Insulation moulding and method for its manufacture
First Claim
1. A method for manufacturing an insulation moulding comprisingfilling a cavity between an inner and an outer wall of an open-box-shaped mould with a polyurethane reaction mixture andallowing the polyurethane reaction mixture to cure to a polyurethane comprising polymer C,wherein the inner and outer wall being arranged a fixed distance from one another and each wall comprising a bottom face and a plurality of side faces, wherein the fixed distance between the inner and outer wall can be the same or different for each face,wherein the polyurethane reaction mixture is fed through an inlet opening positioned in a middle area of the bottom face of the outer wall,wherein before filling the cavity, the mould is turned with the bottom face of the outer wall downwards so that the polyurethane reaction mixture is foaming upwards to fill the cavity,wherein the polyurethane reaction mixture comprises an isocyanate component B, which is reacted with an emulsion comprising(I) an isocyanate-reactive composition A, comprising a polyol mixture A1 comprising at least three polyols A1a, A1b and A1c as a continuous phase and(II) at least one physical blowing agent T as a disperse phase, wherein:
- (i) Ala is a polyether polyol having a hydroxyl value from 15 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 6.0, obtained by addition of an epoxy to at least one starter compound selected from the group consisting of carbohydrates, difunctional alcohols, and higher-functional alcohols;
(ii) A1b is a polyether polyol having a hydroxyl value from 100 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 5.0, obtained by addition of an epoxy to an aromatic amine;
(iii) A1c is a polyester polyether polyol having a hydroxyl value from 100 mg KOH/g to 450 mg KOH/g and an OH functionality from 1.5 to 3.5, obtained by addition of an epoxy to an esterification product of an aromatic dicarboxylic acid derivative and a difunctional and/or higher-functional alcohol.
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Accused Products
Abstract
A cavity between inner and outer walls of an open-box-shaped mold is filled with a polyurethane reaction mixture, containing an isocyanate and an emulsion of an isocyanate-reactive composition with three polyols and a blowing agent, which is cured to a polyurethane containing polymer. The inner and outer wall are a fixed distance from one another and each wall comprises a bottom and sides. The mixture is fed through an inlet in the bottom of the outer wall. Before filling the cavity, the mold is turned downwards so that the mixture foams upwards, filling the cavity. The three polyols are polyether polyol obtained by adding an epoxy to carbohydrates or difunctional or higher-functional alcohols; polyether polyol obtained by adding an epoxy to an aromatic amine; and polyester polyether polyol obtained by adding an epoxy to the esterification product of an aromatic dicarboxylic acid derivative and a difunctional or higher-functional alcohol.
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Citations
22 Claims
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1. A method for manufacturing an insulation moulding comprising
filling a cavity between an inner and an outer wall of an open-box-shaped mould with a polyurethane reaction mixture and allowing the polyurethane reaction mixture to cure to a polyurethane comprising polymer C, wherein the inner and outer wall being arranged a fixed distance from one another and each wall comprising a bottom face and a plurality of side faces, wherein the fixed distance between the inner and outer wall can be the same or different for each face, wherein the polyurethane reaction mixture is fed through an inlet opening positioned in a middle area of the bottom face of the outer wall, wherein before filling the cavity, the mould is turned with the bottom face of the outer wall downwards so that the polyurethane reaction mixture is foaming upwards to fill the cavity, wherein the polyurethane reaction mixture comprises an isocyanate component B, which is reacted with an emulsion comprising (I) an isocyanate-reactive composition A, comprising a polyol mixture A1 comprising at least three polyols A1a, A1b and A1c as a continuous phase and (II) at least one physical blowing agent T as a disperse phase, wherein: -
(i) Ala is a polyether polyol having a hydroxyl value from 15 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 6.0, obtained by addition of an epoxy to at least one starter compound selected from the group consisting of carbohydrates, difunctional alcohols, and higher-functional alcohols; (ii) A1b is a polyether polyol having a hydroxyl value from 100 mg KOH/g to 550 mg KOH/g and an OH functionality from 1.5 to 5.0, obtained by addition of an epoxy to an aromatic amine; (iii) A1c is a polyester polyether polyol having a hydroxyl value from 100 mg KOH/g to 450 mg KOH/g and an OH functionality from 1.5 to 3.5, obtained by addition of an epoxy to an esterification product of an aromatic dicarboxylic acid derivative and a difunctional and/or higher-functional alcohol. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification