Composition of and nozzle for spraying a single-component polyurethane foam

Abstract

A composition for a single-component polyurethane foam and a method of using the same. The composition comprises a polyether or polyester or a combination thereof with functionality 2 and a hydroxyl number between about 22 mgKOH/g and about 374 mgKOH/g, a polyether or polyester or a combination thereof with functionality 3 and a hydroxyl number between about 84 mgKOH/g and about 842 mgKOH/g, a fire-retarding agent, a silicone stabilizer, a catalyst, polymeric diphenylmethane diisocyanate, a dimethyl ether, propane, isobutane or a combination thereof, and 1,1-difluoroethane or any other Freon, or any combination thereof.

Claims

1. A composition of a single-component polyurethane foam, comprising: a) a polyether or polyester or a combination thereof each with a functionality of 2; b) a polyether or polyester or a combination thereof each with a functionality of 3 c) a fire-retarding agent; d) a silicone stabilizer; e) a catalyst; f) polymeric diphenylmethane diisocyanate; g) dimethyl ether; h) propane, isobutane or a combination thereof; and i) 1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other other refrigerant, or any combination thereof; wherein, when the composition is sprayed from an aerosol container comprising a nozzle onto a spray surface, the composition has a cone-shaped spray pattern with a width of at least 100 mm, measured from a distance of at least 100 mm from the tip of the nozzle to the spray surface.

2. The composition of claim 1, wherein: a) the polyether or polyester or a combination thereof each with a functionality of 2 is from about 5.0 wt. % of the composition to about 18.0 wt. % of the composition; b) the polyether or polyester or combination thereof each with a functionality of 3 is from about 3.0 wt. % of the composition to about 10.00 wt. % of the composition; c) the fire-retarding agent is from about 5.0 wt. % of the composition to about 14.0 wt. % of the composition; d) the silicone stabilizer is from about 2.5 wt. % of the composition to about 14.0 wt. % of the composition; e) the catalyst is from about 0.5 wt. % of the composition to about 3.0 wt. % of the composition; f) the polymeric diphenylmethane diisocyanate is from about 37.0 wt. % of the composition to about 49.0 wt. % of the composition; g) the dimethyl ether is from about 2.00 wt. % of the composition to about 9.10 wt. % of the composition; h) the propane, isobutane or a combination thereof is from about 10.0 wt. % of the composition to about 22.0 wt. % of the composition; and i) 1,1-difluoroethane or trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof is from greater than 0.00 wt. % of the composition to about 16.00 wt. % of the composition.

3. The composition of claim 1, wherein the fire retarding agent is tri-chloroethyl phosphate, tris-chloropropyl-phosphate, tris-dichloropropyl-phosphate or a combination thereof.

4. The composition of claim 1, wherein the silicone stabilizer is a polydimethyl siloxane polyoxyalkylene copolymer surfactant.

5. The composition of claim 1, wherein the catalyst is 2,2-dimorpholinodiethylether.

6. A composition of a single-component polyurethane foam, comprising: a) a polyether or polyester or a combination thereof each with a functionality of 2; b) a fire-retarding agent; c) a silicone stabilizer; d) a catalyst; e) polymeric diphenylmethane diisocyanate; f) dimethyl ether; g) propane, isobutane or a combination thereof; and h) 1,1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof; wherein, when the composition is sprayed from an aerosol container comprising a nozzle onto a spray surface, the composition has a cone-shaped spray pattern with a width of at least 100 mm, measured from a distance of at least 100 mm from the tip of the nozzle to the spray surface.

7. The composition of claim 6, wherein: a) the polyether or polyester or or a combination thereof each with a functionality of 2 is from about 5.0 wt. % of the composition to about 28.0 wt. % of the composition; b) the fire-retarding agent is from about 5.0 wt. % of the composition to about 14.0 wt. % of the composition; c) the silicone stabilizer is from about 2.5 wt. % of the composition to about 14.0 wt. % of the composition; d) the catalyst is from about 0.5 wt. % of the composition to about 3.0 wt. % of the composition; e) the polymeric diphenylmethane diisocyanate is from about 37.0 wt. % of the composition to about 49.0 wt. % of the composition; f) the dimethyl ether is from about 2.00 wt. % of the composition to about 9.10 wt. % of the composition; g) the propane, isobutane or a combination thereof is from about 10.0 wt. % of the composition to about 22.0 wt. % of the composition; and h) 1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof is from greater than 0.00 wt. % of the composition to about 16.00 wt. % of the composition.

8. The composition of claim 6, wherein the fire retarding agent is tri-chloroethyl phosphate, tris-chloropropyl-phosphate, tris-dichloropropyl-phosphate or a combination thereof.

9. The composition of claim 6, wherein the silicone stabilizer is a polydimethyl siloxane polyoxyalkylene copolymer surfactant.

10. The composition of claim 6, wherein the catalyst is 2,2-dimorpholinodiethylether.

11. A composition of a single-component polyurethane foam, comprising: a) a polyether or polyester or a combination thereof each with a functionality of 3; b) a fire-retarding agent; c) a silicone stabilizer; d) a catalyst; e) polymeric diphenylmethane diisocyanate; f) dimethyl ether; g) propane, isobutane or a combination thereof; and h) 1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof; wherein, when the composition is sprayed from an aerosol container comprising a nozzle onto a spray surface, the composition has a cone-shaped spray pattern with a width of at least 100 mm, measured from a distance of at least 100 mm from the tip of the nozzle to the spray surface.

12. The composition of claim 11, wherein: a) the polyether or polyester or a combination thereof each with a functionality of 3 is from about 3.0 wt. % of the composition to about 28.00 wt. % of the composition; b) the fire-retarding agent is from about 5.0 wt. % of the composition to about 14.0 wt. % of the composition; c) the silicone stabilizer is from about 2.5 wt. % of the composition to about 14.0 wt. % of the composition; d) the catalyst is from about 0.5 wt % of the composition to about 3.0 wt. % of the composition; e) the polymeric diphenylmethane diisocyanate is from about 37.0 wt. % of the composition to about 49.0 wt. % of the composition; f) the dimethyl ether is from about 2.00 wt. % of the composition to about 9.10 wt. % of the composition; g) the propane, isobutane or a combination thereof is from about 10.0 wt. % of the composition to about 22.0 wt. % of the composition; and h) 1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof is from greater than 0.00 wt. % of the composition to about 16.00 wt. % of the composition.

13. The composition of claim 11, wherein the fire retarding agent is tri-chloroethyl phosphate, tris-chloropropyl-phosphate, tris-dichloropropyl-phosphate or a combination thereof.

14. The composition of claim 11, wherein the silicone stabilizer is a polydimethyl siloxane polyoxyalkylene copolymer surfactant.

15. The composition of claim 11, wherein the catalyst is 2,2-dimorpholinodiethylether.

16. A composition of a single-component polyurethane foam, comprising: a) a mixture of a polyether or polyester or a combination thereof each with a functionality of 2 and a polyether or polyester or a combination thereof each with a functionality of 3, wherein the average functionality of the mixture is between 2.1 and 2.9; b) a fire-retarding agent; c) a silicone stabilizer; d) a catalyst; e) polymeric diphenylmethane diisocyanate; f) dimethyl ether; g) propane, isobutane or a combination thereof; and h) 1,1-difluoroethane, trans-1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof; wherein, when the composition is sprayed from an aerosol container comprising a nozzle onto a spray surface, the composition has a cone-shaped spray pattern with a width of at least 100 mm, measured from a distance of at least 100 mm from the tip of the nozzle to the spray surface.

17. The composition of claim 16, wherein: a) the mixture is from about 3.0 wt. % of the composition to about 28.0 wt. % of the composition; b) the fire-retarding agent is from about 5.0 wt. % of the composition to about 14.0 wt. % of the composition; c) the silicone stabilizer is from about 2.5 wt. % of the composition to about 14.0 wt. % of the composition; d) the catalyst is from about 0.5 wt. % of the composition to about 3.0 wt. % of the composition; e) the polymeric diphenylmethane diisocyanate is from about 37.0 wt. % of the composition to about 49.0 wt. % of the composition; f) the dimethyl ether is from about 2.00 wt. % of the composition to about 9.10 wt. % of the composition; g) the propane, isobutane or combination thereof is from about 10.0 wt. % of the composition to about 22.0 wt. % of the composition; and h) 1,1-difluoroethane, trans 1,3,3,3-tetrafluoroprop-1-ene, any other refrigerant, or any combination thereof is from greater than 0.00 wt. % of the composition to about 16.00 wt. % of the composition.

18. The composition of claim 16, wherein the fire retarding agent is tri-chloroethyl phosphate, tris-chloropropyl-phosphate, tris-dichloropropyl-phosphate or a combination thereof.

19. The composition of claim 16, wherein the silicone stabilizer is a polydimethyl siloxane polyoxyalkylene copolymer surfactant.

20. The composition of claim 16, wherein the catalyst is 2,2-dimorpholinodiethylether.

21. A method of using the composition of claim 1, the method comprising the steps of: a) placing the composition of claim 1 within a pre-pressurized container or any other container; and b) dispensing the composition from the container in a wide cone shaped spray.

22. A method of using the composition of claim 6, the method comprising the steps of: a) placing the composition of claim 6 within a pre-pressurized container or any other container; and b) dispensing the composition from the container in a wide cone shaped spray.

23. A method of using the composition of claim 11, the method comprising the steps of: a) placing the composition of claim 11 within a pre-pressurized container or any other container; and b) dispensing the composition from the container in a wide cone shaped spray.

24. A method of using the composition of claim 16, the method comprising the steps of: a) placing the composition of claim 16 within a pre-pressurized container or any other container; and b) dispensing the composition from the container in a wide cone shaped spray.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 shows a flow diagram of an exemplary method of production of the composition of the present invention.

(2) FIG. 2 shows a cross-sectional side view of the nozzle for spraying the composition of the present invention.

(3) FIG. 3 shows a perspective view of the nozzle for spraying the composition of the present invention.

(4) FIG. 4 shows a side view of the nozzle for spraying the composition and the spray pattern of the present invention.

(5) FIG. 5 shows a top view of the nozzle for spraying the composition of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(6) The detailed description set forth below in connection with the appended drawing is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

(7) Unless otherwise stated, the following terms as used herein have the following definitions.

(8) Hydroxyl number of a polyol refers to the concentration of hydroxyl groups, per unit weight of the polyol, that are able to react with isocyanate groups. Hydroxyl number is reported as mg KOH/g, and is measured according to the standard ASTM D 1638.

(9) The average functionality, or average hydroxyl functionality of a polyol indicates the number of OH groups per molecule, on average. The average functionality of an isocyanate refers to the number of NCO groups per molecule, on average.

(10) The meaning of the term isocyanate prepolymer includes but is not limited to comprising a mixed polyisocyanate and a polyol in a liquid state.

(11) The meaning of the term polyisocyanate includes but is not limited to di or higher isocyanates. The meaning of the term polyol includes, but is not limited to, mixtures of polyol and any polyol that can react in a known fashion with an isocyanate in preparing polyurethane foam. A polyol typically contains more than one hydroxyl group, wherein molecules that contain two hydroxyl groups are diols and those that contain three hydroxyl groups are triols, etc.

(12) The meaning of the term container refers to either a pressurized container such as a pressurized spray can or pressured spray canister, or like device, or any other container in which polyurethane foam can be put.

(13) The term single-component is defined to contrast the prior art two-component polyurethane foam, which hardens by a chemical reaction of a resin and hardener, more specifically a reaction between methylene diphenyl diisocyanate (MDI) and glycols that takes place directly during the spraying process. The single-component aspect of the polyurethane foam, although it comprises multiple components/ingredients, refers to the main reaction of polymerization of polyisocyanate and polyol forming an isocyanate prepolymer inside a container, which then hardens through reacting with ambient moisture in the atmosphere.

(14) A single-component polyurethane foam may comprise an isocyanate prepolymer filled into a pressurized spray canister or spray can together with at least one blowing agent or hydrocarbon propellant. A user then, for example, may bring the isocyanate prepolymer out of the pressurized spray canister, while the components of the isocyanate prepolymer cure by cross-linking during reaction with ambient moisture.

(15) The invention accordingly relates to a single-component polyurethane foam comprising at least one polyether or polyester or a combination thereof, with an average functionality =2, and therefore a linear polymer formed by polymerizing (i.e., a thermoplastic), a hydroxyl value between about 22 mgKOH/g to about 374 mg KOH/g and/or a molar mass of between about 300 g/mol and about 5000 g/mol, water within the polyester, if present, with volume less than 0.80 wt. %, a pH value of the polyester between about 4-8.5, an acid value below or equal to 0.2 mg KOH/g, and a propellant or blowing agent, preferably hydrocarbon-based and of an alkaline type having the formula C.sub.nH.sub.(2n+2) (n being equal to or between 2 and 5).

(16) Optionally, the single-component polyurethane foam further comprise at least one polyether or polyester or a combination thereof, with an average functionality =3, with a hydroxyl number between about 84 mgKOH/g and about 842 mgKOH/g and/or a molar mass between about 200 g/mol and about 2000 g/mol, either in combination with or as a replacement for the polyether or polyester having a functionality =2. Optionally, the hydroxyl value of the polyether or polyester with an average functionality =3 can be between about 340 mg KOH/g to about 842 mg KOH/g.

(17) If the polyether or polyester having a functionality =2 used in combination with the polyether or polyester having a functionality =3, the average functionality of the combination is between 2.1 and 2.9.

(18) Optionally, the foam can further comprise:

(19) a fire-retarding agent such as tris(2-chloroethyl) phosphate (TCEP), tris(chloropropyl) phosphate, or tris(dichloropropyl) phosphate, or any combination thereof;

(20) a silicone stabilizer such as polydimethylsiloxane-polyoxyalkylene, which is a copolymer surfactant;

(21) a catalyst such as 2,2-dimorpholinodiethylether;

(22) polymeric diphenylmethane diisocyanate (MDI);

(23) a dimethylether;

(24) propane, isobutane, or any combination thereof; and

(25) 1,1-difluoroethane or any other Freon, or any combination thereof.

(26) The functionality of a monomer molecule is the number of functional groups that participate in the polymerization. Monomers with functionality greater than two will introduce branching into a polymer, and the degree of polymerization will depend on the average functionality fav per monomer unit.

(27) The polyether or polyester with a functionality =2 can comprise from about 5.0 wt. % to about 18.0 wt. % of the foam or from about 5.0 wt. % to about 28.0 wt. % of the foam.

(28) The polyether or polyester with a functionality =3 can comprise from about 3.0 wt. % to about 10.0 wt. % of the foam or from about 3.0 wt. % to about 28.0 wt. % of the foam.

(29) If the polyether or polyester having a functionality =2 is used in combination with the polyether or polyester having a functionality =3, the combination is from about 3.0 wt. % to about 28.0 wt. % of the foam.

(30) The fire retarding agent can comprise from about 5.0 wt. % to about 14.0 wt. % of the foam.

(31) The silicone stabilizer can comprise from about 4.0 wt. % to about 14.0 wt. % of the foam or from about 2.5 wt. % to about 14.0 wt. %.

(32) The catalyst can comprise from about 0.5 wt. % to about 3.0 wt. % of the foam.

(33) The polymeric diphenylmethane diisocyanate (MDI) can comprise from about 37.0 wt. % to about 49.0 wt. % of the foam.

(34) The dimethylether can comprise from about 2.0 wt. % to about 9.10 wt. % of the foam.

(35) The propane, isobutene, or combination thereof, can comprise from about 10.0 wt. % to about 22.0 wt. % of the foam.

(36) The 1,1-difluoroethane or any other Freon, or any combination thereof can comprise from about 0.0 wt. % to about 16.0 wt. % of the foam.

EXAMPLES

(37) In preferred first embodiment, the one-component polyurethane pre-polymer composition comprises:

(38) TABLE-US-00001 Components Parts by Weight a polyether or polyester, or combination 5.0-18.0 wt. % thereof, with a functionality of two a polyether or polyester, or combination 3.0-10.0 wt. % thereof, with a functionality of three a fire-retarding agent 5.0-1.4.0 wt. % a silicone stabilizer 2.5-14.0 wt. % a catalyst for foams or their mix 0.5-3.0 wt. % polymeric diphenylmethane diisocyanate 37.0-49.0 wt. % a dimethyl ether 2.0-9.10 wt. % a propane or a isobutane, or combination 10.0-22.0 wt. % thereof 1,1-difluoroethane or any other Freon, or any 0.0-16.0 wt. % combination thereof

(39) In a second embodiment, the one-component polyurethane pre-polymer composition comprises:

(40) TABLE-US-00002 Components Parts by Weight a mixture of: a polyether or polyester, or 3.0-28.0 wt. .% combination thereof, with a functionality of two and a polyether or polyester, or combination thereof, with a functionality of three a fire-retarding agent 5.0-14.0 wt. % a silicone stabilizer 2.5-14.0 wt. % a catalyst for foams or their mix 0.5-3.0 wt. % polymeric diphenylmethane diisocyanate 37.0-49.0 wt. % a dimethyl ether 2.0-9.10 wt. % a propane or a isobutane, or combination 10.0-22.0 wt. % thereof 1,1-difluoroethane or any other Freon, or any 0.0-16.0 wt. % combination thereof

(41) In a third embodiment, the one-component polyurethane pre-polymer composition comprises:

(42) TABLE-US-00003 Components Parts by Weight a polyether or polyester, or combination 5.0-28.0 wt. % thereof, with a functionality of two a fire-retarding agent 5.0-14.0 wt. % a silicone stabilizer 2.5-14.0 wt. % a catalyst for foams or their mix 0.5-3.0 wt. % polymeric diphenylmethane diisocyanate 37.0-49.0 wt. % a dimethyl ether 2.0-9.10 wt. % a propane or a isobutane, or combination 10.0-22.0 wt. % thereof 1,1-difluoroethane or any other Freon, or any 0.0-16.0 wt. % combination thereof

(43) In a fourth embodiment, the one-component polyurethane pre-polymer composition comprises:

(44) TABLE-US-00004 Components Parts by Weight a polyether or polyester, or combination 3.0-28.0 wt. % thereof, with a functionality of three a fire-retarding agent 5.0-14.0 wt. % a silicone stabilizer 2.5-14.0 wt. % a catalyst for foams or their mix 0.5-3.0 wt. % polymeric diphenylmethane diisocyanate 37.0-49.0 wt. % a dimethyl ether 2.0-9.10 wt. % a propane or a isobutene, or combination 10.0-22.0 wt. % thereof 1,1-difluoroethane or any other Freon, or any 0.0-16.0 wt. % combination thereof

(45) Herein, the weight percentages combining to total 100%, with water volume within the polymer, if present, to be less than 0.1%.

(46) The single-component polyurethane foam may be prepared by mixing the following components into a mixed collective component in a reactor (S1):

(47) a, from about 5.0 wt. % to about 18.0 wt. % polyether or polyester or a combination thereof with functionality 2 and a hydroxyl number between about 22 mgKOH/g and about 374 mgKOH/g (and/or a molar mass between about 300 g/mol and about 5000 g/mol),

(48) a, from about 3.0 wt. % to about 10.00 wt. %, polyether or polyester or a combination thereof with functionality 3 and a hydroxyl number between about 84 mgKOH/g and about 842 mgKOH/g (and/or a molar mass between about 200 g/mol and about 2000 g/mol),

(49) a, from about 5.0 wt. % to about 14.0 wt. % fire-retarding agent,

(50) a, from about 2.5 wt. % to about 14.0 wt. % silicone stabilizer, and

(51) a, from about 0.5 wt. % to about 3.0 wt. % catalyst.

(52) Optionally, instead of using both the polyether or polyester or a combination thereof with functionality 2 and the polyether or polyester or a combination thereof with functionality 3, either the polyether or polyester or a combination thereof with functionality 2 can used alone, or the polyether or polyester or a combination thereof with functionality 3 can be used alone. If the polyether or polyester or a combination thereof with functionality 2 is used alone, then it comprises from about 5.0 wt. % to about 28.0 wt. %. If the polyether or polyester or a combination thereof with functionality 3 is used alone, then it comprises from about 3.0 wt. % to about 28.0 wt. %.

(53) Additionally, it is possible to combine the polyether/polyester with functionality 2 with the polyether/polyester with functionality 3, producing a mixture of the two having an average functionality between 2.1 and 2.9. In this instance, the mixture would have a wt. % from about 3.0 wt. % to about 28.0 wt. %.

(54) Afterwards, one of the four different mixed collective components outlined above is introduced into the container (S2) and polymeric MDI and all other gaseous components are introduced separately into the container (S3).

(55) Experimental results show that the composition of the present invention is an improvement over the prior art because it allows to form a cone-shaped stream, while retaining all of the product's qualities (adhesiveness, structural uniformity, eco-friendliness, etc.) Hence, the present invention is the first one-component polyurethane foam, which has functionality of two-component polyurethane foams in that it is able form a wide cone-shaped stream.

(56) Further, the chemical composition, comprising polyurethane pre-polymer dissolved in liquid hydrocarbons, or other volatile polar solvents, would be in a suspended condition wherein the polymer would be exposed with the gases, namely the hydrocarbon propellant matching the formula C.sub.nH.sub.(2n+2) (n being equal to or between 2 and 5), or any combination of such hydrocarbons. The volume of the gases must be considerably larger than pre-polymer in the system, and must compound to more than 20 wt. %. Further, in the preferred embodiment, the hydrocarbon is a halogenoalkane gas, which not only participates in foaming and formation of a spongy polymer, but also plays a role in spreading the polymer homogeneously over a surface from the distance.

(57) Further, the composition is suitable for use for general insulation purposes, particularly well-suited to be sprayed from a pressurized container, such as a spray can, or any other container. With a suitable nozzle, the foam composition of the present invention can be sprayed over a surface with a capacity of 1 m.sup.2/minute, at a flow rate of the spray of approximately 6 grams per second to approximately 10 grams per second, and gaining a thickness of the coated layer up to 30-50 mm, at typical spray can operating pressures of about 3.5 to 12 atm.

(58) The round slot-shaped orifice allows the polymer to be sprayed over a surface in one very smooth layer; and so that after the final foaming, which takes place not earlier than 15 minutes after spraying, the layer will be smooth and uniform. Other geometrical configurations of the orifice can cause irregularities to the sprayed layer on a surface, which may lead to excessive consumption of product from the spraying system. Further, the viscosity of the product may be varied as necessary to allow the product to be sprayed from spray equipment operating with greater or smaller orifice openings and/or at higher or lower internal pressures.

(59) With reference to FIGS. 2-5, a nozzle 100 of the present invention includes a pressure chamber 102 having a proximate end 104 and distal end 106 with a generally circular bore 108 therebetween. Immediately adjacent the pressure chamber 102 is a nozzle head 103. In fluid communication with the distal end 106 of the generally circular bore 108 of the pressure chamber 102 is a discharge tube 110, having a diameter 121 and a proximate end 112, which is exposed to the generally circular bore 108 of the pressure chamber 102. The discharge tube 110, having a central axis 101, terminates at a distal end 114, which terminates at a round slot-shaped discharge orifice 116.

(60) In the exemplary embodiment, formed into the nozzle head 103 are inwardly angled v-shaped walls 118 (see FIG. 3), forming a 60 degree angle that has a bisecting angle 105. The inwardly angled v-shaped walls 118 intersect with and cut through a portion of the round slot-shaped discharge orifice 116, such that the bisecting angle 105 is 45 degrees from the central axis 101 of the discharge tube 110. Accordingly, the length 122 of the round slot-shaped orifice 116 corresponds to the diameter 121 of the discharge tube 110.

(61) As shown in FIG. 4, the shape of the round slot-shaped discharge orifice 116 allows foamable product to be dispensed from the pressurized source of sprayable foam material in a cone-shaped pattern 120. The length 122 of the round slot-shaped discharge orifice 116 tends to control the effective length 124 of the cone-shaped spray pattern 120. The width 126 of the round slot-shaped discharge orifice 116 tends to control the width 128 of the spray pattern 120. The width of the cone-shaped spray pattern depends on the temperature of the balloon, which must be between 10-50 C., as well as on the distance from the nozzle to the surface being sprayed, and can vary from 100 mm to 400 mm. The distance from the nozzle tip to the sprayed surface should be within 100 mm to 800 mm.

(62) Experimentation has shown that the nozzle 100 having a round slot-shaped orifice 116 helps the foam achieve a uniform structure. Experimentation has further shown that the length 122 of the round slot-shaped orifice 116 should ideally be approximately 1.1 mm to approximately 3.5 mm, or ideally at 2 mm.

(63) Experimental results have shown that the polyurethane foam composition of the present invention when loaded in a spray can with an operating pressure of 3.5 to 12 atm and equipped with the nozzle 100 of the present invention provides structural uniformity in the sprayed foam, as well as high adhesiveness, such that the sprayed foam could not be easily removed from a surface. Further, experimental results also show that, when the nozzle 100 of the present invention is used with other one-component polyurethane compositions, the following results are obtained:

(64) When other one-component polyurethane compositions' foams are cut in half, they have ununiformed structuresthere were big and small holes.

(65) Half of the other one-component polyurethane compositions' foams were spraying tiny streams (unlike the foam of the present invention that comes out in a wide cone), and the other half of the one-component polyurethane compositions' foams hardly came out at all. The wide, cone-shaped spray of the present invention is advantageous because it provides better surface area coverage than other spray-foams that dispense in tiny streams. This is something that was difficult to achieve with a one-component foam. Greater coverage when being sprayed means quicker application to large surface areas, allowing the present invention to effectively perform its insulation function.

(66) Additionally, all other one-component polyurethane compositions' foams had low adhesiveness, such that we could easily remove the sprayed foams from a surface (unlike the foam of the present invention that could not be removed from the surface without equipment).

(67) The maximum thickness of the coating layer of all other one-component polyurethane compositions' foams was approximately 1 cm (while thickness of the coating layer of the foam of the present invention reached up to approximately 5 cm).