Claims
- 1. A method of producing a rigid thermosetting foam, the method comprising the steps of:
- (1) preparing a first of two foam forming blends using a multi-isocyanate functional compound chosen from the group consisting of polymeric polymethylene polypheylisocyanate, and a prepolymer made therefrom;
- (2) preparing a second of two foam forming blends by mixing together:
- (a) a polyol;
- (b) a first blowing agent which is not carbon dioxide derived from water;
- (c) an alkali metal organo-salt catalyst of a minimum concentration of about 63% in an aqueous solution free of aliphatic glycols;
- (d) optionally an additional amount of water for producing carbon dioxide as a second blowing agent;
- (3) mixing together the first and second foaming blends to cause a polymerization reaction producing the rigid foam such that the total amount of water utilized is less than 1% by weight of the total foam.
- 2. The method of claim 1, wherein the total amount of water utilized is less than 0.88% by weight of the multi-isocyanate functional compound.
- 3. The method of claim 1, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of an alkali metal hydroxide, carboxylic acid, and water.
- 4. The method of claim 3, wherein the alkali metal hydroxide is potassium hydroxide, and the carboxylic acid is acetic acid.
- 5. The method of claim 3, wherein the alkali metal hydroxide is potassium hydroxide, and the carboxylic acid is 2-ethyl-hexoic acid.
- 6. The method of claim 3, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of at least one alkali metal hydroxide, at least two carboxylic acids, and water, wherein the alkali metal hydroxide is potassium hydroxide, and the carboxylic acids are a mixture of 2-ethyl-hexoic acid and acetic acid.
- 7. The method of claim 3, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of at least one alkali metal hydroxide, at least two carboxylic acids, and water, wherein the alkali metal hydroxide is sodium hydroxide, and the carboxylic acids are a mixture of 2-ethyl-hexoic acid and acetic acid.
- 8. The method of claim 3, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of at least two alkali metal hydroxides, at least one carboxylic acid, and water, wherein the alkali metal hydroxides are potassium hydroxide and sodium hydroxide, and the carboxylic acid is acetic acid.
- 9. The method of claim 3, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of at least two alkali metal hydroxides, at least one carboxylic acid, and water, wherein the alkali metal hydroxides are potassium hydroxide and sodium hydroxide, and the carboxylic acid is 2-ethyl-hexoic acid.
- 10. The method of claim 3, wherein the alkali metal organo-salt catalyst is a pre-blended and reacted mixture of at least two alkali metal hydroxides, at least two carboxylic acids, and water, wherein the alkali metal hydroxides are potassium hydroxide and sodium hydroxide, and the carboxylic acids are a mixture of acetic acid and 2-ethyl-hexoic acid.
- 11. The method of claim 3, wherein the alkali metal hydroxide is sodium hydroxide, and the carboxylic acid is succinic acid.
- 12. The method of claim 1, wherein the alkali metal organo-salt catalyst is a pre-blended mixture of an alkali metal-organo salt and water.
- 13. The method of claim 12, wherein the alkali metal salt is potassium acetate.
- 14. The method of claim 12, wherein the alkali metal salt is sodium succinate.
- 15. The method of claim 12, wherein the alkali metal salt is sodium acetate.
- 16. The method of claim 3, wherein the catalyst contains more carboxylic acid chemical equivalents than it does alkali metal hydroxide chemical equivalents dissolved in water.
- 17. The method of claim 16, wherein a liquid mixture of at least one carboxylic acid with at least one alkali metal hydroxide dissolved in water is stabilized by the addition of a surfactant.
- 18. The polyisocyanurate modified polyurethane foam of claim 16.
- 19. The polyisocyanurate modified polyurethane foam of claim 17.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 07/720,735 filed Jun. 25, 1991, now U.S. Pat. No. 5,252,625; and U.S. patent application Ser. No. 07/851,889 filed Mar. 16, 1992, now U.S. Pat. No. 5,254,600; U.S. patent application Ser. No. 08/018,304, filed Feb. 16, 1993, now U.S. Pat. No. 5,294,677, and U.S. patent application Ser. No. 08/040,032, filed Mar. 30, 1993, which is now abandoned; all of which are incorporated herein by reference.
US Referenced Citations (18)
Non-Patent Literature Citations (1)
Entry |
N. Malwitz, P. A. Manis, S. W. Wong and K. C. Frisch, "Amine Catalysis of Polyurethane Foams" Annual Polyurethane Conference-Oct. 15-17-1986-pp. 338-353. |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
720735 |
Jun 1991 |
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