Insulation boards and methods for their manufacture

• US 7,612,120 B2
• Filed: 08/13/2003
• Issued: 11/03/2009
• Est. Priority Date: 08/13/2002
• Status: Active Grant

• Current Assignee: Holcim Technology, Ltd. (Holcim Limited)
• Original Assignee: BFS Diversified Products LLC (Bridgestone Corporation)
• Inventors: Letts, John B.
• Primary Examiner(s): Zemel; Irina S
• Application Number:
  US10/640,895
• Publication Number:
  US 20040087674A1
• Time in Patent Office: 2,274 Days
• Field of Search: 521 50-189, 521/902
• US Class Current: 521/131
• CPC Class Codes: C08G 18/42 Polycondensates having carboxylic or carbonic ester groups in the main chain
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: C08G 2115/02 to isocyanurate groups
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/141 Hydrocarbons
• CPC Class Codes: Y10S 521/902 Cellular polymer containing an isocyanurate structure

Abstract

A method for producing polyisocyanurate insulation foams, the method comprising contacting an A-side stream of reactants that includes an isocyanate with a B-side stream of reactants that include a polyol and a blowing agent, where the blowing agent includes isopentane and n-pentane in a substantial absence of cyclopentane.

Claims

1. A method for producing isocyanurate insulation foams, the method comprising:

(i) forming a B-side stream of reactants including a polyol and a blowing agent blend, where the blowing agent blend includes isopentane and n-pentane at a weight ratio of isopentane to n-pentane of about 1;

1 to about 2.7;

1 in the substantial absence of cyclopentane, where said step of forming includes introducing the polyol and the blowing agent within a pin mixer under a pressure in excess of about 80 psi and a temperature in excess of about 10°

C.;

(ii) increasing the temperature of the B-side stream of reactants to a temperature of about 16°

C. to about 29°

C. and a pressure of about 1800 psi to about 2400 psi;

(iii) after said step of increasing, delivering the B-side stream of reactants to a mix head, where the temperature of the B-side stream of reactants is increased to about 27°

C. to about 35°

C.;

(iv) introducing an A-side stream of reactants to the mix head at a temperature of about 29°

C. to about 35°

C. and a pressure of about 1800 to about 2400 psi to thereby mix with the B-side stream and form a mixture of polyisocyanurate ingredients;

(v) depositing the mixture of polyisocyanurate ingredients onto a laminator and allowing the mixture of polyisocyanurate ingredients to form a developing foam.

2. The method of claim 1, where the laminator includes a facer material onto which the developing foam is deposited.

3. The method of claim 2, further comprising the step of providing a second facer material to the upper surface of the foam.

4. The method of claim 3, further comprising the step of cutting the foam to a desired length.