US5034424A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Rigid foam and process for producing the same
Assignee: BSH Hausgeräte GmbH
•
Filing: 1990-06-28
•
Granted: 1991-07-23
•
Expires: 2010-06-28
Abstract
Abstract A rigid foam, especially a largely closed-cell polyurethane or polyisocyanurate rigid foam, includes a cell structure being formed by the expansion of rigid foam raw materials with carbon dioxide as an inflating agent. The cell structure is substantially homogeneous and has a cell content of substantially CO2 inflating agent and proportions of a physical inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials. A process for producing a rigid foam having a cell structure formed by the expansion of rigid foam raw materials with carbon dioxide includes forming a fine-celled rigid foam material by preparing an inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials. The inflating agent is homogeneously emulsified in at least one of the rigid foam raw materials prior to the beginning of a chemical reaction, in the form of the disperse phase of an emulsion having a liquid droplet size being at most equal to 10 mu m in diameter and a proportion by weight of less than 3.5% of the rigid foam material. The rigid foam raw materials include components for producing an essential required amount of inflating agent in the form of carbon dioxide. The rigid foam raw materials in particular are polyols and isocyanates. Activators and/or stabilizers are optionally additionally used to form the cell structure. The cell structure preferably has a cell size of less than 100 mu m in diameter.
Inventors
- 👤 Udo Wenning
- 👤 Jan Brodsky
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 20:32
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/12; C08J9/14; C08J9/143; C08J9/147; C08J9/148; C08J2375/00; C08J2375/04
Claims Analysis
Total Claims: 72
Claim 1
Independent Claim
62 words
Rigid foam, comprising a cell structure being formed by the expansion of rigid foam raw materials with carbon dioxide as an inflating agent, said cell structure being substantially homogeneous and having a cell content of substantially CO 2 inflating agent and proportions of a physical inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 2
Dependent Claim
62 words
Rigid foam, comprising a cell structure being formed by the expansion of rigid foam raw materials with carbon dioxide as an inflating agent, said cell structure being substantially homogeneous and having a cell content of substantially CO 2 inflating agent and proportions of a physical inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 3
Dependent Claim
22 words
Rigid foam according to claim 1, wherein the rigid foam raw materials are selected from the group consisting of polyols and isocyanates.
Claim 4
Dependent Claim
22 words
Rigid foam according to claim 1, wherein at least one of activators and stabilizers are additionally used to form said cell structure.
Claim 5
Dependent Claim
21 words
Rigid foam according to claim 1, wherein said cell structure has a cell size of less than 100 μm in diameter.
Claim 6
Dependent Claim
23 words
Rigid foam according to claim 1, wherein said cell structure has a cell size of between 50 μm and 80 μm in diameter.
Claim 7
Dependent Claim
38 words
Rigid foam according to claim 1, wherein the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, is less than 3.5% of the rigid foam.
Claim 8
Dependent Claim
38 words
Rigid foam according to claim 1, wherein the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, is less than 2% of the rigid foam.
Claim 9
Dependent Claim
37 words
Rigid foam according to claim 1, wherein the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, is approximately 1% of the rigid foam.
Claim 10
Dependent Claim
37 words
Rigid foam according to claim 1, wherein said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials is selected from the group consisting of perfluorinated and substantially perfluorinated ethers.
Claim 11
Dependent Claim
37 words
Rigid foam according to claim 1, wherein said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials is selected from the group consisting of perfluorinated and substantially perfluorinated hydrocarbons.
Claim 12
Dependent Claim
42 words
Rigid foam according to claim 1, wherein said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials has a normal boiling point range within a temperature range of substantially between 20° and 80° C.
Claim 13
Dependent Claim
42 words
Rigid foam according to claims 1, wherein said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials is selected from the group consisting of perfluorinated and substantially perfluorinated pentane (C 5 F 12 ).
Claim 14
Dependent Claim
42 words
Rigid foam according to claims 1, wherein said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials is selected from the group consisting of perfluorinated and substantially perfluorinated hexane (C 6 F 14 ).
Claim 15
Dependent Claim
53 words
Rigid foam according to claim 1, including at least one inflating agent being soluble in the rigid foam raw materials and having a proportion by weight at most equal to the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 16
Dependent Claim
22 words
Rigid foam according to claim 14, wherein said inflating agent being soluble in the rigid foam raw material is an aliphatic hydrocarbon.
Claim 17
Dependent Claim
34 words
Rigid foam according to claim 15, wherein said inflating agent being soluble in the rigid foam raw material is at least one of the materials selected from the group consisting of n-pentane and n-hexane.
Claim 18
Dependent Claim
22 words
Rigid foam according to claim 14, wherein said inflating agent being soluble in the rigid foam raw material is a cyclic hydrocarbon.
Claim 19
Dependent Claim
34 words
Rigid foam according to claim 17, wherein said inflating agent being soluble in the rigid foam raw material is at least one of the materials selected from the group consisting of cyclopentane and cyclohexane.
Claim 20
Dependent Claim
31 words
Rigid foam according to claim 1, including emulsifiers having a nucleating effect on said inflating agents being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 21
Dependent Claim
10 words
Rigid foam according to claim 19, including an inorganic emulsifier.
Claim 22
Dependent Claim
9 words
Rigid foam according to claim 20, including silica gel.
Claim 23
Dependent Claim
10 words
Rigid foam according to claim 19, including an organic emulsifier.
Claim 24
Dependent Claim
10 words
Rigid foam according to claim 22, including starch (amylum soluble).
Claim 25
Dependent Claim
38 words
Rigid foam according to claim 19, wherein the proportion of emulsifier is approximately 2% of the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 26
Dependent Claim
38 words
Rigid foam according to claim 20, wherein the proportion of emulsifier is approximately 2% of the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 27
Dependent Claim
38 words
Rigid foam according to claim 22, wherein the proportion of emulsifier is approximately 2% of the proportion by weight of said inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 28
Dependent Claim
67 words
Largely closed-cell polyurethane or polyisocyanurate rigid foam, comprising a cell structure being formed by the expansion of rigid foam raw materials with carbon dioxide as an inflating agent, said cell structure being substantially homogeneous and having a cell content of substantially CO 2 inflating agent and proportions of a physical inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 29
Dependent Claim
67 words
Largely closed-cell polyurethane or polyisocyanurate rigid foam, comprising a cell structure being formed by the expansion of rigid foam raw materials with carbon dioxide as an inflating agent, said cell structure being substantially homogeneous and having a cell content of substantially CO 2 inflating agent and proportions of a physical inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 30
Dependent Claim
22 words
Rigid foam according to claim 27, wherein the rigid foam raw materials are selected from the group consisting of polyols and isocyanates.
Claim 31
Dependent Claim
22 words
Rigid foam according to claim 27, wherein at least one of activators and stabilizers are additionally used to form said cell structure.
Claim 32
Dependent Claim
21 words
Rigid foam according to claim 27, wherein said cell structure has a cell size of less than 100 μm in diameter.
Claim 33
Dependent Claim
133 words
Process for producing a rigid foam having a cell structure formed by the expansion of rigid foam raw materials with carbon dioxide, which comprises forming a fine-celled rigid foam material by preparing an inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, homogeneously emulsifying the inflating agent in at least one of the rigid foam raw materials prior to the beginning of a chemical reaction, in the form of the disperse phase of an emulsion having a liquid droplet size at most equal to 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material, and selecting rigid foam raw materials including components for producing an essential required amount of inflating agent in the form of carbon dioxide.
Claim 34
Dependent Claim
133 words
Process for producing a rigid foam having a cell structure formed by the expansion of rigid foam raw materials with carbon dioxide, which comprises forming a fine-celled rigid foam material by preparing an inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, homogeneously emulsifying the inflating agent in at least one of the rigid foam raw materials prior to the beginning of a chemical reaction, in the form of the disperse phase of an emulsion having a liquid droplet size at most equal to 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material, and selecting rigid foam raw materials including components for producing an essential required amount of inflating agent in the form of carbon dioxide.
Claim 35
Dependent Claim
28 words
Process according to claim 31, which comprises forming the cell structure by expansion of the rigid foam raw materials selected from the group consisting of polyols and isocyanates.
Claim 36
Dependent Claim
21 words
Process according to claim 31, which comprises additionally using at least one of activators and stabilizers to form the cell structure.
Claim 37
Dependent Claim
40 words
Process according to claim 31, which comprises providing the disperse phase of the emulsion with a liquid droplet size of less than 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material.
Claim 38
Dependent Claim
38 words
Process according to claim 31, which comprises providing the disperse phase of the emulsion with a liquid droplet size of approximately 10 μm in diameter and a proportion by weight of approximately 2% of the rigid foam material.
Claim 39
Dependent Claim
38 words
Process according to claim 31, which comprises providing the disperse phase of the emulsion with a liquid droplet size of approximately 4 μm in diameter and a proportion by weight of approximately 1% of the rigid foam material.
Claim 40
Dependent Claim
26 words
Process according to claim 32, which comprises enriching the polyol raw material with a required quantity of water for forming carbon dioxide during the expansion process.
Claim 41
Dependent Claim
22 words
Process according to claim 37, which comprises adjusting a proportion by weight of a water content to from 2-6% of the polyol.
Claim 42
Dependent Claim
52 words
Process according to claim 31, which comprises incorporating the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials as a disperse phase of an emulsion utilizing high shear forces, in the rigid foam material in which the inflating agent is at least substantially insoluble.
Claim 43
Dependent Claim
65 words
Process according to claim 31, which comprises incorporating and dissolving an inflating agent being soluble in the rigid foam raw materials into the rigid foam raw materials, and adjusting proportions by weight of the soluble inflating agent to be at most equal to proportions by weight of the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 44
Dependent Claim
56 words
Process according to claim 40, which comprises carrying out the step of incorporating the inflating agent being soluble in the rigid foam raw material prior to incorporating the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials into the rigid foam raw material, and forming a solution therewith.
Claim 45
Dependent Claim
36 words
Process according to claim 31, which comprises selecting the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials from the group consisting of perfluorinated and substantially perfluorinated ethers.
Claim 46
Dependent Claim
36 words
Process according to claim 31, which comprises selecting the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials from the group consisting of perfluorinated and substantially perfluorinated hydrocarbons.
Claim 47
Dependent Claim
40 words
Process according to claim 31, which comprises adjusting the boiling range of the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials to a temperature range substantially between 20° and 80° C.
Claim 48
Dependent Claim
41 words
Process according to claim 31, which comprises selecting the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials from the group consisting of perfluorinated and substantially perfluorinated pentane (C 5 F 12 ).
Claim 49
Dependent Claim
41 words
Process according to claim 31, which comprises selecting the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials from the group consisting of perfluorinated and substantially perfluorinated hexane (C 6 F 14 ).
Claim 50
Dependent Claim
54 words
Process according to claim 31, which comprises adding at least one inflating agent being soluble in the rigid foam raw materials in a proportion by weight being at most equal to the proportion by weight of the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials.
Claim 51
Dependent Claim
23 words
Process according to claim 47, which comprises selecting the inflating agent being soluble in the rigid foam raw material as an aliphatic hydrocarbon.
Claim 52
Dependent Claim
32 words
Process according to claim 48, which comprises selecting the inflating agent being soluble in the rigid foam raw material as at least one material from the group consisting of n-pentane and n-hexane.
Claim 53
Dependent Claim
23 words
Process according to claim 47, which comprises selecting the inflating agent being soluble in the rigid foam raw material as a cyclic hydrocarbon.
Claim 54
Dependent Claim
32 words
Process according to claim 50, which comprises selecting the inflating agent being soluble in the rigid foam raw material as at least one material from the group consisting of cyclopentane and cyclohexane.
Claim 55
Dependent Claim
60 words
Process according to claim 31, which comprises incorporating the inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials as a disperse phase of an emulsion, utilizing an emulsifier acting in a nucleating fashion upon the inflating agent in the rigid foam material in which the inflating agent is at least substantially insoluble.
Claim 56
Dependent Claim
74 words
Process according to claim 52, which comprises initially mixing the inflating agent being at substantially insoluble in at least one of the rigid foam raw materials with the emulsifier acting in a nucleating fashion upon the inflating agent, and subsequently incorporating the inflating agent being at substantially insoluble in at least one of the rigid foam raw materials into the rigid foam raw material in which the inflating agent is at least substantially insoluble.
Claim 57
Dependent Claim
23 words
Process according to claim 52, which comprises selecting the emulsifier as an inorganic emulsifier acting in a nucleating fashion upon the inflating agent.
Claim 58
Dependent Claim
14 words
Process according to claim 54, which comprises selecting silica gel as the inorganic emulsifier.
Claim 59
Dependent Claim
11 words
Process according to claim 52, which comprises adding an organic emulsifier.
Claim 60
Dependent Claim
15 words
Process according to claim 56, which comprises selecting starch (amylum soluble) as the organic emulsifier.
Claim 61
Dependent Claim
44 words
Process according to claim 32, which comprises intensively and homogeneously incorporating the inflating agent being at least substantially insoluble in the polyol raw material into the polyol raw material as the disperse phase of an emulsion, in which it is at least substantially insoluble.
Claim 62
Dependent Claim
42 words
Process according to claim 58, which comprises initially mixing the inflating agent with an emulsifier to form a mixture; distributing the mixture in the polyol raw material to form an emulsion; and uniting and foaming the emulsion with the isocyanate raw material.
Claim 63
Dependent Claim
69 words
Process according to claim 58, which comprises stirring the inflating agent being soluble in the polyol raw material into the polyol raw material to form a solution, and subsequently intensively and homogeneously incorporating the inflating agent being at least substantially insoluble in the polyol raw material into the solution in the polyol raw material, as a disperse phase of the emulsion in which it is at least substantially insoluble.
Claim 64
Dependent Claim
63 words
Process according to claim 59, which comprises stirring the inflating agent being soluble in the polyol raw material into the polyol raw material to form a solution; initially mixing the inflating agent with an emulsifier to form a mixture; distributing the mixture in the polyol raw material to form an emulsion; and uniting and foaming the emulsion with the isocyanate raw material component.
Claim 65
Dependent Claim
33 words
Process according to claim 31, which comprises selecting the inflating agents being at least substantially insoluble in at least one of the rigid foam raw materials as inflating agents of different chemical types.
Claim 66
Dependent Claim
138 words
Process for producing a rigid largely closed-cell polyurethane or polyisocyanurate foam having a cell structure formed by the expansion of rigid foam raw materials with carbon dioxide, which comprises forming a fine-celled rigid foam material by preparing an inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, homogeneously emulsifying the inflating agent in at least one of the rigid foam raw materials prior to the beginning of a chemical reaction, in the form of the disperse phase of an emulsion having a liquid droplet size at most equal to 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material, and selecting rigid foam raw materials including components for producing an essential required amount of inflating agent in the form of carbon dioxide.
Claim 67
Dependent Claim
138 words
Process for producing a rigid largely closed-cell polyurethane or polyisocyanurate foam having a cell structure formed by the expansion of rigid foam raw materials with carbon dioxide, which comprises forming a fine-celled rigid foam material by preparing an inflating agent being at least substantially insoluble in at least one of the rigid foam raw materials, homogeneously emulsifying the inflating agent in at least one of the rigid foam raw materials prior to the beginning of a chemical reaction, in the form of the disperse phase of an emulsion having a liquid droplet size at most equal to 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material, and selecting rigid foam raw materials including components for producing an essential required amount of inflating agent in the form of carbon dioxide.
Claim 68
Dependent Claim
28 words
Process according to claim 51, which comprises forming the cell structure by expansion of the rigid foam raw materials selected from the group consisting of polyols and isocyanates.
Claim 69
Dependent Claim
21 words
Process according to claim 51, which comprises additionally using at least one of activators and stabilizers to form the cell structure.
Claim 70
Dependent Claim
40 words
Process according to claim 51, which comprises providing the disperse phase of the emulsion with a liquid droplet size of less than 10 μm in diameter and a proportion by weight of less than 3.5% of the rigid foam material.
Claim 71
Dependent Claim
38 words
Process according to claim 51, which comprises providing the disperse phase of the emulsion with a liquid droplet size of approximately 10 μm in diameter and a proportion by weight of approximately 2% of the rigid foam material.
Claim 72
Dependent Claim
38 words
Process according to claim 51, which comprises providing the disperse phase of the emulsion with a liquid droplet size of approximately 4 μm in diameter and a proportion by weight of approximately 1% of the rigid foam material.
References Cited (Backward Citations)
US4246356A
Cited
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1994-07-22 | 1995-01-21 | 1995-07-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-07-22 | 1999-01-21 | 1999-07-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-07-22 | 2003-01-21 | 2003-07-23 | $7700.00 | Window Closed / Lapsed |