Development of Novel Blowing Agents for Polyurethane Foams · PDF fileDevelopment of Novel...
Transcript of Development of Novel Blowing Agents for Polyurethane Foams · PDF fileDevelopment of Novel...
Development of Novel Blowing Agents for
Polyurethane Foams
John McMenaminMark L. Robin, Ph.D.Gary LohJoseph A. Creazzo
Presented at:UTECH Europe 2009Maastricht, NetherlandsMarch 31-April 2, 2009
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Development of a Novel Blowing Agent for Polyurethane Foams
OUTLINE
• Introduction
• Blowing Agents for Polyurethane
• Novel Blowing Agent FEA-1100Polyurethane foams (PUR)
Polyisocyanurate foams (PIR)
• Conclusion
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• Largest family of rigid thermoset foams
• Primary Markets• Construction insulation • Appliance insulation
• Use as insulation materials based on low thermal conductivity ( ), or high thermal resistivity (R-value) of foams
• Insulating characteristics of foam • Largely dependent upon the composition of the gas (Blowing agent) trapped in the cells
Rigid Polyurethane Foams
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Thermal Conductivity of Foam
λ = λsolid + λgas + λconvective + λradiative
λgas : gas in cells responsible for most of heat transfer
- foam usually over 90% gas or more by volume
λsolid : small
- 2 pcf PU foam, consists of 3% of solid polymer
λconvective, λradiative : small
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Blowing Agents for PU foams: Historical
Generation Main Characteristics Examples
First Generation
Low thermal conductivity
High ODP, GWP CFC-11
Second Generation
Low thermal conductivity
Low ODP, Moderate GWP
Moderate thermal conductivity
Zero ODP, Moderate GWP
Low thermal conductivity
Zero ODP, Low GWP
HCFC-141b
Third Generation
HFC-245fa, HFC-365mfc
Pentane, Isopentane
Fourth Generation FEA-1100
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Comparison of Blowing Agents
1st
Generation
2nd
Generation
3rd
Generation
CFC-11 HCFC-141b HFC-245fa HFC-365mfc Isopentane
ODP 1 0.12 0 0 0GWP 4750 725 1020 782 11bp oC 23.9 32.1 15.3 40.0 27.9
λ gas 25 oC
mW/mK 8.4 9.7 12.7 10.5 13.3Flash Point None None None - 25 oC - 51 oC
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Insulation Performance (measured by vapor thermal conductivity) among top three most important customer concerns … and a significant “pain point” because each previous conversion resulted in decreased performance.
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CFC-11HCFC
-141b
HFC-245fa
HFC-365m
fcIso
pentan
e
Pentan
e
mW
/mK
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Boiling Point among top three most important customer concerns …and a significant “pain point” among existing users of HFC-245fa.
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CFC-11HCFC-14
1bHFC-245
faHFC-365
mfcCyclo
pentaneIso
pentane
Pentan
e
Tem
pera
ture
- °C
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Ideal Blowing Agent• Zero ODP• Low GWP• Low vapor thermal conductivity• Nonflammable• Liquid at room temperature ( bp > 25 oC)• Low toxicity• Chemically/thermally stable• Soluble in formulation• Low rate of diffusion• Economically feasible
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FEA-1100: A Novel “4th Generation” Blowing Agent for Polyurethane Foams
ODP = 0
GWP = 5
Low vapor thermal conductivity10.7 mW/mK @ 25 oC
NonflammableASTM E 681; 60 oC, 100 oC
Boiling point > 25 oC
LC50 (4h, rat) > 106,000 ppm
Ames test negative
Chromosomal aberration negative
28 day inhalation NOEL = 2,500 ppm
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Insulation Performance (measured by vapor thermal conductivity) among top three most important customer concerns … and a significant “pain point” because each previous conversion resulted in decreased performance.
0
2
4
6
8
10
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CFC-11HCFC
-141b
HFC-245fa
HFC-365m
fcIso
pentan
e
Pentan
eFEA-11
00
mW
/mK bp > 25 oC
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PUR Foams: FEA-1100 and HFC-245faBlowing Agent
Ingredients (pbw) FEA-1100 HFC-245fa
water 1.5 1.5
Rise time (s) 100
B-side 106.0 106.0
FEA-1100 32.2 0.0
HFC-245fa 0.0 26.3
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Isocyanate 155.0 155.0
PROCESS DATA
Cream time (s) 7 6
Tack free time (s) 110 140
INITIAL PROPERTIES
Foam Index 1.1 1.1
Foam density (pcf) 2.2 2.1
R-value, BTU-in/ft2 h oF @ 75 oF 7.1 6.6
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Polyurethane Foams (PUR)
Polyurethane Foam HFC-245fa
Polyurethane Foam FEA-1100
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FEA-1100 and HFC-365mfc (PUR Foams)
Blowing Agent
Ingredients (pbw) FEA-1100 HFC-365mfc
water 1.5 1.5
Rise time (s) 120
B-side 106.0 106.0
FEA-1100 32.2 0.0
HFC-365mfc 0.0 29.1
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Isocyanate 120.6 120.6
PROCESS DATA
Cream time (s) 7 7
Tack free time (s) 140 135
INITIAL PROPERTIES
Foam Index 1.1 1.1
Foam density (pcf) 1.9 1.8
R-value, BTU-in/ft2 h oF @ 75 oF 7.0 6.5
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FEA-1100 and Cyclopentane (PUR Foams)Blowing Agent
Ingredients (pbw) FEA-1100 cyclopentane
water 1.0 1.0
Rise time (s) 105
B-side 104.0 104.0
FEA-1100 29.4
cyclopentane 0.0 12.6
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Isocyanate 132.0 132.0
PROCESS DATA
Cream time (s) 9 10
Tack free time (s) 105 100
INITIAL PROPERTIES
Foam Index 1.2 1.2
Foam density (pcf) 2.1 2.4
R-value, BTU-in/ft2 h oF @ 75 oF 7.2 6.6
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PIR Foams: FEA-1100 & HFC-245faBlowing Agent
Ingredients (pbw) FEA-1100 HFC-245fa
B-side 109.7 109.7
FEA-1100 39.7 0.0
HFC-245fa 0.0 32.4
Isocyanate 158.2 158.2
PROCESS DATA
Cream time (s) 15 12
Rise time (s) 110 110
Tack free time (s) 120 120
INITIAL PROPERTIES
Foam Index 2.5 2.5
Foam density (pcf) 2.1 2.2
R-value, BTU-in/ft2 h oF @ 75 oF 7.7 7.2
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Polyisocyanurate Foams (PIR)
PolyisocyanurateFoam HFC245fa
PolyisocyanurateFoam FEA-1100
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R-Value Comparisons
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Conclusion
Development of FEA-1100, a Novel Foam Expansion Agent for Polyurethane Foams
Zero ODPLow GWPLow vapor thermal conductivity NonflammableLow ToxicityPUR and PIR foamsGood dimensional stabilityUniform cell sizeR values exceed those obtained with HFC-245fa,HFC-365mfc and cyclopentane