Tetsuaki Fukushima

The effect of tertiary amine catalyst systems for lower density rigid foam with HCFC-141b

The replacement of blowing agent from CFC-11 to HCFCs is proceeding in rigid polyurethane foam applications in order to meet the revised Montreal Protocol. The foams using HCFCs, however, have about 5 to 10% higher thermal conductivity than that using CFC, owing to the high thermal conductivity of HCFCs. Though improved HCFC blown foams have realized similar thermal conductivity to conventional CFC-11 blown foams, these foams have about 15 to 20% higher densities. This performance level can not be accepted as an insulation foam for refrigeration appliances. Kao Corporation has developed new catalyst systems, which is Kaolizer KLP-200 series. The use of our new catalysts for HCFC-141b blown foams can realize low thermal conductivity, derived from formation of finer cell structure by acceleration of initial gelling reaction, and has performance to improve flowability in the foaming process at the same time. These characteristics give about 10 to 15% lower density foams than that using conventional catalysts in comparison with similar thermal conductivity. In addition, the formulation using Kaolizer KLP-200K can reduce the level of HCFC-141b compared with that using conventional catalysts to obtain the expected thermal conductivity of the foams, provided these foams have the same density. This paper describes the effect of Kaolizer KLP-200K for HCFC-141b blown rigid foam. The system using Kaolizer KLP-200K results in lower density foam and reduced HCFC-141b compared to that using conventional catalysts. Moreover, Kaolizer KLP-200 is effective for cyclopentane blown rigid foam