Patent Application
20250065544
This invention relates to apparatus and methods for producing laminated panel products having a facing layer and a polyurethane foam layer.
Single- and double-faced laminated panels are materials that include a polymer foam layer and a facing layer bonded to one or both sides of the foam layer. These products are useful as thermal insulation panels due to the insulating properties of the foam layer.
Sandwich panels of the present invention are useful in both industrial and residential applications. Uses include, for example, cold stores insulation, doors, windows and sliding shutters. The laminated panels are also useful as construction or decorative panels even when thermal insulation properties are not needed. The panels are useful, for example, in constructing building facades.
The panels can be made industrially through a continuous or discontinuous process. A typical continuous process is commonly known as double band lamination. In this process, the components of the foam formulation are combined in a mixhead and the resulting foam formulation is transferred through a distribution system to multiple outlets, through which it is dispensed onto a bottom facing layer. The outlets are arranged across the width of the bottom facing layer, and are nowadays generally stationary. The bottom facing layer moves horizontally beneath the outlets. This motion produces from each outlet a strip of foam formulation on the bottom facing layer.
The individual strips should meet and combine to form a continuous layer before they cure so much they can no longer flow. Unfortunately, that requirement is not met in some cases, in particular when the process is operated outside of its optimal range of operating speeds and flow rates through the distribution system. This leads to product defects.
Other challenges with this process include the need to obtain a uniform distribution of the foam formulation across the panel width, and the need to minimize fouling within the apparatus. Fouling is often due to stagnant or low flow regions within the distribution system, where the foam formulation can produce high viscosity gels or even solid material that partially or entirely blocks a section of the distributor.
EP2125323 and EP2234732 describe a distributor which includes a fixed tube with multiple orifices; the length of the exit tubes decreases from the middle to the end of the tube. The performance of these distributors is highly dependent on specific material rheologies and flowrates for which they are designed. Performance drops considerably when these conditions are varied. This is a significant disadvantage because the process usually must operate at different flow rates at different times, and because specific distributors are typically restricted to making products that all use a single foam formulation. In addition, the time needed for a foam formulation to reach the various orifices of these distributors is not the same; the foam formulation expelled through the outermost orifices often experiences a longer residence time within the distributor. This is a significant problem because material exiting from different orifices are not all in the same state of cure. This results in uneven foam rise and therefore poor panel quality. The age difference becomes greater at low flow rates.
Good results can be obtained using a distributor such as shown in FIG. 3 of WO 2021/045888 when the flow rates through the distributor are somewhat high. At these higher flow rates, fouling is minimized, a highly uniform distribution of the foam formulation across the width of the panel is obtained, and the individual strips of applied foam formulation meet and combine. Some of these benefits are lost at low flow rates. Better distribution can in principle be obtained by increasing the number of outlets, thereby reducing the spacing between adjacent ones, but as a practical matter spatial considerations limit how many outlets can be provided.
Further improvements would be desirable; in particular, a process that produces good quality laminates over a wider range of operating conditions (product rheology and flow rate) is wanted.
This invention is in one aspect a apparatus for forming and dispensing a fluid mixture, comprising:
This apparatus is suitable for making laminated panels in a continuous process in which a reactive foam formulation is dispensed onto a moving bottom facing layer. The apparatus dispenses the foam formulation in the form of divergent jets that move apart from each other before reaching the bottom facing and then readily combine with foam formulation dispensed from adjacent jets to produce a highly uniform layer. The apparatus works well across a wide range of flow rates and with foam formulations having a wide range of rheologies, which allows line speeds and foam thicknesses to be varied as may be needed or desirable.
Accordingly, the invention is also a process for making a laminated panel, comprising
I. continuously dispensing a reactive foam formulation onto a moving bottom facing layer, through an apparatus of the first aspect by introducing components comprising at least one polyisocyanate, at least one physical blowing agent, at least one polyol and at least one catalyst into the mixing zone of the mixhead through the multiple inlets of the mixhead, mixing the components in the mixing zone to form the reactive foam formulation and continuously transferring the reactive foam formulation out of the mixhead outlet and then through the distribution system and out of the nozzle outlets of the nozzles onto the moving bottom facing layer, wherein the nozzle outlets are arranged parallel to and across at least a portion of the width of the bottom facing layer and the nozzle outlets each dispense a jet of foam formulation, which jets travel in a diverging pattern and come into contact the moving bottom facing layer where foam formulation dispensed from adjacent jets combine to form a layer of reactive foam formulation on the bottom facing layer, and
II. curing the layer of reactive foam formulation on the bottom facing layer to form a laminated panel comprising the bottom facing layer and a polymer foam layer bonded to the bottom facing layer.
Turning to
Reactive foam formulation 4 is supplied via distribution system 16 in the direction indicated by arrow 9 to outlet 10, where it is dispensed onto bottom facing layer 2 as bottom facing layer 2 travels in the indicated horizontal direction. For simplicity of illustration, only one outlet 10 is shown in
Upon being dispensed onto bottom facing layer 2, reactive foam formulation 4 is carried along with bottom facing layer 2, and expands upwardly to form layer 4A of reactive foam formulation 4. Optionally but preferably, top facing layer 3 is applied to the top surface of layer 4A of reactive foam formulation 4. When applied, top facing layer 3 preferably also travels in the direction indicated by arrow 6, i.e., in the same direction as bottom facing layer 2 travels, and preferably at the same linear speed. Top facing layer 3 can be moved through the process using any of the methods and apparatus as described above with regard to moving bottom facing layer 2.
As shown, the vertical distance between bottom facing layer 2 and top facing layer 3 is established mechanically, in this particular embodiment by passing top facing layer 3 under roller 7. Although only a single roller is shown, multiple rollers 7 may be present. In the double belt lamination process shown, the vertical distance so established defines the thickness of layer 4A of foam formulation 4, as foam formulation 4 expands upwardly until further upward expansion is constrained by top facing layer 3. Upon curing, layer 4A therefore has a thickness equal to the vertical distance between bottom facing layer 2 and top facing layer 3. Pressure may be applied to top facing layer 3 and to bottom facing layer 2, such as via a double belt or other mechanical means, or via air pressure, to maintain the desired spacing. A double belt laminator is an example of an apparatus suitable for performing the lamination process.
Turning to
Turning now to
As shown in
In this invention, the “fluid” foam formulation is a liquid or a liquid/gas mixture (sometimes referred to an “emulsion”); therefore, at least one of the starting materials introduced into mixhead 12 through an inlet 13 is a liquid under the operating conditions.
Each of multiple inlets 13 is in fluid communication with mixing zone 14 such that starting materials entering mixhead 12 through inlets 13 flow into mixing zone 14. Starting materials introduced into mixhead 12 through multiple inlets 13 are combined in mixing zone 14 to form a fluid mixture. Mixing zone 14 may contain various types of mixing elements, the selection of which is not considered critical to the invention. Mixing zone 14 usually contains impingement mixing elements, but may contain, for example, static mixing elements, centrifugal mixing elements, various types of agitators and the like, or any combination of two or more of such mixing elements. It is contemplated that the selection of mixing elements in any particular case will be made in accordance with the particular materials being mixed and the particular mixing requirements for any specific application.
Mixing zone 14 is in fluid communication with mixhead outlet 15, such that the fluid mixture produced in mixing zone 14 is discharged from mixhead 12 via mixhead outlet 15.
Mixhead outlet 15 is in fluid communication with distribution system 11 such that the fluid mixture discharged from mixhead 12 via mixhead outlet 15 flows into distribution system 11. Distribution system 11 distributes the fluid mixture produced in mixhead 12 to multiple outlets 10 from which the fluid mixture is dispensed through nozzles 40 (not shown in
The conduit system includes at least one branch point at which the conduit system is divided to define the multiple flowpaths. Seven such branch points (including first branch point 17A and downstream branch points 17) are arbitrarily illustrated in the embodiment shown in
Distribution system 11 as shown in
The number of flowpaths into which the fluid mixture is divided within distribution system may be as few as 2 and can be any arbitrarily larger number, such as at least 2, at least 3, at least 4, at least 5, at least 7, at least 8, at least 10, at least 16 or at least 32, and, for example, up to 100, up to 50 or up to 25.
Distribution system 11 further includes outlets 10 at the termini of the multiple flowpaths of the conduit system for dispensing the fluid mixture from distribution system 11 into nozzles 40 (
As is true with regard to the number of branches and flowpaths, the number of outlets 10 may be as few as 2 and can be any arbitrarily larger number, such as at least 2, at least 3, at least 4, at least 5, at least 7, at least 8, at least 10, at least 16 or at least 32, and, for example, up to 100, up to 50 or up to 25. In
Outlets 10 may be arranged in a straight line, a staggered configuration, or other useful configuration.
Other useful distribution systems include, for example, a distributor bar as described in US Published Patent Application No. 2014/00417412, a rake-type distributor bar as described in US Published Patent Application No. 2017/0285619 and/or US 2010/0080900, a jointed casting rake/accommodation element assembly as described in U.S. Pat. No. 9,718,223, an apparatus as described in German Utility Model 20 2011 001 109 U1 and/or 20 2009 015 838U1, an apparatus as described in EP 2 125 323 B1, an apparatus as described in EP 2 234 732 B1 or an apparatus as described in WO 2008/018787.
Nozzles 40 are associated with each outlet 10. Nozzles 40 may be integral with distribution system 11 or may be a separate component affixed to distribution system 11. As shown in
Each nozzle outlet 42′ and 42″ is at a diverging angle of 5 to 45° from each adjacent nozzle outlet. Accordingly, adjacent nozzle outlets produce jets 30 that diverge at an angle of 5 to 45°, corresponding to the angle between the two adjacent nozzle outlets. Jets 30 are dispensed from nozzle outlets 42′ and 42″ within the plane in which the nozzle outlets lie, and travel in a diverging pattern to moving bottom facing layer 2. The angle θ between adjacent nozzle outlets (and corresponding adjacent streams) in some embodiments is at least 5° and up to 30°, up to 20°, up to 15° or up to 10°. Terminal outlets 42′ are at an angle θ of 30 to 90° to each other, a preferred angle being 30 to 60° or 45 to 60°. The center-to-center distances between adjacent nozzle outlets is 1 to 3 mm, a preferred distance being 3 to 25 mm, 3 to 20 mm or 5 to 12 mm. The center-to-center distance between the two terminal outlets 42′ may be, for example, 20 to 100 mm, 20 to 80 mm or 20 to 60 mm.
The total number of nozzle outlets may be 2 to 12, and in some embodiments is 3 to 8 or 4 to 6.
Nozzle outlets 42′ and 42″ may have diameters of, for example, 0.25 to 8 mm, 0.75 to 4 mm, or 1 to 3 mm. It is preferred that all nozzle outlets have the same diameter and cross-sectional shape. Nozzle outlets 42′ and 42″ may have circular cross-sections or other cross-sections (such as slits, squares, rectangles, rhombuses and the like); the diameter of a nozzle outlet having a non-circular cross-section is taken as that of a circle having the same cross-sectional area.
Exterior housing 50 of nozzles 40 further each include or define one or more interior fluid paths 43 that extend within exterior housing 50 from nozzle inlet 41 to the nozzle outlets 42′ and 42″. Fluid paths 43 are in fluid communication with nozzle outlets 42′ and 42″ and with nozzle inlet 41. In the embodiments shown in
Individual ducts 43″ may or may not all be the same. They may have different shapes, cross-sections and/or lengths, for example. Individual ducts 43″ are shown as straight conduits in
In the specific embodiment shown in
The apparatus of the invention is useful in any process in which starting materials are combined to form a fluid mixture which is then distributed to multiple outlets. An example of such a process is a laminated panel manufacturing process, such as one of the general type illustrated in
The distance from nozzle outlets 42′ and 42″ and bottom facing layer 2 in some embodiments is selected such that jets dispensed from terminal nozzle outlets 42′ are separated by 30 to 200 mm, 60 to 150 mm or 80 to 125 mm at the point of their respective contact with bottom facing layer 2. The jets diverge as they travel toward bottom facing layer 2; the jets dispensed from adjacent nozzles should not combine until they have made contact the bottom facing layer 2. Operating pressures preferably are selected to achieve this; the jets of foam formulation preferably are dispensed at a velocity high enough that the jets diverge (and remain separate) as they travel to bottom facing layer 2. The direction of travel of each of the jets is typically a straight line or very nearly so. Jets dispensed from adjacent nozzle outlets 42′ and 42″ may be separated, at the point of their respective contact with bottom facing layer 2, by a distance equal to 1.5 to 5 times, especially 2 to 4 times, the distance between those nozzle outlets. In absolute terms, jets dispensed from terminal nozzle outlets 42′ may be separated, at the point of their respective contact with bottom facing layer 2, by a distance equal to 30 to 400 mm, 40 to 150 mm, especially 50 to 100 mm.
A top facing layer may be added in the manner described before to form a sandwich panel. Nozzle outlets 42′ and 42″ are generally oriented transverse to the direction of movement of bottom facing layer 2, i.e., across its width. As discussed before, the movement of bottom facing layer 2 as reactive foam formulation 4 is dispensed through nozzle outlets 42′ and 42″ forms parallel strips 35 of reactive foam formulation 4 on bottom facing layer 2. As shown in
The spacing of nozzles 40 is advantageously selected together with flow rates through nozzle outlets 42′ and 42″ and the line speed (i.e., the linear speed at which bottom facing layer 2 moves past nozzle outlets 42′ and 42″) such that the individual strips of reactive foam formulation 4 combine to form a continuous layer 4A of reactive foam formulation 4 on the top surface of bottom facing layer 2.
The apparatus shown in
Adjustable flow restriction means 18 in some embodiments takes the form of an adjustment screw which penetrates into distribution system 11 at (in the embodiment shown) or upstream of first branch point 17A of the conduit system, where (in the embodiment shown) conduits 20 and 20A meet conduit 19.
Other types of adjustable flow restriction means include, for example, a pin arrangement, in which the pin can be inserted at various depths into distribution system 11 to restrict the flow of the fluid mixture and thus adjust mixhead backpressure; a butterfly, iris, knife or other type of valve may incorporated into mixhead 12 downstream of mixing zone 14, and/or into distribution system 11; apparatus for squeezing conduit 19 (or some portion thereof) or other portion of distribution system 11 at or upstream of the first branch point, to diminish the internal flow path and increase back pressure. A portion of distribution system 11, at or upstream of the first branch point, may be constructed of a material that changes shape in response to an external input, such as a magnetorestrictive material, an electroactive material, a pH sensitive material. Adjustable flow restriction means 18 can be operated manually or through a suitable automated system.
In a particular embodiment of a laminated panel manufacturing process, reactive foam formulation is dispensed onto a moving bottom facing layer by introducing components comprising at least one polyisocyanate, at least one physical blowing agent, at least one polyol and at least one catalyst through the multiple inlets 13 of mixhead 12, into mixing zone 14 of mixhead 12. There the components are combined to form reactive foam formulation 4. Reactive foam formulation 4 is then transferred through distribution system 11 and nozzles 40 and out of nozzle outlets 42′ and 42″ onto moving bottom facing layer 2 to form a layer 4A of reactive foam formulation 4 on bottom facing layer 2. Layer 4A of reactive foam formulation 4 is then cured to form a polymer foam layer on top of and bonded to bottom facing layer 2. When top facing layer 3 is applied the top surface of layer 4A of reactive foam formulation 4 as described above with regard to
The various components of the reactive foam formulation can be introduced into mixhead 12 individually or as various subcombinations. Typically, the polyisocyanate is introduced into mixhead 12 through one inlet 13, and the polyol is introduced into mixhead 12 through at least one other inlet 13. The remaining components can be introduced into mixhead 12 separately through additional inlets 13, and/or can be introduced together with the polyol. In some embodiments, the physical blowing agent is combined with the polyol upstream of mixhead 12 and introduced into mixhead 12 together with the polyol. The catalyst (and/or other optional ingredients such as a surfactant) can be introduced into mixhead 12 in a similar manner if desired. It is also possible to introduce the catalyst and/or optional ingredients (if any) by combining them with the polyisocyanate upstream of mixhead 12 and introducing them together with the polyisocyanate.
A nucleating gas such as air, nitrogen, hydrogen or argon may be introduced into mixhead 12, separately through its own inlet 13 and/or as a mixture with one or more of the other components, notably the polyol.
In a particular laminated panel manufacturing process, the physical blowing agent and nucleating gas (if used) are continuously mixed with the polyol upstream of mixhead 12 and the resulting polyol/physical blowing agent/nucleating gas mixture is introduced into mixhead 12 together through a single inlet 13. The polyisocyanate is introduced into mixhead 12 through another inlet 13. In such embodiments the catalyst and optional ingredients (if any) can be introduced individually and/or pre-combined with each other, the polyol/physical blowing agent/nucleating gas mixture, and/or the polyisocyanate.
Layer 4A of reactive foam formulation 4 is cured on the bottom facing layer to form a laminated panel comprising the bottom facing layer and a polymer foam layer bonded to the bottom facing layer. In cases in which a sandwich structure is produced, the polymer foam layer also becomes bonded to the top facing layer.
Curing conditions are selected such that the blowing agent volatilizes and the reactive components of the reactive foam formulation react to produce a polymer foam. The conditions typically include a temperature above the boiling temperature of the physical blowing agent at the pressures employed. The polyisocyanate and polyol(s) typically will react spontaneously when mixed, even at room temperature, and the exothermic heat of reaction is often sufficient to produce the temperature needed to volatilize the physical blowing agent. Therefore, it is often necessary only to produce the reactive foam formulation and form it into a layer on the bottom facing sheet at or about room temperature, such as 10 to 35° C., and allow the reaction to complete without further applied heat. However, if desired, the components of the reactive foam formulation can be heated at the time of or prior to combining them and/or at the time of or after forming the reactive foam formulation into a layer on the bottom facing sheet. The elevated temperature may be, for example, 35 to 100° C. Metal facings are also typically heated between 20° C. and 80° C. in order to increase the adhesion of the foam to the metal facings. The process of forming the laminated panel may be performed on a heated conveyor, such as a double band laminator in which one or both of the bands are heated, to provide a suitable curing temperature.
The process of the invention may and preferably does include various additional steps (and associated apparatus) as are needed to produce a laminated panel product. The facing layers, particularly metal ones, may be pre-treated to promote good adhesion to the polymer foam or otherwise to facilitate panel manufacture. Examples of pre-treatment steps include deoiling, corona discharge treatment, profiling, heating to the process temperature, and application of a layer of an adhesion promoter.
Similarly, the process may and preferably does include one or more downstream steps, such as cutting the laminated panel to a desired length, cooling the laminated panel from the curing temperature, stacking the laminated panels, and wrapping the laminated panels or otherwise preparing them for shipment or storage.
Suitable organic polyisocyanates for use in a laminated panel manufacturing process of the invention include aliphatic, cycloaliphatic, araliphatic or aromatic polyisocyanates, or combinations of any two or more thereof. Such may include, for example, alkylene diisocyanates, particularly those having from 4 to 12 carbon atoms in the alkylene moiety, such as 1,12-dodecane diisocyanate, 2-ethyltetramethylene 1,4-diisocyanate, 2-methyl-pentamethylene 1,5-diisocyanate, 2-ethyl-2-butylpentamethylene 1,5-diisocyanate, tetramethylene 1,4-diisocyanate and preferably hexamethylene 1,6-diisocyanate; cycloaliphatic diisocyanates such as cyclohexane 1,3- and 1,4-diisocyanate and any mixture of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanato-methylcyclohexane (isophorone diisocyanate), 2,4- and 2,6-hexahydrotoluene diisocyanate and the corresponding isomer mixtures, 4,4′-, 2,2′- and 2,4′-dicyclohexylmethane diisocyanate and the corresponding isomer mixtures, araliphatic diisocyanates such as 1,4-xylylene diisocyanate and xylylene diisocyanate isomer mixtures, and preferably aromatic diisocyanates and polyisocyanates, such as 2,4- and 2,6-toluene diisocyanate and the corresponding isomer mixtures, 4,4′-, 2,4′- and 2,2′-diphenylmethane diisocyanate and the corresponding isomer mixtures, mixtures of 4,4′- and 2,4′-diphenylmethane diisocyanates, polyphenyl-polymethylene polyisocyanates, mixtures of 4,4′-, 2,4′- and 2,2′-diphenylmethane diisocyanates and polyphenylpolymethylene polyisocyanates (crude MDI), and mixtures of crude MDI and toluene diisocyanates. Modified polyisocyanates, i.e., products which are obtained by chemical reaction of organic diisocyanates and/or polyisocyanates, may also be used. Specific examples are ester-, urea-, biuret-, allophanate-, uretoneimine-, carbodiimide-, isocyanurate-, uretdione- and/or urethane-containing diisocyanates and/or polyisocyanates, that contain from 33.6 to 15 percent by weight, preferably from 31 to 21 percent by weight, of isocyanate groups, based on the total weight of the modified polyisocyanate. The organic polyisocyanates may be employed individually or in the form of combinations thereof.
The reactive foam formulation typically includes at least one polyol, i.e., a compound having two or more hydroxyl groups. A wide range of polyols can be used, depending in part on the desired properties of the polymer foam. Useful polyols therefore include polyether polyols, polyester polyols, hydroxyl-terminated polybutadiene rubbers, polyacrylate polyols and polycarbonate polyols, as well as other types. Useful polyols have hydroxyl equivalent weights of about 30 to 3000; however for laminate panel production it is preferred to use at least one polyol having a hydroxyl equivalent weight of 30 to 1000, especially 125 to 560. The polyols may have hydroxyl functionalities of 2 to 8 or more hydroxyl groups per molecule.
Useful polyether polyols include ethoxylates and/or propoxylates of one or more hydroxyl- and/or amine group containing starters that have an equivalent weight of 30 to 59, including, for example, one or more of ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propane diol, 1,3-propanediol, dipropylene glycol, tripropylene glycol, glycerin, trimethylolpropane, trimethylolethane, neopentyl glycol, 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,2,6-hexanetriol, monoethanolamine, diethanolamine, triethanolamine, pentaerythritol, erythritol, sorbitol, sucrose, mannitol, N,N,N′,N′-tetrakis(2-hydroxypropyl)-ethylenediamine, diethyl toluenediamine, dimethylthiotoluenediamine and combinations thereof.
Useful polyester polyols may be reaction products of, for example, an organic dicarboxylic acid (or corresponding acid anhydridesor ester) having about 2 to about 12 carbon atoms with a polyhydric alcohol, preferably a diol and/or triol having 2 to 12 carbon atoms, preferably from 2 to 6 carbon atoms. Examples of suitable dicarboxylic acids are succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, maleic acid, fumaric acid, and preferably orthophthalic acid, isophthalic acid, terephthalic acid and the isomeric naphthalene-dicarboxylic acids. The dicarboxylic acids may be used either individually or mixed with one another. Examples of dihydric and polyhydric alcohols used to make the polyester polyol are ethanediol, diethylene glycol, 1,2- and 1,3-propanediol, dipropylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, glycerol, trimethylolpropane. Also useful are modified aromatic polyester polyols such as described in U.S. Pat. No. 6,359,022, which contain one or more pendant aliphatic hydrocarbyl groups that have 6 or more carbon atoms in a straight or branched chain.
Furthermore, polyester-polyols made from lactones such as C-caprolactone or hydroxycarboxylic acids such w-hydroxycaproic acid and hydrobenzoic acid may also be employed. Hybrid polyether-polyester polyols such as are described, for example, in WO 2011/137011 are also useful.
Other useful polyols include compounds having 2 to 8 hydroxyl groups, equivalent weights of up to 125 and molecular weights up to 200, such as ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propane diol, 1,3-propanediol, dipropylene glycol, tripropylene glycol, glycerin, trimethylolpropane, trimethylolethane, neopentyl glycol, 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,2,6-hexanetriol, mannitol, sucrose and sorbitol.
The physical blowing agent is a one or more compounds that have boiling temperatures (at 1 atmosphere pressure) of 10° C. to 80° C., preferably 10° C. to 50° C., and which lack hydroxyl, primary and/or secondary amine, thiol, carboxyl or other groups other than halogen groups that are reactive toward isocyanate groups under the conditions of the curing reaction. Useful physical blowing agents include hydrocarbons, hydrofluorocarbons, hydrochlorocarbons, hydrofluorochlorocarbons, ethers and the like that have the aforementioned boiling temperatures. C4-C6 hydrocarbons such as any isomer (or mixture of isomers) of butane, pentane and hexane are particularly useful. Also useful are hydrofluoroolefins and hydrofluorochloro olefins such as described, for example, in US 2007/0100010. Specific examples thereof are trifluoropropene, 1,3,3,3-tetrafluoropropene (1234ze), 1,1,3,3-tetrafluoropropene, 2,2,3,3-tetrafluoropropene (1234yf), 1,2,3,3,3-pentafluoropropene (1225ye), 1,1,1-trifluoropropene, 1,1,1,3,3-pentafluoropropene (1225zc), 1,1,2,3,3-pentafluoropropene (1225yc), (Z)-1,1,1,2,3-pentafluoropropene (1225yez), 1-chloro-3,3,3-trifluoropropene (1233zd) and 1,1,1,4,4,4-hexafluorobut-2-ene (1336mzzm). Mixture of any two or more physical blowing agents can be used.
The invention is particularly applicable to cases in which the physical blowing agent is present in an amount of at least 12 parts by weight per 100 parts by weight of the polyol(s). The amount of physical blowing agent may be, for example, at least 12, at least 14 or at least 15 parts by weight on that basis and may be, for example, up to 25 parts, up to 22 parts, up to 20 parts or up to 18 parts, again on the same basis. Similarly, the invention is also applicable when the blowing agent has limited miscibility in the polyol(s) at the relative proportions thereof that are present in the reactive foam formulation. Immiscibility can be evaluated by forming a mixture of the polyol(s) and physical blowing agent in the relevant proportions and observing whether phase separation takes place upon standing at room temperature (23±2° C.).
The catalyst is a material that catalyzes the curing of the reactive foam formulation. Preferred catalysts include urethane catalysts, i.e., a catalyst for the reaction of an alcohol group and/or water with an isocyanate group, isocyanate trimerization catalysts, and carbodiimide catalysts. Among suitable urethane catalysts are tin (II) and tin (IV) catalysts, catalysts that contain other Group III to Group XV metals; tertiary amine compounds, amidines, tertiary phosphines, and the like. Useful isocyanate trimerization catalysts include strong bases such as alkali metal phenolates, alkali metal alkoxides, alkali metal carboxylates, quaternary ammonium salts, and the like. Useful carbodiimide catalysts include phospholene oxides such as 3-methyl-1-phenyl-2-phospholene oxide (MPPO), 3-methyl-1-ethyl-2-phospholene oxide (MEPO), 3,4-dimethyl-1-phenyl-3-phospholene oxide, 3,4-dimethyl-1-ethyl 3-phospholene oxide, 1-phenyl-2-phospholen-1-oxide, 3-methyl-1-2-phospholen-1-oxide, 1-ethyl-2-phospholen-1-oxide, 3-methyl-1-phenyl-2-phospholen-1-oxide, and 3-phospholene isomers thereof.
The reactive foam formulation may further contain various optional ingredients. A foam-stabilizing surfactant is a useful optional ingredient. Suitable such surfactants include, but are not limited to, silicones such as silicone oils and organosilicone-polyether copolymers, including polydimethyl siloxane and polydimethylsiloxane-polyoxyalkylene block copolymers. Other suitable surfactants include organic surfactants such as nonylphenol ethoxylates and ethylene oxide/butylene oxide block co-polymers.
Another optional ingredient is a flame retardant, such as a phosphorus-containing flame retardant, a halogenated flame retardant and melamine.
Water is another optional ingredient that, when present, reacts to produce carbon dioxide and provide auxiliary blowing.
In addition to the foregoing components, the formulated polyol composition or reaction mixture may contain one or more fillers and/or reinforcing agents such as fiber glass, carbon fibers, flaked glass, mica, talc, melamine and calcium carbonate; one or more pigments and/or colorants such as titanium dioxide, iron oxide, chromium oxide, azo/diazo dyes, phthalocyanines, dioxazines and carbon black; one or more biocides; one or more preservatives; one or more antioxidants; one or more flame retardants; and the like.
The top and bottom facing of a laminated panel made in accordance with the invention can be, for example, a metal (which may have an applied coating), kraft or other paper, a fiber-reinforced paper, a metal foil-paper composite layer, a plastic sheet or film, or the like. In cases in which the facings are flexible (as is the case with paper, plastic sheets and films and metal foils, for example, the laminated panel is sometimes referred to as “insulating board”. The term “laminated panel” is used herein to encompass panels made with rigid facings (such as metal sheets) as well as those made with flexible facings, which are often referred to in the art as “insulating board”. Each facing layer preferably has a thickness of at most 5 mm, preferably up to 2.5 mm or up to 1 mm.
Foam layer of a laminated panel made in accordance with the invention may have a foam density of, for example, 20 to 120 kg/m3 or 30 to 80 kg/m3 as measured according to ASTM 1622-88. The cells may be at least about 70 percent closed, at least about 80 percent closed or at least about 85 percent closed.
Laminated panels made in accordance with the invention can be used in the same manner and for the same purposes as laminate panels made using conventional processes. The panels can be used as thermal insulation for buildings, vehicles, pavement and other constructions. The panels are useful as lightweight decorative panels for building facades, interior wall partitions, and other uses.
The following example is provided to illustrate the invention but is not intended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated.
An apparatus as generally described in
Mixhead 12 has two inlets 13. A polyisocyanate is continuously pumped into one of the inlets. A formulated polyol containing a polyol, urethane catalyst and silicone foam-stabilizing surfactant is fed continuously into the other inlet 13 after being combined in-line with 16 parts of n-pentane per 100 parts of formulated polyol and 1 L (at standard conditions) per minute of nucleation air. The two streams entering mixhead 12 through inlets 13 are combined in mixing zone 14 of mixhead and the resulting fluid mixture is discharged out of mixhead 12 through mixhead outlet 15 and into distribution system 11. The continuous flowrate out of mixhead outlet 15 is set at either 16 or 24 kg/minute. The fluid mixture then travels through the distribution system and nozzles 40 and is discharged through nozzle opening 42′ and 42″ onto a moving metal facing layer having a width of 1000 mm.
For Example 1, each outlet 10 is fitted with a nozzle 40 as generally shown in
For Comparative Sample A, each outlet 10 of distribution system 11 is fitted with a V-shaped flat nozzle having a slit opening 2 mm wide and 19 mm long. At the 24 kg/minute flow rate, jets exiting the flat nozzles do not widen before contacting the facing layer. As a result, strips only about 19 mm wide are produced; these can combine somewhat slowly to form a reactive foam layer. At the 16 kg/mm flow rate, the jets assume a circular cross-section before making contact with the facing layer, thereby producing strips only about 6 mm wide, which only incompletely combine before hardening. A highly non-uniform foam layer is produced.
For Comparative Sample B, each outlet 10 is fitted with a Venturi nozzle. The nozzle has an inlet with a circular cross-section (diameter 6 mm), which reduces over a length of 5 mm to a cross-sectional diameter of 3 mm before widening to form a slit opening 15 mm long and 1.5 mm wide. Results are very similar to those obtained using the V-shaped flat nozzle. At the higher flow rate, the strips produced using the Venturi nozzle are only about as wide as the nozzle opening is long, and at the lower flow rate the jets assume a circular cross-section before contacting the facing layer, producing narrow strips that only incompletely combine.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102021000031814 | Dec 2021 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/052619 | 12/13/2022 | WO |
