US 11,772,309 B2
Flexible foaming process for producing thermally insulated articles
Hendrik Wagner, Lemfoerde (DE); Marko Grever, Lemfoerde (DE); Joachim Holle, Lemfoerde (DE); and Joerg Krogmann, Lemfoerde (DE)
Assigned to BASF SE, Ludwigshafen am Rhein (DE)
Appl. No. 17/757,461
Filed by BASF SE, Ludwigshafen am Rhein (DE)
PCT Filed Dec. 8, 2020, PCT No. PCT/EP2020/085138
§ 371(c)(1), (2) Date Jun. 16, 2022,
PCT Pub. No. WO2021/122177, PCT Pub. Date Jun. 24, 2021.
Claims priority of application No. 19217206 (EP), filed on Dec. 17, 2019.
Prior Publication US 2023/0025840 A1, Jan. 26, 2023
Int. Cl. B29C 44/34 (2006.01); B29C 44/06 (2006.01); B29C 44/08 (2006.01); B29C 45/16 (2006.01); C08G 18/48 (2006.01); C08G 18/76 (2006.01); C08J 9/14 (2006.01); B29K 75/00 (2006.01); B29K 105/04 (2006.01); B29L 31/00 (2006.01)
CPC B29C 44/3442 (2013.01) [B29C 44/06 (2013.01); B29C 44/08 (2013.01); B29C 45/16 (2013.01); C08G 18/4829 (2013.01); C08G 18/4845 (2013.01); C08G 18/7664 (2013.01); C08J 9/141 (2013.01); C08J 9/144 (2013.01); C08J 9/146 (2013.01); B29K 2075/00 (2013.01); B29K 2105/046 (2013.01); B29K 2995/0015 (2013.01); B29L 2031/7152 (2013.01); B29L 2031/7622 (2013.01); C08G 2110/0025 (2021.01); C08G 2330/00 (2013.01); C08J 2203/14 (2013.01); C08J 2203/162 (2013.01); C08J 2205/052 (2013.01); C08J 2205/10 (2013.01); C08J 2375/04 (2013.01)] 15 Claims
 
1. A discontinuous process for producing a series of at least two articles containing thermally insulating polyurethane foam from at least
a stream (A) comprising at least one isocyanate reactive compound,
a stream (B) comprising at least one organic polyisocyanate, and
a stream (C) comprising either
at least one compound selected from the group consisting of catalysts, blowing agents, chain extenders, stabilizers, crosslinkers, flame retardants, and additives, or
at least one isocyanate reactive compound or at least one organic polyisocyanate, and optionally, at least one further compound selected from the group consisting of catalysts, blowing agents, chain extenders, stabilizers, crosslinkers, flame retardants, and additives;
wherein stream (C) is different from both streams (A) and (B);
wherein the process comprises:
(a) producing at least one first article containing a first thermally insulating polyurethane foam by
(a1) providing a first polyurethane reaction mixture in a mixing device (MD) by mixing at least two of streams (A), (B), and (C);
(a2) injecting the first polyurethane reaction mixture provided in (a1) into a cavity of the at least one first article and forming the first thermally insulating polyurethane foam; and
(b) producing at least one second article containing a second thermally insulating polyurethane foam by
(b1) providing a second polyurethane reaction mixture in the mixing device (MD) by mixing at least two of streams (A), (B), and (C);
(b2) injecting the second polyurethane reaction mixture provided in (b1) into a cavity of the at least one second article and forming the second thermally insulating polyurethane foam;
wherein a mixing ratio of streams (A), (B), and (C) in (at) is different from a mixing ratio of streams (A), (B), and (C) in (b1),
wherein an amount of stream (C) may be zero either in (a1) or in (b1), and
wherein in case the amount of stream (C) is not zero in (a1) or (b1), an amount of stream (A) may be zero if stream (C) comprises at least one isocyanate reactive compound, and an amount of stream (B) may be zero if stream (C) comprises at least one organic polyisocyanate.