Dow Global Technolgoies LLC

Paolo Golini

Luigi L Bertucelli

Giuseppe Vairo

Luigi Pellacani

Luca Lotti

Maurizio Guandalini

Cecilia Girotti

Francesca Pignagnoli

Matthew A Robinson

Swithin P Adu-Peasah

Giuseppe Fantera

Kai-Sheng Bian

Berrin Degirmenci

Peter Keller

Luigi Bertucelli

Formulated polyol compositions include a non-halogenated polyol, a halogenated polyol, a phosphorus-containing flame retardant, an HFO and/or HCFO blowing agent and certain urethane catalysts. The compositions exhibit excellent storage stability. Foams made from the formulated polyol compositions have unexpectedly improved fire performance, as indicated by certain fire tests.

Storage stable HFO- or HCFO-containing polyol compositions for making flame-resistant rigid polyurethane foams

A method of producing a polyurethane based foam that includes providing a ground crop residue having an average particle size of less than 10 mm and that is prepared by grinding crop residues, providing a polyurethane system that includes an isocyanate component and an isocyanate-reactive component, of which the polyurethane system has an isocyanate index from 70 to 350, forming a modified polyurethane system by adding the ground crop residue to the polyurethane system in a range from 1.0 wt % to 20.0 wt %, based on a total weight of the modified polyurethane system, and forming the polyurethane based foam so as to have an applied density from 30 kg/m3 to 75 kg/m3, according to ASTM D-1622, and to have the ground crop residue embedded within polyurethane polymers that are a reaction product of the isocyanate component and the isocyanate-reactive component of the polyurethane system.

Polyurethane foams with agricultural by-products

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

Method for making fire-resistant foam insulation panels

Embodiments of the present disclosure are foam formulations. As an example, foam formulation can include a polyol composition having an amine-imitated polyol that is from 10 percent to 20 percent of a total weight of the polyol composition and an additional polyol that is from 80 percent to 90 percent of the total weight of the polyol composition, a polyisocyanate, a blowing catalyst, and a gel catalyst, where a combination of the blowing catalyst and the gel catalyst is from 0.5 percent to 1.5 percent the total weight of the polyol composition and where the blowing catalyst is from 50 percent to 100 percent of a total weight of the blowing catalyst and the gel catalyst.

Foam formulations

The present invention discloses the production of panels by a discontinuous process. The panels are produced by injecting a polyisocyanurate foam forming composition into the mold cavity at reduced pressure. The combination of certain polyisocyanurate foam forming formulation and the reduced pressure in the mold cavity allows production of and resulting sandwich panels in a discontinuous process where the produced panels are characterized by improved fire resistance.

Production of polyisocyanurate foam panels

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel () is continuously supplied. A mat () of reinforcing fibers and a foamable resin composition () are applied to the bottom facing panel. A flexible barrier layer () is applied atop the foamable resin composition, and the assembly is passed through nip rolls () to compress the assembly and force the resin composition into the fiber mat. An adhesive layer () and top metallic facing layer () are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator ().

Polyisocyanurate foam composition, articles comprising the composition and a method of making the composition are described. The polyisocyanurate foam composition comprises the reaction product of a polyisocyanate compound; and a first polyester polyol comprising the residue of orthophthalic acid; a second polyester polyol comprising the residue of terephthalic acid; at least one polyether polyol having a functionality of at least 3 and a hydroxyl number greater than 200; and a physical blowing agent, wherein the isocyanate index is greater than 250.

Polyisocyanurate composition

Disclosed is a polyol composition comprising an aliphatic polyester polyol having a hydroxyl value of less than about 100 and prepared by the reaction of at least a polycarboxylic acid with a polyhydroxy compound; an aromatic polyester polyol; a Novolac-type polyether polyol; and a hydrofluorocarbon blowing agent; that may be storage-stable for at least 60 days. This composition may be reacted with a polyisocyanate at an isocyanate index of from about 2.5 to about 4 to form a rigid poly-isocyanurate foam. The foam shows improved cohesion in general and also improved adhesion and a reduced incidence of voids when applied to a metal substrate.

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Reggio Emilia, Italy

Paolo Golini