The present disclosure provides for an isocyanate-reactive composition that can react with an isocyanate compound in a reaction mixture to form a polyurethane-based foam. The isocyanate-reactive composition includes an isocyanate reactive compound and a combustion modifier composition. The isocyanate reactive compound has an isocyanate reactive moiety and an aromatic moiety. The combustion modifier composition includes both phosphorus from a halogen-free flame-retardant compound and a transition metal from a transition metal compound. The combustion modifier composition can have a molar ratio of the transition metal to phosphorus (mole transition metal:mole phosphorous) of 0.05:1 to 5:1.

C

A flame-retardant rigid polyurethane foam contains a flame retardant, the foam having a ratio of the maximum peak intensity ratio (P1) of the foam after moist heat treatment of the foam for one week at a temperature of 80° C. and a humidity of 85% to the maximum peak intensity ratio (P2) of the foam before this moist heat treatment of 85% or more (P1/P2x100). The P1 and P2 each refer to the ratio of the maximum peak intensity of 1390 to 1430 cm.sup.−1 to the maximum peak intensity of 1500 to 1520 cm.sup.−1 when the infrared absorption spectrum is measured at a position 5 to 10 mm from the surface of the foam, and the average intensity of 1900 to 2000 cm.sup.−1 is adjusted to zero.

The present invention relates to a process for producing a rigid polyurethane-polyisocyanurate foam C, comprising the step of reacting (i) an isocyanate-terminated prepolymer B with (ii) an activator component A comprising at least one trimerization catalyst A1 and at least one blowing agent A3 in a reaction mixture to form a foam, characterized in that—there is used an isocyanate-terminated prepolymer B obtained from a reaction of an isocyanate B1 having a mean isocyanate functionality of from ≧2.3 to ≦2.9 with a polyol component B2, and—the activator component A comprises water as the blowing agent A3 in an amount of from ≧5 wt. % to ≦50 wt. %,—the isocyanate index in the reaction mixture is in a range of from ≧400 to ≧500, and—the isocyanate content of the prepolymer B is in a range of from ≧21 wt. % to ≦30 wt. %, based on the total mass of the prepolymer B, and—wherein in the reaction of the prepolymer B and the activator component A a conversion contribution to polyisocyanurate of ≦75% is achieved. Rigid foams C so produced have good flame retarding properties while at the same time having good insulating properties and stability properties. The present invention relates further to a rigid polyisocyanurate foam C produced by the process according to the invention, to the use of such a rigid polyisocyanurate foam C in the production of heat-insulating structural components, and to a heat-insulating structural component comprising such a rigid polyurethane-polyisocyanurate foam.

The present invention provides trimerization catalyst compositions having an α,β-unsaturated carboxylate salt and methods to produce a polyisocyanurate/polyurethane foam using such trimerization catalyst compositions.

Polyisocyanurate or polyurethane-isocyanurate polymers are made by curing an aromatic polyisocyanate or a mixture of at least one aromatic polyisocyanate and at least one polyol having a hydroxyl equivalent weight of up to 200 in which the isocyanate index is at least 2.00, in the presence of at least one isocyanate trimerization catalyst, to form a polyisocyanurate or polyurethane-isocyanurate polymer having a glass transition temperature of at least 100° C., and then exposing the polyisocyanurate or polyurethane-isocyanurate polymer formed step a) to water under superatmospheric pressure at a temperature of at least 70° C.

According to one embodiment, a polyisocyanurate foam board is described. The foam board includes a polyisocyanurate core that is produced from: an isocyanate, a polyol, and a phosphorous containing non-halogenated fire retardant. The foam board also includes a facer material that is applied to at least one surface of the polyisocyanurate core. The polyisocyanurate core has an isocyanate index greater than about 200 and is able to forms a sufficiently stable char when exposed to flame conditions to enable the polyisocyanurate core to pass the ASTM E-84 test. The foam board has an initial R-value of at least 6.40 and exhibits an ASTM E1354-11b test performance that is equivalent with or better than a similar foam board having a halogenated fire retardant, such as tris(2-chloroisopropyl)phosphate (TCPP).

A spray foam formulation used to form a spray foam insulation layer in a wall structure is described. The formulation may include the reaction product of a polyisocyanate compound and a polyol compound; a fire retardant chosen from at least one of a non-halogenated fire retardant; and a reactive halogen-containing fire retardant, and a carbohydrate. The spray foam insulation layer has an insulative R value of 3.0 to 7.2 per inch, and a density of between about 0.3 to about 4.5 pcf. Further, spray foam insulation made from the spray foam formulation may have fire retardant characteristics that are equivalent to or better than a similar spray insulation foam insulation using non-reactive halogenated fire retardants such as tris(1-chloro-2-propyl)phosphate (TCPP).

Polyurethane/polyisocyanurate foam insulation described herein is derived from a composition that contains an organic polyisocyanate, an isocyanate reactive material containing at least about 20% by weight, based on the total weight of the composition, of an aromatic polyester polyol, a hydrocarbon blowing agent, a first catalyst selected from the group consisting of a carboxylate salt of an alkali metal, a carboxylate salt of an alkaline earth metal, a carboxylate salt of a quaternary ammonium, and combinations thereof, and a second catalyst comprising a non-reactive tertiary amine, wherein a molar ratio of the first catalyst to the second catalyst is less than about 1.25, the composition gels quickly, and the composition has an isocyanate index greater than about 175. Such an insulating foam has a ratio of thermal conductivity at 75° F. to thermal conductivity at 25° F. between about 0.98 and about 1.10.

The present invention provides a polyisocyanate composition wherein the composition is obtained from an aliphatic diisocyanate unit including 1,6-diisocyanatohexane, and has an isocyanurate group, a uretdione group, a uretonimine group, and an iminooxadiazinedione group, and the molar ratio of the uretonimine group to the isocyanurate group is 0.0010 to 0.0050, and the molar ratio of the iminooxadiazinedione group to the isocyanurate group is 0.00050 to 0.30.

The present invention provides a polyisocyanate composition wherein the composition is obtained from an aliphatic diisocyanate unit including 1,6-diisocyanatohexane, and has an isocyanurate group, a uretdione group, a uretonimine group, and an iminooxadiazinedione group, and the molar ratio of the uretonimine group to the isocyanurate group is 0.0010 to 0.0050, and the molar ratio of the iminooxadiazinedione group to the isocyanurate group is 0.00050 to 0.30.