The present invention provides a process for producing a rigid polyisocyanurate foam involving reacting at an isocyanate index of from about 175 to about 400, a polyisocyanate with at least one natural-oil polyol containing at least about 35 wt. %, based on the weight of the polyol, of natural oil, having a hydroxyl number from about 175 to about 375 and a hydroxyl functionality of about 2.0 to about 2.8, in the presence of a blowing agent and optionally, in the presence of one or more of surfactants, flame retardants, pigments, catalysts and fillers, wherein the resulting foam has a renewable biobased content of at least 8% by weight. The foams provided by the inventive process possess properties similar to foams produced from petroleum-derived materials and may find use in wall or roof insulation systems. The high biobased content (>8%) may allow wall or roof insulation systems containing these foams to be considered for the U.S. Government's preferred procurement program.

The present technology provides a method of manufacturing a rigid polyurethane foam having a low thermal conductivity from a foam composition comprising a polyol, an isocyanate, a polyurethane catalyst, a surfactant, water, a modified phenolic resin, optionally a physical blowing agent, and optionally a fire retardant.

The flame-retardant urethane resin composition contains a polyisocyanate compound, a polyol compound, a trimerization catalyst, a blowing agent, and an additive, wherein the additives include red phosphorus and a filler, and the filler has an aspect ratio of 5 to 50, an average particle diameter of 0.1 μm or larger, but smaller than 15 μm, and a melting point of 750° C. or higher.

The instant invention provides an isocyanate trimerisation catalyst system, a precursor formulation, a process for trimerising isocyanates, rigid foams made therefrom, and a process for making such foams. The trimerisation catalyst system comprises: (a) a phosphatrane cation; and (b) an isocyanate-trimer inducing anion; wherein said trimerisation catalyst system has a trimerisation activation temperature in the range of equal to or less than 73° C. The precursor formulation comprises (1) at least 25 percent by weight of polyol, based on the weight of the precursor formulation; (2) less than 15 percent by weight of a trimerisation catalyst system, based on the weight of the precursor formulation, comprising; (a) a phosphatrane cation; and (c) an isocyanate-trimer inducing anion; wherein said trimerisation catalyst system has a trimerisation activation temperature in the range of equal to or less than 73° C.; and (4) optionally one or more surfactants, one or more flame retardants, water, one or more antioxidants, one or more auxiliary blowing agents, one or more urethane catalysts, one or more auxiliary trimerisation catalysts, or combinations thereof. The process for trimerisation of isocyanates comprises the steps of: (1) providing one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof; (2) providing a trimerisation catalyst system comprising; (a) an phosphatrane cation; and (b) an isocyanate-trimer inducing anion; (c) wherein said trimerisation catalyst system has a trimerisation activation temperature in the range of equal to or less than 73° C.; (3) trimerising said one or more monomers in the presence of said trimerisation catalyst; (4) thereby forming an isocyanurate ring. The process for making the PIR foam comprises the steps of: (1) providing one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof; (2) providing polyol; (3) providing a trimerisation catalyst system comprising; (a) a phosphatrane cation; and (b) an isocyanate-trimer inducing anion; wherein said trimerisation catalyst system has a trimerisation activation temperature in the range of equal to or less than 73° C.; and (4) optionally providing one or more surfactants, one or more flame retardants, water, one or more antioxidants, one or more auxiliary blowing agents, one or more urethane catalysts, one or more auxiliary trimerisation catalysts, or combinations thereof; (5) contacting said one or more monomers, and said polyol, and op

According to one embodiment, a halogen free roof system is described. The roof system includes a structural deck that is positioned above joists or other support members. Polyisocyanurate foam insulation is positioned atop the structural deck. The polyisocyanurate foam insulation has an isocyanate index greater than 200 and includes a polyisocyanurate core having a halogen free fire retardant. A water proof membrane is positioned atop the polyisocyanurate foam insulation. The polyisocyanurate core is able to form a sufficiently stable char when exposed to flame conditions such that the polyisocyanurate core is able to pass the ASTM E-84 test.

The invention relates to a method for producing a polyisocyanurate composite material, comprising the following steps: a) providing a polyisocyanate composition A) which contains monomer polyisocyanates at an amount of at least 2 wt. %, and b) catalytically trimerising the polyisocyanate composition A) in the presence of at least one fibrous filler material B) and a trimerisation catalyst C), to form the polyisocyanurate composite material, said trimerisation catalyst C) comprising at least one quaternary ammonium salt and/or a metal salt. The invention also relates to polyisocyanurate composite materials that can be obtained according to the claimed method, and to the use of same to produce a component and components consisting of or containing a claimed polyisocyanurate composite material.

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.

The present invention relates to a process for preparing polyurethanes by mixing a) polyisocyanate, b) a mixture obtainable by introducing an alkali metal or alkaline earth metal salt into a compound comprising urethane groups, c) compounds comprising one or more epoxide groups, and, optionally, d) polyol, e) chain extenders, and f) fillers and further additives to form a reaction mixture and fully reacting the mixture to give the polyurethane, where the amount of alkali metal or alkaline earth metal ions per equivalent urethane groups in the compound (b) is 0.0001 to 3.5. The present invention further relates to a polyurethane obtainable by such a process, and to the use of such a polyurethane for producing bodywork components for vehicles.

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).