Rigid

Understanding Polyurethanes
Polyurethane Applications Grid

1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.09 0.08 0.07 0.06 0.05 0.04 0.03 0.02 0.01 0 Industrial Elastomers, Coatings, Adhesives, Binders Body Panels Auto RIM Fascia 74.9 68.6 62.4 56.2 49.9 43.7 37.4 31.2 25.0 18.7 12.5 6.2 5.6 5.0 4.4 3.7 3.1 2.5 1.9 1.3 0.6
Specific Gravity, gms/cc
Footwear Structural Foam
Density, lbs/ft3
Bumpers, Energy Management Instrument Pads Cushioning Packaging 10 20 30 40 50 60 70 Hardness 80 90 40 50
Decorative Moldings
Insulation
60
70
80
Shore A
Shore D
SynUthane International Inc.
Rigid Polyurethane and Polyisocyanurate Foams Applications and Technologies
Roy McClellan
Rigid Foam Application Technologies DETOUR
Before we proceed to the basic rigid foam applications, we must take a

detour and discuss a very important and major critical Issue. This issue involves the very essence of rigid foamswhat makes them foam As we speak, all of the supplier and foam companies have active programs to study all parameters of this issue and come up with solutions which will permit us to continue to make insulating and other products using the most versatile process and chemistry in the world.polyurethane and polyisocyanurate foams.
CRITICAL ISSUE:
The blowing Agent problem

Rigid Foam Application Technologies
CRITICAL ISSUE :
What is the problem?
Blowing Agents
20+ years ago, it was discovered that certain halogen substituted

chemicals, CFCs (chlorofluorocarbons), caused a depletion of ozone in the upper atmosphere potentially allowing harmful UV rays to penetrate to the planets surface
Among these chemicals was a large assortment of refrigerants,

blowing agents, solvents and fire suppressors (Halons)
In 1989 the United Nations established the Montreal Protocol to

organize the gradual phase out of these materials over time
CRITICAL ISSUE :
Blowing Agents (Cont)
What materials for urethanes are affected?
When this protocol was established, CFC-11 (trichlorofluoromethane)

was the workhorse blowing agent for urethane rigid foams and coblowing agent for flexible foams. frothed rigid urethane systems
A sister product, CFC-12 (dichlorodifluoromethane) was used for Both products were in large commercial production, had very
reasonable prices and contributed excellent insulating values (k and R factors) to the rigid urethane foams. used extensively to produce flexible, rigid and microcellular urethane foams with an integral skin, formed in place during the molding process.
CFC-11, due its unique boiling and solubility characteristics, was
CRITICAL ISSUE :
The industry immediately sought replacements and relatively

quickly found that 141b (1,1-dichloro,1-fluoroethane) was a reasonable substitute, however it still has a small ozone depleting effect. This material is among a family called HCFCs or hydrochlorofluorocarbons.
In the meantime, scientists discovered further that the CFC and

HCFC materials (as well as others) had varying degrees of global warming contribution (greenhouse effect).
CFC-11 CFC-12 HCFC-141b
ODP* 1.0 1.0 0.1
GWP** 4000 8500 630

*Ozone Depleting Potential

** Global Warming Potential
CRITICAL ISSUE :
Blowing Agents, (Cont)
Global Production Phase-out* of CFC-11, 12 & HCFC 141b Latest Schedule Agreed to by all Parties of the Montreal Protocol 6/1989 1/1994 1/1996 6/1999 Freeze Production of all CFCs world wide. Reduce Production levels by 75% from 1986 levels. Total phase out of CFCs except for essential uses. Freeze HCFCs at 89 levels + 2.8% of 89 CFC consumption. Reduce CFCs to 95-97 avg. levels or 300 gms/capita (lowest amt.)
*Halon and other non-urethane related agents have been omitted. SynUthane International Inc.
CRITICAL ISSUE :
Global Production Phase-out* of CFC-11, 12 & HCFC 141b Latest Schedule Agreed to by all Parties of the Montreal Protocol (cont) 1/2004 1/2005 1/2007 1/2015 1/2016 1/2040 Reduce HCFCs by 35% below base levels Reduce CFCs by 50% from 95-97 levels (essential users) Reduce CFCs by 85% from 95-97 levels (essential users) Reduce HCFCs by 90% Freeze HCFCs at base line 2015 average levels HCFCs completely phased out
*Halon and other non-urethane related agents have been omitted. SynUthane International Inc.
CRITICAL ISSUE :
USA HCFC Situation
Despite the schedule in place by the Montreal Protocol, the US has

enacted additional legislation through the Clean Air Act.
This section* of the Act, if implemented on the present schedule, will

prohibit all production and importation of all HCFC 141b starting in 2003. plastic foam insulation products as they are currently made.
This will severely hamper the manufacture of polyurethane and other There are some new developmental materials and techniques that
may mitigate this situation to some degree. These are discussed in the following slides.
*www.epa.gov/ozone/title6/phaseout/hcfc.html SynUthane International Inc.
CRITICAL ISSUE :
Europe:
No Clean Air Act but want to implement 0 ODP technology.
Concentrating on developing the use of HCs
(hydrocarbons) such as, isopentane and cyclopentane for refrigeration, insulating board and panels.
The above may be used with water (CO2) as co-blowing There seems to be a trend in Europe toward PIR foams to
reduce need for halogenated flame retardants
Developments proceeding with Solvays 365 mfc (pentafluorobutane)

in combination with other HFCs and in azeotropes with HCs.
CRITICAL ISSUE :
USA:
Clean Air Act bans 141b starting in 2003
All SNAP (Significant New Alternatives Program) alternatives plus HCs and
water (CO2) co-blow are under investigation
HCs not popular due to fire potential in plant and insurance cost
implications, but some blends give excellent properties
HFC-134a (tetrafluoroethane) and HFC 245fa (pentafluoropropane) work in
combinations with water and/or HCs parallels European activities with HFC 365mfc (pentafluorobutane) panel products while 245fa seems to be favored for spray foam using some water co-blowing ruling could be initiated to delay implementation.
One of the preceding approaches will probably be used in the laminate and Always the outside possibility that Industry litigation against the EPA
While the replacement of CFC 11 by HCFC 141 b caused some technical difficulties, the use of the new generation(s) of blowing agents will cause major technical and economic challenges.
CRITICAL ISSUE: The blowing Agent problem
Various Process/Property Trends Using Alternate Blowing Agents

Blowing Agent Insulating Process Shrinkage Cost Flammability
CFC CO2 (H2O) HCFC HC HFC Blends

CFC-11 base
Base
Base
Base
Base
Base
Goal
Goal
nearly equal
Goal
better
Goal
Goal
poorer
Understanding Polyurethanes Rigid Foam Application Technology

Property Challenges: Shrinkage and Dimensional Instability Cell Geometry and Blowing Agents
Blowing agents function by providing a gas either by boiling or by
chemical reaction during the polyurethane polymerization. Critical to their function is:
Boiling range Solubility and efficiency as a solvent in the raw materials and the developing polymer matrix during the foaming process Solubility and diffusion of the blowing agent gas or liquid through the polymer matrix out of the cell during aging
Each blowing agent will have different behavior with respect to
these functions, and, in some cases, can result in collapsed foams or foams with severe shrinkage or dimensional instability over both the short and long terms.
Understanding Polyurethanes Rigid Foam Application Technology
Cell Geometry and Blowing Agents (Cont)
For example, shrinkage has always been an issue in rigid foams, but
has been exacerbated recently with the use of R 141b blowing agent due to its fugitive nature and the creation of low cell pressure. Some of the foams made with HC materials and perhaps others will need monitoring of medium to long term cell pressure behavior. polymerization causing large voids and gas pockets.
In some cases, blowing agents become more insoluble during The safest method is to formulate with a balanced, compatible
system, using surfactants and solubilizers where required to prevent uncontrolled volatilization and separation of blowing agents during the polymerization. have focused on the need to strive for maximum cell strength. This property depends in large part on cell isotropicity
The anomalous effects of these new materials on cell pressure also
Rigid Foam Application Technology Cell Geometry (Cont)
During foaming, cells may become elongated (anisotropic) due to

gellation of the foam mix prior to the achievement of complete expansion.
Note the ratio of strength of the cells parallel and perpendicular to the
rise direction of the foam and the gel point for each.
Cell Isotropicity Cell Anisotropicity Parallel, Strength~ 2X Parallel Strength, 1X Perpendicular Strength ~ 0.3-0.5X
Perpendicular Strength, 1X
Gel Point
RISE
Gel Point
Cell Geometry (Cont)
Cell anisotropicity can cause shrinkage when

the cell gas pressure is lower than than atmospheric pressure and the foam has insufficient strength to withstand distortion
Raising the foam density can prevent

shrinkage in anisotropic foams but is not cost effective
A preferred solution is to formulate the foam to

avoid premature gellation and stretching of the cells
Cell Geometry (Cont) Premature gellation is caused by elastic polymer formation prior to completion of blowing process It may be addressed by:
Reducing the functionality of the polyol or NCO Increasing the NCO index Adding water to the formulation Use pre-expansion (froth) technique Reduce the level of polymerization catalyst In general, increase the MW per crosslink
Property Challenges: Insulating Value
The new blowing agent candidates under the most scrutiny seem to
be the HCs, HFCs and water. The HC materials are flammable, have high k factors (poorer insulators) but are very economical The HFC materials are non-flammable, have fairly good k factors, but are quite expensive CO2 is non-flammable, has a poor k factor, but is very economical when added directly as a gas, and higher when added through the isocyanate (water reaction)
It is not surprising then that the direction research and
development are taking us is toward mixtures, matches and compromises.

Compromise is not new to us in the polyurethane business!!
K-Factors of Selected HC, HFC and HCFC Blowing Agents @ 250C

0.3
0.25
0.2
BTU-in/hr. ft2 0F
0.15
0.1
0.05
0 HCFC-141b
BRITISH UNITS Series1
HFC365mfc 0.073
cyclo pentane 0.083
HFC-245 fa HFC-134a 0.086 0.090
iso pentane 0.104
n-pentane 0.109
CO2 0.250
0.066
K-Factors of Selected HC, HFC and HCFC Blowing Agents @ 250C

40.0 35.0 30.0 25.0
mW/m . 0C
20.0 15.0 10.0 5.0 0.0 HCFC-141b
HFC365mfc 10.5
cyclo pentane 12.0
HFC-245 fa HFC-134a 12.4 13.0
iso pentane 15.0
n-pentane 15.8
CO2 36.1
METRIC UNITS Series1
9.5
Technical Challenges: Processing
As with k-factor, the new blowing agents have very different

solubilities in typical PU ether and PIR ester polyols
The HC materials are less soluble than the HFCs and both
groups have still poorer solubility in aromatic ester polyols
They also have different boiling ranges. These different properties make formulating systems which
need to shipped in trucks, IBCs or drums a problem because of the different container pressures which develop due to solubility differences. and additives to mitigate these differences and keep the blowing agent in the polyol side during transport and storage.
Much work is going with various mixtures of blowing agents

Compromise and balance will be needed here as well
Technical Challenges: Flammability
Although it might seem ludicrous to add a flammable liquid to a

material which needs to be combustion resistant for many application, initial testing has shown that conventional flame retardants seem to work quite well
The actual mole gas content is quite low, and much of the blowing
agent migrates from the exposed foam surface relatively quickly.
Many are leaning toward using mixtures of non-flammable HFCs to
reduce the consumption of the HCs for these applications as well as water to further reduce HC levels. met with strong resistance in the US due to worries about extraordinarily high insurance premiums
The use of HC in the factory seems to be accepted in Europe, but has

Some additional balance and compromise
OK, thats the blowing agent story!!

Let us hope that we can Balance and Compromise and find some completely non-ozone depleting blowing agent mixtures and blends with low global warming potentials, at reasonable prices and properties. Because.. on the following pages, you are going to learn about many ways these foams can being used.
Rigid Foam Applications
Insulation Foam Products for:

Refrigerators and Freezers, Cold Storage Industrial and Residential Roofing and Wall Panels Chemical Equipment, Pipes, Tanks Hot Water Heaters Solar Panels
Specialty Foam Products for:

Packaging, In-Situ Shock Protection Structural Foam, Electronic Equipment Cabinets Decorative Moldings and Wood Imitation Products
Rigid Foam Application Technology
Important Application Technologies for Manufacturing are:

Pour/Injection of Refrigeration Appliances, Water Heaters Pour/Injection of Discontinuous Panels Pour for Continuous Panels Pour-in-Place Packaging, Shock Protection Pour/Injection of Structural Foam, Wood Imitation Spray Foam Pour for Bun and Block Foam
High Pressure Pour/Injection Machine for Polyurethane
Photo, courtesy Cannon USA
Each Application Technology area will include the following topics:

Foam density, configuration Process/equipment Polymer characteristics Illustrative Formulation Application issues (rules/regulations) Application issues (technology wish-list)
Rigid Foam Application Technology Insulation for Domestic Refrigerators and Commercial Cold Stores
Rigid Foam Application Technology Pour-in Place for Refrigerators, Freezers, Cool Containers
Foam density, configuration
1.8-2.5 PCF (28-40kg/m3), 0.8-1.5 (20-40 mm) thick

Process/equipment
Machine poured/injected foam into jigged refrigerator shell;

Highly automated and controlled
High or low pressure equipment may be used. 2 -5 minute cycles Pre-expansion (froth) technique sometimes employed to assist
with reacting polymer flow in the tool and prevent cell stretching (anisotropicity)
Multi axial molding press for refrigerators
Pour-in Place for Refrigerators, Freezers, Cool Containers
Polymer characteristics
Highly crosslinked, 500-600 mw/x-link 3-5 OH functional polyols used with TDI or 2.5-3.0 NCO
functional polymeric MDI
Chemically delayed gel time required for maximum cell

isotropicity to achieve low density foams and no shrinkage
Pour-in Place for Refrigerators, Freezers, Cool Containers
Typical PUR Formula for Refrigerator Foam Sucrose/Glycerine/PO or TDA/PO Polyol OH# 400 Water Silicone Surfactant Amine Catalyst(s) R-141b + Compatibilizer Polymeric MDI @ 1.10 Index
100.0 1.5 0.5 0.5 15-30 125.0
Rigid Foam Application Technology Pour-in-Place for Refrigerators, Freezers, Cool Containers
Application issues (rules/regs)
Blowing agents; Domestic industry, now phased out of CFC-11
and CFC-12, using 141b. Must achieve complete non-ODS by 2003 Increased use of water blowing and alternate zero ODS blowing agents under development Increasing use of pentane/isomers in Europe, despite flammability concerns Direct injection of CO2 being evaluated
Application issues (technology wish-list)
Improved adhesion of foam to various plastic liners Eliminate residual amine catalyst odors Higher insulating value foams (lower k-factor); reduced cell size
and/or new blowing technology
Insulation Panels (PUR, PIR or PIUR)
Pour-in-Place for Insulating Panels (discontinuous)
2.0 -3.0 pcf (32-48 kg/m3), 1-4 (25-100mm) thick

Process/equipment
Machine poured/injected into panel shell pre-positioned in clamp

or press. Varying degrees of automation in use Both high and low pressure machines are in use. Depending on panel configuration, various foam distribution devices employed Pre-expansion (froth) technique often used to assist in flow of the foam in the panel cavity and prevent cell anisotropicity and potential shrinkage
Polyurethane Panel Presses
Highly crosslinked, 400-500 mw/x-link 3-5 OH functional polyols used with 2.5-3 NCO functional
polymeric MDI for urethane types 2-2.5 OH functional aromatic ester polyols used for polyisocyanurate (PIR) foams
Typical Formula for Panel Foam (F.R. PUR)

Sucrose/Glycerine/PO or TDA/PO or Amine based Polyol OH# 400 Water Silicone Surfactant Amine Catalyst(s) Flame Retardant (s) R-141b Polymeric MDI @ 1.10 Index
100.0 1.5 0.5 0.5 10-20 15-25 125.0
Typical Formula for Panel Foam ( PIUR)

Aromatic Ester, OH# 250, 2.25 Silicone Surfactant Amine/Trimer Catalyst(s) Flame Retardant (s) R-141b +Compatibilizer 100.0 0.5 0.5 5-10 25-35
Polymeric MDI @ 2.0-3.0 Index
125-175
Application issues (rules and regs.)

Blowing agents:
Most of this industry, now phased out of CFC 11, 12, mainly
using 141b Must achieve complete non-ODS by 2003 Increased use of water (CO2) blowing and alternate zero ODS materials under development Flammability:
Most domestic producers using PIR foams to meet requirements
of UL E-84 tests for flame spread and smoke generation European producers, faced with emerging halogen standards, are now converting to PIR after many years of using heavily flame retarded polyurethane to meet local fire and smoke standards
Rigid Foam Application Technology Pour-in-Place for Insulating Panels (discontinuous)
Improve adhesion of foam to panel facers Minimize/eliminate shrinkage when converting to co-blown
chemistry at low density (141b + water) Continuing need for better insulating foam (lower K factor); reduced cell size, and/or new blowing agent materials Continuing need for improved flammability and smoke values
Rigid Foam Application Technology Continuous Lamination of Insulating Panels
Foam density/configuration
1.9-2.5 PCF (30-40 kg/m3), 0.5 to 2.5 (12-60 mm) thick

Process/equipment
Very large, automated lines Liquid foam components dispensed from high pressure metering
machines,between continuously moving substrates (skins) Panels are 36-48 wide (.9-1.2m) wide The panels are foamed in a heated pressure conveyor section and subsequently cut into desired lengths Line speeds vary from 75 to 300 ft/min (25 to 100 m/min.) Both flexible (aluminum foil) and rigid (steel) facing materials are used
Laminating Equipment for Manufacture of Continuous Panels
Continuous Lamination of Insulating Panels
Highly crosslinked, 300-500 mw/x-link PIR types Uses 2-2.3 OH functional aromatic polyester polyols and 2.7-3.3
NCO functional polymeric MDI
Reaction profile can be very rapid to allow high speed production

(completed in 30-45 seconds)
Europe now converting from flame retarded PUR to PIR systems
Typical Formula for Panel Foam ( PIR)

Aromatic Ester, OH# 200, 2. 0 Silicone Surfactant Amine/Trimer Catalyst(s) Flame Retardant (s) R-141b +Compatibilizer 100.0 0.5 1.0 5-10 25-35
Polymeric MDI @ 3.5-5.0 Index
175-240

Blowing agents: Most of this industry, now phased out of CFC 11,
mainly using 141b Must achieve complete non-ODS by 2003 Increased use of water (CO2) blowing and alternate zero ODS materials under development
--Flammability: Most domestic producers using PIR foams to meet

requirements of UL E-84 and Corner tests for flame spread and smoke generation European producers, faced with emerging halogen standards, are now converting to PIR after many years of using heavily flame retarded polyurethane to meet European fire and smoke standards
Rigid Foam Application Technology Continuous Lamination of Insulating Panels
Improve adhesion of foam to panel facers Minimize/eliminate shrinkage when converting to co-blown
chemistry at low density (141b + water)
Improve foam insulating values (lower K factor); reduced cell

size, and/or new blowing agent materials
Continuing need to improve flammability and smoke generation
Rigid Foam Application Technology Pour-in-Place General Systems for Packaging, Shock Protection Foam density, configuration
0.3-.8 PCF (5-13 kg/m3), variable

Process/equipment
Foam is machine-poured into cardboard packaging box for item.
Box is lined with PE film as is the item to be packaged Foam completely surrounds object and fills the box Pouring equipment is generally small, high pressure units (piston pumps) In other applications, foam is molded to shape in a mold and items are placed into the foam structure for shipping
Foams are water blown and are usually grossly under-indexed Polymers are essentially open-celled polyurea materials Based on 2.2-2.4 NCO functional polymeric MDI with some high
MW polyol diol or triol used to provide ductility, lower friability
Rigid Foam Application Technology Pour-in-Place General Systems for Packaging, Shock Protection
Typical Formula for Packaging Foam

Glycerine/PO, OH# 35, 3 Water Compatibilizer Silicone Surfactant Amine Catalyst(s) Polymeric MDI @ 0.4-0.6 Index Flame Retardant (s) 100.0 15-25 8-15 0.5-1.0 1.0-2.0 120-140 5-10 (If Required)
Pour-in-Place General Systems for Packaging, Shock Protection

Typical Foam Packaging Application
Pour-in-Place General Systems for Packaging, Shock Protection
Blowing agent: historically a water-blown foam, no blowing agent

issues Flammability: seldom an issue unless specific rules are enforced for storage and warehousing areas
Eliminate friability (dustiness) Reduce resilience, improve high impact absorbing qualities Minimize/eliminate residual amine catalyst odor
Rigid Foam Application Technology Decorative Wood Imitation Polyurethane
Pour-in-Place General Systems for Structural Foam, Wood Imitation
Structural foam: 25-40PCF (400-650 kg/m3), variable Wood imitation: 3-35 PCF (48-560 kg/m3), variable
Process/equipment
Structural foam: Reaction injection molding (RIM) machine, steel or high

grade epoxy tooling and clamping mechanism Foam is injected into a closed tool. High reaction rate permits fairly short demolding cycles Wood imitation: For higher densities, the process and tooling is similar to structural foam For low densities, silicone, urethane and epoxy tools are used and a low pressure pouring machine dispenses the foam
Press for Molding Polyurethane Wood Imitation (Mold not Shown)

Structural foam:
Moderately crosslinked, 800-1000 mw/x-link 2-3 hydroxyl functionality polyether and/or polyester polyols plus low
MW crosslinkers/chain extenders are used 2.1-2.3 NCO functional modified polymeric MDI is also used Fast reaction rates, compatible with RIM processing are used to afford short demolding cycles
Wood Imitation: Typical moderately crosslinked, (500-650 MW/x-link)rigid foam

polymers are used, sometimes with some high MW polyether polyol added for impact strength. Conventional 2.6-2.8 NCO functional polymeric MDI is used for the isocyanate. Viscosity is kept low and gel is delayed to allow mold detail to be fully reproduced.
Typical Formula for Structural Foam Adipate Polyester, 110 Oh#, 2.3 Amine Based PO triol OH 560 Water Silicone Surfactant Amine Catalyst(s) Flame Retardant (s) R-141b Polymeric MDI @ 1.07 Index 60.0 40.0 1.5 0.5 0.5 10-20 2-10 98.0
Typical Formula for Wood Imitation Sucrose/Glycerine/PO or TDA/PO or Amine based Polyol OH# 400 Water Silicone Surfactant Amine Catalyst(s) Flame Retardant (s) R-141b Polymeric MDI @ 1.10 Index
100.0 1.5 0.5 0.5 10-20 5-15 125.0
Application Issues (rules and regs.)
Blowing agents, structural foam: HCFC 141b has replaced CFC-11 in this application and some co
blowing with water is commonplace Blowing levels are quite low and it is generally felt 141b can be replaced by a non ODS by 2003
Blowing agents, wood imitation: HCFC 141b is also used in this application but in larger amounts Co-blowing with water is practiced and attempts are being made to
find alternates to 141b to maintain high surface density (Integral skin)
Rigid Foam Application Technology Pour-in-Place General Systems for Structural Foam, Wood Imitation
Application issues (rules and regs., cont)
Flammability: structural foam: Compliance with UL V-O testing is usually required for structural
foam cabinets used for electrical components
Other flammability specification are required in different

application areas
Flammability: wood imitation: The foams are usually flame retarded but are seldom affected by flammability regulations
Structural foam & wood imitation: improved surface quality eliminate large cells/blisters improve strength, lower density, better impact
Spray Foam for Industrial, Commercial and Residential Roofing, Tanks, Pipes and Equipment
1.8-2.5 PCF (29-40 kg/m3), usually in multiples of 1-2 (20-50 mm)

layers
Process/equipment
As most foam is sprayed on site, the equipment is portable and
simple The chemicals (usually 1:1or 1:2 by volume ratio) are metered by piston pumps at high pressure through heated hoses to a small impingement mixing chamber After mixing, the foam is spray-applied similarly to airless paint. The foam rises and hardens rapidly so that additional layers can be applied quickly Often the exposed foam is coated with silicone, acrylic or aliphatic urethane topcoat for weather, UV and traffic protection
Highly crosslinked, 400-500 mw/x-link PUR formulations based

on 3-6 OH functional polyether polyols
Reactive Mannich base polyols are also popular PIR formulations based on 2.0-2.3 OH functional aromatic
polyester polyols
2.6-2.8 NCO functional polymeric MDI used for both PUR and PIR Very reactive chemistry, foam is completely reacted in 10-15 sec
Typical Formula for Spray Foam (PUR)

Sucrose/Glycerine/PO or TDA/PO or Amine based Polyol OH# 450 Water Silicone Surfactant Amine Catalyst(s) Flame Retardant (s) R-141b + compatibilizer Polymeric MDI @ 1.10 Index
100.0 1.5 0.5 0.5 10-20 15-25 144.0
Typical Formula for Spray Foam (PIR)

Aromatic Polyester OH# 250, 2.3 Water Silicone Surfactant Amine/Trimer Catalyst(s) Flame Retardant (s) R-141b + Compatibilizer 100.0 0.5 0.5 1.5 5-10 25-35
Polymeric MDI @ 4.0 Index
266

Blowing agents: Conversion to 141b is complete, most spray systems use 141b and water co-blow Industry working on use of zero ODS compliance in 2003 Flammability: UL E-84 class I foams required for most applications, modified PIR technology will pass in most cases Some applications require foam be covered with a 30 minute flame penetration Building codes: Foams must often satisfy many local building codes implemented by individual states and building code organizations barrier (gypsum board or equivalent)
Elimination of foam blistering after aging Smooth surface Improved adhesion of foam to substrate and foam itself Lower K factor, lower density Improvement in flammability/smoke properties
Bun (Block) Foam for Fabrication into Low Density Pipe or Sheet Insulation
1.6-3.0 PCF (26-48 kg/m3), 48w x 32h, (1.2m x 0.8m) for conventional
insulation products
Process/equipment
Foam mix is dispensed by low or high pressure open pour machine into
a paper lined, continuous conveyor belt with moving sides High dispensing output capacity is required for continuous, low density production lines Foam can be cut into lengths after a reaction time of 6-10 minutes Blocks should be aged for 7 days before cutting into desired configuration Discontinuous blocks can also be made by timed machine pours or in mechanically mixed batches High exotherm can scorch (and char) interior of the blocks or buns
Continuous Bun Foam Manufacturing Line
Bun (Block) Foam for fabrication into low density pipe or sheet insulation
Highly crosslinked, 350-500 mw/x-link 3-5 OH functional polyether polyols used for PUR foams 2-2.3 OH functional aromatic polyester polyols used for PIR
foams Controlled reactivity important for generation and maintenance of rectangular bun shape and cell isotropicity 2.7-3.2 NCO functional polymeric MDI used for both PUR and PIR foams
Bun (Block) Foam for fabrication into low density pipe or sheet insulation
Typical Formula for Bun Foam (PIR)

Aromatic Polyester OH# 250, 2.3 Water Silicone Surfactant Amine/Trimer Catalyst(s) Flame Retardant (s) R-141b + Compatibilizer 100.0 0.5 0.5 1.5 5-10 15-25
Polymeric MDI @ 4.0 Index
266
Rigid Foam Application Technologies Bun (Block) Foam for fabrication into low density pipe or sheet insulation
Blowing agents: Producers using 141b and some water co-blowing Alternate zero ODS materials being researched Flammability: End use applications will dictate which fire and smoke
tests must be passed Most existing bun/block foams are either UL E-84 class I or class II
Higher degree of cell isotropicity, greater foam stability in hot

environments Maintenance of properties under extended exposure at high temperature (180-200oc)
Maintenance or improvement in k-factor with zero ODS

conversion
This has been an overview of polyurethane rigid foam technology We hope you have found it interesting and informative
Questions?
Thank you very much for your attention!!


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Understanding Polyurethanes

Polyurethane Applications Grid

Specific Gravity, gms/cc

Footwear Structural Foam

Bumpers, Energy Management Instrument Pads Cushioning Packaging 10 20 30 40 50 60 70 Hardness 80 90 40 50

SynUthane International Inc.

Rigid Polyurethane and Polyisocyanurate Foams Applications and Technologies

Before we proceed to the basic rigid foam applications, we must take a

The blowing Agent problem

20+ years ago, it was discovered that certain halogen substituted

Among these chemicals was a large assortment of refrigerants,

In 1989 the United Nations established the Montreal Protocol to

SynUthane International Inc.

Blowing Agents (Cont)

What materials for urethanes are affected?

When this protocol was established, CFC-11 (trichlorofluoromethane)

CFC-11, due its unique boiling and solubility characteristics, was

SynUthane International Inc.

Blowing Agents (Cont)

The industry immediately sought replacements and relatively

In the meantime, scientists discovered further that the CFC and

CFC-11 CFC-12 HCFC-141b

ODP* 1.0 1.0 0.1

GWP** 4000 8500 630

*Ozone Depleting Potential

Blowing Agents, (Cont)

Blowing Agents (Cont)

Blowing Agents (Cont)

Despite the schedule in place by the Montreal Protocol, the US has

This section* of the Act, if implemented on the present schedule, will

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Blowing Agents (Cont)

No Clean Air Act but want to implement 0 ODP technology.

Concentrating on developing the use of HCs

Developments proceeding with Solvays 365 mfc (pentafluorobutane)

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Blowing Agents (Cont)

Clean Air Act bans 141b starting in 2003

HFC-134a (tetrafluoroethane) and HFC 245fa (pentafluoropropane) work in

CRITICAL ISSUE: The blowing Agent problem

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Various Process/Property Trends Using Alternate Blowing Agents

CFC CO2 (H2O) HCFC HC HFC Blends

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Understanding Polyurethanes Rigid Foam Application Technology

Blowing agents function by providing a gas either by boiling or by

Each blowing agent will have different behavior with respect to

Understanding Polyurethanes Rigid Foam Application Technology

Cell Geometry and Blowing Agents (Cont)

The anomalous effects of these new materials on cell pressure also

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During foaming, cells may become elongated (anisotropic) due to

Cell Geometry (Cont)

Cell anisotropicity can cause shrinkage when

Raising the foam density can prevent

A preferred solution is to formulate the foam to

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Property Challenges: Insulating Value

It is not surprising then that the direction research and

development are taking us is toward mixtures, matches and compromises.

K-Factors of Selected HC, HFC and HCFC Blowing Agents @ 250C

cyclo pentane 0.083