Patents by Inventor Joseph S. Costa

Joseph S. Costa has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20220267600
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is predominately the trans isomer of the hydrochlorofluoroolefin (HCFO) HFCO-1233zd alone or in combination with a hydrofluoroolefin (HFO), hydrofluorocarbon (HFC), hydrochlorofluoroolefin (HCFO), a hydrocarbon. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Application
    Filed: April 25, 2022
    Publication date: August 25, 2022
    Inventors: Benjamin Bin Chen, Joseph S. Costa
  • Publication number: 20210261716
    Abstract: A stable polyol pre-mix composition comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst and a metallic salt. The oxygen-containing amine catalyst may be, for example, one or more of an alkanol amine, an ether amine, or a morpholine group-containing compound such as, for example, 2-(2-dimethylaminoethoxy)ethanol or N,N,N?-trimethylaminoethyl-ethanolamine.
    Type: Application
    Filed: March 29, 2021
    Publication date: August 26, 2021
    Inventors: Benjamin Bin CHEN, Joseph S. COSTA, Laurent T. ABBAS, Haiming LIU, Sri R. SESHADRI, William D. HONNICK
  • Patent number: 10961339
    Abstract: A stable polyol pre-mix composition comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst and a metallic salt. The oxygen-containing amine catalyst may be, for example, one or more of an alkanol amine, an ether amine, or a morpholine group-containing compound such as, for example, 2-(2-dimethylaminoethoxy)ethanol or N,N,N?-trimethylaminoethyl-ethanolamine. The metallic salt may be, for example, alkali earth carboxylates, alkali carboxylates, and carboxylates of metals selected form the group consisting of zinc (Zn), cobalt (Co), tin (Sn), cerium (Ce), lanthanum (La), aluminum (Al), vanadium (V), manganese (Mn), copper (Cu), nickel (Ni), iron (Fe), titanium (Ti), zirconium (Zr), chromium (Cr), scandium (Sc), calcium (Ca), magnesium (Mg), strontium (Sr), and barium (Ba).
    Type: Grant
    Filed: April 29, 2019
    Date of Patent: March 30, 2021
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Laurent T. Abbas, Haiming Liu, Sri R. Seshadri
  • Publication number: 20190248946
    Abstract: A stable polyol pre-mix composition comprises a blowing agent, a polyol, a surfactant, and a catalyst composition comprising an oxygen-containing amine catalyst and a metallic salt. The oxygen-containing amine catalyst may be, for example, one or more of an alkanol amine, an ether amine, or a morpholine group-containing compound such as, for example, 2-(2-dimethylaminoethoxy)ethanol or N,N,N?-trimethylaminoethyl-ethanolamine.
    Type: Application
    Filed: April 29, 2019
    Publication date: August 15, 2019
    Inventors: Benjamin Bin Chen, Joseph S. COSTA, Laurent T. ABBAS, Haiming LIU, Sri R. SESHADRI
  • Publication number: 20190233605
    Abstract: A polyol pre-mix composition includes a blowing agent having a halogenated hydroolefin, a polyol, a catalyst composition, and an antioxidant. The antioxidant may be, for example, a benzene diol or a benzene triol or other polyhydroxy-substituted aromatic compound, which is optionally substituted with one or more substituents such as alkyl groups. A two-part system for producing a thermosetting foam blend includes (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) the polyol pre-mix composition. A method for producing a thermosetting foam blend includes combining: (a) a polyisocyanate; and (b) the polyol pre-mix composition.
    Type: Application
    Filed: April 11, 2019
    Publication date: August 1, 2019
    Inventors: Benjamin Bin Chen, Joseph S. COSTA, Laurent T. ABBAS, Sri R. SESHADRI, Gary S. SMITH
  • Publication number: 20190177465
    Abstract: Incorporating a cycloaliphatic epoxide such as cyclohexene oxide into a polyol pre-mix containing an amine catalyst and a halogenated hydroolefin blowing agent such as HCFO-1233zd helps to improve the storage-stability of the pre-mix and to ensure that a thermoset foam prepared therefrom is of satisfactory quality.
    Type: Application
    Filed: July 20, 2017
    Publication date: June 13, 2019
    Inventors: Benjamin Bin CHEN, Joseph S. COSTA, Laurent T. ABBAS, Sri R. SESHADRI
  • Patent number: 10308783
    Abstract: A polyol pre-mix composition includes a blowing agent having a halogenated hydroolefin, a polyol, a catalyst composition, and an antioxidant. The antioxidant may be, for example, a benzene diol or a benzene triol or other polyhydroxy-substituted aromatic compound, which is optionally substituted with one or more substituents such as alkyl groups. A two-part system for producing a thermosetting foam blend includes (a) a polyisocyanate and, optionally, one or more isocyanate compatible raw materials; and (b) the polyol pre-mix composition. A method for producing a thermosetting foam blend includes combining: (a) a polyisocyanate; and (b) the polyol pre-mix composition.
    Type: Grant
    Filed: September 19, 2013
    Date of Patent: June 4, 2019
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Laurent Abbas, Sri R. Seshadri, Gary S. Smith
  • Publication number: 20190119461
    Abstract: The present invention relates to imidazole and/or its derivative as polyurethane or polyisocyanurate foam catalyst in the presence of Low Global Warming Potential (GWP) halogenated olefinic blowing agents, such as the hydrochlorofluoroolefin (HCFO) HCFO-1233zd. More particularly, the present invention relates to catalyst compositions comprising imidazole and/or its derivative. The present invention further relates to the stable pre-blend formulations and resulting polyurethane or polyisocyanurate foams. A method for stabilizing thermosetting foam blends comprises combining: (a) a polyisocyanate and, optionally, isocyanate compatible raw materials; and (b) a polyol pre-mix composition comprising a halogenated olefinic blowing agent, a polyol, a surfactant, and a catalyst, wherein the catalyst comprises substituted imidazole having C2 or greater substitutions at the N1 nitrogen and/or its derivative.
    Type: Application
    Filed: December 21, 2018
    Publication date: April 25, 2019
    Inventors: Benjamin Bin Chen, Joseph S. Costa
  • Patent number: 10113046
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is 2,4,4,4-tetrafluorobutene-1 alone or in combination with a hydrofluoroolefin (HFO), hydrofluorocarbon (HFC), hydrochlorofluoroolefin (HCFO), or a hydrocarbon. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Grant
    Filed: October 20, 2010
    Date of Patent: October 30, 2018
    Assignee: ARKEMA INC
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Philippe Bonnet
  • Patent number: 9914815
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is a hydrofluoroolefin (HCFO), preferably HFCO-1234yf in combination with a hydrochlorofluoroolefin (HCFO) preferably one selected from HCFO-1233zd, HCFO-1223, HCFO-1233xf and mixtures thereof. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Grant
    Filed: February 4, 2016
    Date of Patent: March 13, 2018
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Philippe Bonnet, Maher Y. Elsheikh, Brett L. Van Horn
  • Patent number: 9868837
    Abstract: The present invention is directed towards a method of stabilizing thermosetting foam blends such as polyurethane poly blends containing a blowing agent with negligible (low or zero) ozone-depletion and low GWP based upon unsaturated halogenated hydroolefins in which one or more ester is added to the thermosetting foam blends. The thermosetting foam blends typically in clued: polyol(s); surfactant(s); catalyst(s); flame retardent(s); organic acid inhibitor(s)/stabilizer(s); carbon dioxide generating agent(s). The addition of the one or more esters to the thermosetting foam blends was unexpectedly found to result in blends which were stable over time and the resulted foams have a uniform cell structure with little or no foam collapse.
    Type: Grant
    Filed: April 22, 2011
    Date of Patent: January 16, 2018
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Philippe Bonnet
  • Publication number: 20170369668
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is predominately the trans isomer of the hydrochlorofluoroolefin (HCFO) HFCO-1233zd alone or in combination with a hydrofluoroolefin (HFO), hydrofluorocarbon hydrochlorofluoroolefin (HCFO), a hydrocarbon. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Application
    Filed: August 18, 2017
    Publication date: December 28, 2017
    Inventors: Benjamin Bin Chen, Philippe Bonnet, Brett L. Van Horn, Joseph S. Costa
  • Patent number: 9738768
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is predominately the trans isomer of the hydrochlorofluoroolefin (HCFO) HFCO-1233zd alone or in combination with a hydrofluoroolefin (HFO), hydrofluorocarbon (HFC), hydrochlorofluoroolefin (HCFO), a hydrocarbon. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Grant
    Filed: January 11, 2016
    Date of Patent: August 22, 2017
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Philippe Bonnet, Brett L. Van Horn, Joseph S. Costa
  • Publication number: 20170088685
    Abstract: The shelf life of polyurethane polyol pre-blends containing halogenated olefins is extended by encapsulation of active components such as catalysts anti/or surfactants. The active component is encapsulated in a crystallizable or thermoplastic polymer. The encapsulated particles have a size of 2,800 microns or less and the active components are not significantly leaked out, particularly in the presence of halogenated olefins.
    Type: Application
    Filed: December 14, 2016
    Publication date: March 30, 2017
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Laurent Abbas, Sri R. Seshadri
  • Publication number: 20170081491
    Abstract: A polyol pre-mix containing at least one halogenated hydroolefin blowing agent and having improved shelf life stability is provided, wherein each polyol combined with the halogenated hydroolefin blowing agent has an apparent pH of between 3 and 11.4. Controlling the apparent pH of the polyol(s) enables the polyol pre-mix to be stored for extended periods of time and then used in combination with organic polyisocyanate to produce foam formulations having gel times and tack free times not significantly different from those exhibited when freshly prepared polyol pre-mix is used.
    Type: Application
    Filed: May 26, 2016
    Publication date: March 23, 2017
    Inventors: Benjamin Bin CHEN, Joseph S. COSTA, Sri R. SESHADRI, Laurent ABBAS
  • Patent number: 9556335
    Abstract: The shelf life of polyurethane polyol pre-blends containing halogenated olefins is extended by encapsulation of active components such as catalysts and/or surfactants. The active component is encapsulated in a crystallizable or thermoplastic polymer. The encapsulated particles have a size of 2,800 microns or less and the active components are not significantly leaked out, particularly in the presence of halogenated olefins.
    Type: Grant
    Filed: January 31, 2013
    Date of Patent: January 31, 2017
    Assignee: Arkema Inc.
    Inventors: Benjamin Bin Chen, Joseph S. Costa, Laurent Abbas, Sri R. Seshadri
  • Publication number: 20160362531
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is a hydrofluoroolefin (HCFO), preferably HFCO-1234ze in combination with a hydrochlorofluoroolefin (HCFO) preferably one selected from HCFO-1233zd, HCFO-1223, HCFO-1233xf and mixtures thereof. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Application
    Filed: August 24, 2016
    Publication date: December 15, 2016
    Inventors: Benjamin Bin CHEN, Joseph S. COSTA, Philippe BONNET, Maher Y. ELSHEIKH, Brett L. VAN HORN
  • Publication number: 20160152787
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is a hydrofluoroolefin (HCFO), preferably HFCO-1234yf in combination with a hydrochlorofluoroolefin (HCFO) preferably one selected from HCFO-1233zd, HCFO-1223, HCFO-1233xf and mixtures thereof. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Application
    Filed: February 4, 2016
    Publication date: June 2, 2016
    Inventors: Benjamin Bin Chen, Joseph S. COSTA, Philippe BONNET, Maher Y. ELSHEIKH, Brett L. VAN HORN
  • Publication number: 20160130416
    Abstract: The present invention relates to imidazole and/or its derivative as polyurethane or polyisocyanurate foam catalyst in the presence of Low Global Warming Potential (GWP) halogenated olefinic blowing agents, such as the hydrochlorofluoroolefin (HCFO) HCF0-1233zd. More particularly, the present invention relates to catalyst compositions comprising imidazole and/or its derivative. The present invention further relates to the stable pre-blend formulations and resulting polyurethane or polyisocyanurate foams. A method for stabilizing thermosetting foam blends comprises combining: (a) a polyisocyanate and, optionally, isocyanate compatible raw materials; and (b) a polyol pre-mix composition comprising a halogenated olefinic blowing agent, a polyol, a surfactant and a catalyst.
    Type: Application
    Filed: May 20, 2014
    Publication date: May 12, 2016
    Inventors: Benjamin Bin CHEN, Joseph S. COSTA
  • Publication number: 20160122495
    Abstract: A blowing agent for thermosetting foams is disclosed. The blowing agent is predominately the trans isomer of the hydrochlorofluoroolefin (HCFO) HFCO-1233zd alone or in combination with a hydrofluoroolefin (HFO), hydrofluorocarbon (HFC), hydrochlorofluoroolefin (HCFO), a hydrocarbon. The blowing agent is effective as a blowing agent in the manufacture of thermosetting foams.
    Type: Application
    Filed: January 11, 2016
    Publication date: May 5, 2016
    Applicant: Arkema Inc.
    Inventors: Benjamin Bin CHEN, Philippe BONNET, Brett L. VAN HORN, Joseph S. COSTA