.9 28.9 29.2 Lambda 3 week/70°C mW/mK 28.4 29.8 30.1 Lambda 5 week/70°C mW/mK 29.0 30.8 30.5 Ref.B foam severely shrank. EXAMPLE 5 Construction type rigid polyurethane foams were prepared starting from the formulations indicated in Table 5 along the lines described in example 1. Of the obtained foams density, isotropic cell size, friability (according to standard BS 4370) and lambda value (initial and after 1 week, 2, 3, 4 and 5 weeks) were measured. The results are indicated in Table 5 below. These results show that foams of the present invention which also incorporate an insoluble fluorinated compound have finer cells, improved thermal insulation properties and improved friability compared to such foams not containing an insoluble fluorinated compound. TABLE 5 Foam H I J K L M Polyol blend Polyol A pbw 100 100 100 100 100 100 TEP pbw 15 15 15 15 15 15 Tegostab B8406 pbw 4 4 4 4 4 4 DMEA pbw 3.6 3.6 3.6 3.6 3.6 3.6 NIAX Al pbw 0.13 0.13 0.13 0.13 0.13 0.13 DABCO T45 pbw 2.69 2.69 2.69 2.69 2.69 2.69 MIX 2 pbw 32.8 32.8 32.8 32.8 32.8 32.8 Emulsion Suprasec 2085 pbw 100 99 98.5 97.5 96.5 94.5 SR234 pbw 0.5 0.5 0.5 0.5 0.5 PFO pbw 0.5 1 2 3 5 Polyol blend pbw 29.25 29 28.85 28.7 28.5 28.1 Emulsion pbw 70.75 71 71.15 71.3 71.5 71.9 Index 250 250 250 250 250 250 Density kg/m 3 23 20.8 20 21.1 21.1 21.9 Cell size μm 350 239 211 215 190 175 1 Friability t 15.8 3.9 0 1 1.6 2.1 Lambda initial mW/mK 25 24 24 23.2 23.2 22.7 Lambda 1 week mW/mK 29 28.1 27.9 27 26.8 26.2 Lambda 2 weeks mW/mK 29.3 28.3 28.4 27.3 27.5 27 Lambda 3 weeks mW/mK 29.6 Lambda 4 weeks mW/mK 30 28.5 28.5 27.9 27.5 27.1 Lambda 5 weeks mW/mK 29.2 28.8 28.8 27.9 27.6 27.3 Example 6 Construction type rigid polyurethane foams were prepared starting from the formulations indicated in Table 6 along the lines described in example 1. Of the obtained foams density and friability were measured. The results are indicated in Table 6 below. TABLE 6 Foam N Foam 0 Foam P Foam Q Polyol blend Daltolac XR144 pbw 4.79 4.79 4.79 4.79 Daltolac P 744 pbw 3.96 3.96 3.96 3.96 Daltorez XP805 pbw 3.42 3.42 3.42 3.42 Daltolac R105 pbw 1.09 1.09 1.09 1.09 SR234 pbw 1.4 1.4 1.4 1.4 TEP pbw 3 3 3 3 Catalyst SFC pbw 0.35 0.35 0.35 0.35 Dabco T45 pbw 1.55 1.55 1.55 1.55 MIX 2 pbw 6 6 6 6 Emulsion Suprasec 2085 pbw 100 98.95 98.5 97 SR234 pbw 0.35 0.5 1 PFO pbw 0.7 1 2 Polyol blend pbw 76 75.4 75.1 74.3 Emulsion pbw 224 224.6 224.9 225.7 Index 400 400 400 400 Density kg/m 3 25.8 24.8 24.9 25 Friability « 47.2 40.8 37.4 33.7

Claims: CLAIMS 1. Rigid polyurethane or urethane-modified polyisocyanurate foam having a closed cell content of above 85 %, a core density of below 32 kg/m 3 and a dimensional stability expressed as the sum of the absolute values of the relative linear changes in the three dimensions after exposure to -20°C for 14 days, of below 15 "i . 2 . Rigid polyurethane or urethane-modified polyisocyanurate foam according to claim 1 having a core density of below 28 kg/m 3 . 3. Rigid polyurethane or urethane-modified polyisocyanurate foam according to claim 2 having a core density of below 27 kg/m 3 . 4. Rigid polyurethane or urethane-modified polyisocyanurate foam according to claim 2 having a core density of below 25 kg/m 3 . 5. Rigid polyurethane or urethane-modified polyisocyanurate foam according to any one of the preceding claims having a dimensional stability expressed as the sum of the absolute values of the relative linear changes in the three dimensions after exposure to -20°C for 14 days, of below 10 t. 6. Rigid polyurethane or urethane-modified polyisocyanurate foam according to claim 5 having a dimensional stability expressed as the sum of the absolute values of the relative linear changes in the three dimensions after exposure to -20°C for 14 days, of below 7.5 -. 7. Process for the preparation of a rigid polyurethane or urethane- modified polyisocyanurate foam as defined in any one of claims 1 to 6 by reaction of a polyisocyanate composition with a polyfunctional isocyanate-reactive composition under foam-forming conditions in the presence of a mixture of physical blowing agents, each of said physical blowing agents having a boiling point in the range -40°C to 80°C. 8. Process according to claim 7 wherein each of said physical blowing agents has a boiling point in the range 15°C to 60°C. 9. Process according to claim 7 or 8 wherein none of said physical blowing agents contains a halogen atom. 10. Process according to any one of claims 7 to 9 wherein at least one of said physical blowing agents has a gas thermal conductivity at the foam operational temperature lower than the gas thermal conductivity of carbon dioxide at that temperature. 11. Process according to claim 10 wherein at least one of said physical blowing agents has a gas thermal conductivity at the foam operational temperature lower than the gas thermal conductivity of n-pentane at that temperature. 12. Process according to claim 11 wherein at least one of said physical blowing agents has a gas thermal conductivity at the foam operational temperature lower than the gas thermal conductivity of cyclopentane at that temperature. 13. Process according to any one of claims 7 to 12 wherein the sum of the gas partial pressures of all the blowing agent components is at least 0.3 bar. 14. Process according to claim 13 wherein the sum of the gas partial pressures of all the blowing agent components is at least 0.45 bar. 15. Process according to claim 14 wherein the sum of the gas partial pressures of all the blowing agent components is at least 0.6 bar. 16. Process according to any one of claims 7 to 15 wherein at the most 40 - of ne physical blowing agent mixture is condensed at the foam operational temperature. 17. Process according to claim 16 wherein at the most 20 z of the physical blowing agent mixture is condensed at the foam operational temperature. 18. Process according to claim l "7 wherein at the most 10 s of the physical slowing agent mixture is condensed at the foam operational temperature. 19 Process according to claim 18 wherein at the most 2 - of the physical blowing agent mixture is condensed at the foam operational temperature. 20. Process according to any one of claims 7 to 19 wherein said physical blowing agent mixture comprises at least 3 components. 21. Process according to any one of claims 7 to 20 wherein at least one of the components of said physical blowing agent mixture is an alkane or a cycloalkane. 22. Process according to any one of claims 7 to 21 wherein at least one of the components of said physical blowing agent mixture is acetone. 23. Process according to claim 21 or 22 wherein said physical blowing agent mixture contains one or more (cyclo) alkanes having 5 to 6 carbon carbons, optionally acetone and optionally hydrofluorocarbon(s) . 24. Process according to any one of claims 7 to 23 wherein the reaction is carried out in the presence of water. 25. Process according to any one of claims 7 to 24 wherein the reaction is carried out in the presence of an insoluble fluorinated compound. 26. Process according to claim 25 wherein said insoluble fluorinated compound is a substantially fluorinated or perfluorinated hydrocarbon. 27. Process according to claim 26 wherein said insoluble fluorinated compound is perfluoropentane or perfluorohexane or perfluoro(4- methylpent-2-ene) . 28. Polyisocyanate-reactive composition containing a physical blowing agent mixture as defined in any one of claims 7 to 23.

Inventors: BARKER MARTIN, BIESMANS GUY LEON JEAN GHISLAI, BARKER, MARTIN, BIESMANS, GUY, LEON, JEAN, GHISLAIN
Applicants: ICI PLC, IMPERIAL CHEMICAL INDUSTRIES PLC
Application year: 1995
Main classification: C08J9
IPC codes: C08G18, C08J9