New Mannich Polyol for Next Generation Spray Technology

摘要

Mannich polyols provide a number of positive attributes for spray systems - autocatalytic activity, physical property performance, and sprayablility. In the US, the anticipated blowing agent transition for spray foam will be from HCFC-141b to HFC-245fa, as this blowing agent option offers fewer conversion issues versus hydrocarbons or low boiling blowing agents (LBBAs). However, due to its high cost, formulators are expected to minimize the use of HFC-245fa and incorporate high levels of water. This has a negative effect on processing, as spray contractors prefer systems that can be processed at a 1:1 volume ratio, and a polyol blend viscosity of 1000 cps is generally required to insure acceptable processibility. To meet these formulating and processing demands, the need for a Mannich polyol with a lower hydroxyl value and lower viscosity was recognized. This paper describes the development and performance of a new Mannich polyol to meet these challenges. Polyol solubility and vapor pressure data were generated using HFC-245fa, hydrocarbons, and LBBAs. Fully formulated systems using the new Mannich were designed and assessed for processibility, foam physical properties, adhesion, and other performance parameters. Field trials were executed and the system performance and evaluation is disclosed. This work has led to the development and subsequent commercialization of JEFFOL~R R-315X polyol, designed to assist the spray foam industry in developing cost-effective, next generation spray technology solutions.