Abstract: A system and a method of providing PUR/PIR foam using flammable blowing agent. The flammable blowing agent is introduced to PUR/PIR manufacturing equipment via an independent feed-line. This enables a flammable blowing agent storage vessel to be located off site from the foam manufacturing equipment. The independent flammable blowing agent feed-line couples the off-site flammable blowing agent storage vessel with the foam production system. The preferred flammable blowing agent is pentane.

Abstract: An apparatus and a continuous process produce composite structural insulated panels (SIPs). Lower boards are placed on a conveying system through a foam application zone and then upper boards are applied. The foam material adheres to the upper and lower boards to form a structural insulated panel after passing through a curing apparatus.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Abstract: A method for preparing a thermosetting foam, such as polyisocyanurate or polyurethane foam, includes introducing polyol and isocyanate to a screw of an extruder and mixing in the extruder screw. Catalyst is then added and mixed with the already formed mixture in the extruder screw. This mixture is extruded onto a conveyor and foamed on the conveyor. Finely divided carbon black, dispersing agent and/or surfactant may be mixed with polyol before introducing to the screw of the extruder or carbon black may be dispersed in polyol in the extruder and a polyol premix made before the remainder of the polyol is added. Foam cell size is decreased when extruder speed is increased. The foaming agent, which is preferably HCFC or water, may be mixed with one of the components, preferably the polyol, before introducing to the screw of the extruder. The mixture is cooled before extruding onto a conveyor to delay the foaming step until the mixture is outside the extruder.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.