Novel Natural-Oil Based Rigid Foams For Demanding Applications: A Class I Polyisocyanurate Foam For Insulated Metal Building Panels

摘要

Recent federal legislation has placed increased emphasis on reducing energy consumption and using renewable, natural resources to replace petroleum-based products. Using less energy and more renewable resources can provide obvious benefits to the environment and help mitigate climate change, as well as help decrease our dependence on oil. According to the U.S. Department of Energy, commercial and residential buildings are the largest consumers of energy in the United States, and much of this energy is used for heating and cooling. To induce builders to reduce energy consumption in commercial buildings, the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) has recently increased by 33 percent the prescriptive minimum thermal insulation requirement for walls and roofs. To encourage the use of renewable resources, the U.S. Department of Agriculture (USDA) has identified insulating foams used for wall construction which have renewable content above a certain threshold to receive preferential treatment in the Federal Procurement Program. Polyisocyanurate (PIR) foams are among the most efficient commercial insulation materials available and for that reason have found widespread use in the construction industry. However, PIR foams are mostly derived from petroleum-based feed stocks. Natural-oil polyols (NOPs) are becoming more readily available, but due to their chemical structures, often produce foams that do not perform as well as foams made with conventional polyols in some demanding applications. Recent advances at Bayer MaterialScience have resulted in a new generation of NOPs that can be tailored for improved processing and properties in PIR foams. This paper will describe the development of an ASTM E84 Class I rigid PIR foam based on a novel, low-viscosity NOP for use in insulated metal building panels. Some performance characteristics, as well as some advantages and disadvantages of using Bayer’s NOPs, will be discussed.