Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: Polyurethane foams are provided. The polyurethane foams are produced from a formulation that includes an isocyanate reacting mixture, an isocyanate component, and a blowing agent. The isocyanate reacting mixture includes at least 40 wt % of at least one propoxylated polyester-polyether polyol based on the total weight of the isocyanate reacting mixture. The isocyanate reacting mixture also includes at least one of propoxylated sucrose polyol or propoxylated sorbitol polyol. The propoxylated sucrose polyol and/or propoxylated sorbitol polyol has a hydroxyl number of from about 300 mg KOH/g to about 600 mg KOH/g. The polyurethane foam has a compressive strength of at least 130 kPa, and a stoichiometric index of the isocyanate component to the isocyanate reacting mixture is between about 1.0 and 1.7.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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 (2) is continuously supplied. A mat (10) of reinforcing fibers and a foamable resin composition (19) are applied to the bottom facing panel. A flexible barrier layer (5) is applied atop the foamable resin composition, and the assembly is passed through nip rolls (12,13) to compress the assembly and force the resin composition into the fiber mat. An adhesive layer (4) and top metallic facing layer (1) 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 (11).

Abstract: 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.

Abstract: Embodiments of the present disclosure provide for a composition for forming a polyurethane foam and a method of forming the polyurethane foam using the composition. The polyurethane foam includes a formulated polyol, an isocyanate and a blowing agent. The formulated polyol includes 60 weight percent (wt. %) to 80 wt. % of a polyether polyol and 10 wt. % to 25 wt. % of an aromatic polyester polyol, where the wt. % are based on a total weight of the formulated polyol, and where the formulated polyol has a polyol mixture functionality of 3.8 to 5.5.

Abstract: 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.

Abstract: 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 (2) is continuously supplied. A mat (10) of reinforcing fibers and a foamable resin composition (19) are applied to the bottom facing panel. A flexible barrier layer (5) is applied atop the foamable resin composition, and the assembly is passed through nip rolls (12,13) to compress the assembly and force the resin composition into the fiber mat. An adhesive layer (4) and top metallic facing layer (1) 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 (11).

Abstract: 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.

Abstract: The present invention relates to polyurethane rigid foams formulations. More particularly, the present invention relates to polyurethane rigid foams formulations, prepared from aromatic polyester polyols, which show improved compressive strength. The formulations include an isocyanate reacting mixture, at least one polymeric diphenylmethane diisocyanate, having a functionality of at least 2.7, and at least one blowing agent; such that the stoichiometric index of the polyisocyanate to the isocyanate reacting mixture is 1.0-1.8.

Abstract: 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.

Abstract: Embodiments of the invention provide for polyurethane or polyisocyanurate foam formulations. The formulations include a formulated polyol, a polyisocyanate, and a blowing agent such that the stoichiometric index of the polyisocyanate to the formulated polyol is above 250. The formulated polyol includes (i) from about 20 to about 60 percent by weight of an aromatic polyester polyol, (ii) from about 10 to about 30 percent by weight of a Novolac-type polyether polyol, and (iii) from about 5 to about 40 percent by weight of a polyether polyol including a sucrose- or sorbitol-initiated polyol. Components (i), (ii), and (iii) are selected so that the formulated polyol as a whole has an average functionality of at least about 2.4.

Abstract: 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.

Abstract: 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.