ABSTRACT - Foam Supplies, Inc.ecomate® – A Multi-Faceted Blowing Agent AuThoR: John Murphy, Foam...

4387 Rider Trail N. | Earth City, MO 63045 | 1.800.325.4875 | +1.314.344.3330www.foamsupplies.com | www.ecomatesystems.com

TITLE:ecomate® – A Multi-Faceted Blowing Agent

AuThoR:John Murphy, Foam Supplies, Inc.

ABSTRACT:Since its introduction into the foam market as a new blowing agent, ecomate® has been successfullytrialed in many different venues. We will outline below difficult applications that have been successfullymet using ecomate.

Ecomate® seems the ideal replacement for HCFC 14 Ib in integral skin foams because ecomate has the ideal combination of boiling point and solubility to mimic the solubility and boiling point of 14 lb.Additionally it has about half the molecular weight of 14 lb making it even more economical for thisapplication. Combining this efficiency and economy of use with the environmentally friendly nature of ecomate [zero ODP, zero GWP, and VOC-exempt] there is no doubt that it is highly appealing to this market.

Another market having a difficult transition from 14 lb has been the spray foam market. The use of HFC 245fa is fraught with problems because of high drum vapor pressures causing ratio issues in the field. HFC 365mfc [while not available in North America] would have better drum pressures, but has difficulty with cold substrates; and has such a high MW as to be less than economical. HC’s are problematic because of solubility and flammability issues, and are losing some of their cost advantage due to recent price increases. We will show how ecomate can help mitigate the application problems of spray foam blowing agent transition both neat and in combination with other physical BAs.

Finally we will show how ecomate® can be used in pour foams to make economical foams having good dimensional stability, with excellent flammability, at low densities.

ABSTRACT

A Multi-FacetedBlowing Agent

API Salt Lake City 2006

ecomate® advantages A True LIQUID Blowing Agent Patented: US 6,753,357 w others Pending To Replace HCFC’s, HFC’s, HC’s SNAP Approved ZERO ODP, ZERO GWP, VOC Exempt Economically Advantageous Good Solubility Low Volatility Good Foam Properties Good Foam Flammability Resistance

ecomate® Blowing AgentProperties

Clear, Colorless, Flammable Liquid

Boiling Pt Flash Point LEL \ UEL LAMBDA, gas ( 25 °C)

Vapor Pressure ( 25 °C)

Auto Ignition Temp Specific Gravity Molecular Weight

88.7 F 31,5 C-26 F -32 C

5 - 23% 5 - 23%0.074 10,7

11.4 psig 586 mm

>840 F >450 C

0.982 0,98260 60

BA COMPARISONecomate 141b 245fa 365mfc 365/227

93 / 7n-C5 cC5

Mol wt 60 117 134 148 149,6 72 70

Bpt, C 31,5 32 15,3 40,2 30 36 49

Sp Gr 0,982 1,24 1,32 1,25 1,28 0,62 0,75

Lambda 10,7 10 12,2 10,6 10,7 14* 11*

LEL/UEL 5,0 – 23,0 7,6 – 17,7 n/a 3,5 – 9,0 3,8 – 13,3 1,4 – 17,8 1,4 – 8,0

Cost Efficiency

Blowing Agent $/LB Mol Wt Factor

HCFC-141b ** 117 1.00HFC-245fa ***** 134 1.15HFC-365/227 **** 149 1.27cC5 ** 70 0.60nC5 * 72 0.62

ecomate® ** 60 0.51

Cost Efficiency

Blowing Agent $/LB Mol Wt Factor $/mole

HCFC-141b ** 117 1.00 RefHFC-245fa ***** 134 1.15 +350%HFC-365/227 **** 149 1.27 +380%cC5 ** 70 0.60 - 45%nC5 * 72 0.62 - 70%

ecomate® ** 60 0.51 - 65%

Integral Skin

Integral Skin ecomate – best alternative to 141b Solvates all Raws currently used BPt. just above ambient [like 141b]

Permits good skin formation Allows fast demold times

Environmentally Benign Economical – Mol Wt HALF of 141b US EPA SNAP Approved

Flexible FoamsMolded & Slab

Good Solubility Fine Cells Safer than

Hydrocarbons Non-VOC Excellent Hand

Rigid Applications Moulded Roof Panels Pipe-in-Pipe

Insulation Spray Foam

SPRAY FOAM Like other foams – except: Faster Reacting Prolonged Shelf Stability > 3 mos. 1:1 by volume Uncontrolled Application Environments

Two routes PUR & PIR

SPRAY FOAM Blend of Polyols Ester - Cost & Fire Properties Amine - Reactivity & Can Stability Mannich - Adhesion & Can Stability Sucrose - Strength & Char

What is the Best Combination ?

D-Optimal MixtureDESIGN EXPERT 6.0

ESTER, 184 Eqwt

MANNICH, 178 Eqwt

SUCROSE, 152 Eqwt

AMINE, 94 Eqwt

20 – 50 Parts 20 – 40 Parts 0 – 30 Parts 0 – 25 Parts

D-Optimal MixtureDESIGN EXPERT 6.0

ESTER, 184 Eqwt

MANNICH, 178 Eqwt

SUCROSE, 152 Eqwt

AMINE, 94 Eqwt

FIRE RETARDANT ecomate WATER

20 – 50 Parts 20 – 40 Parts 0 – 30 Parts 0 – 25 Parts

15 Parts 6 % 2.5 %

System Flash PointPOLYOL TYPE

3035404550556065707580

2.50% 3.50% 4.50% 5.50% 6.50%

ECOMATE PCT

FLAS

H PT

, C

POLYOL 1POLYOL 2POLYOL 3POLYOL 4POLYOL 5POLYOL 6

D-Optimal Mixture 20 RUNS Adjusted for constant DENS, REACTIVITY

DESIGN RUNSRun ESTER SUCROSE MANNICH AMINE

% % % %

1 25 30 20 25

2 35 0 40 25

3 31 23 26 20

4 43 23 33 0

5 50 10 40 0

6 20 23 40 18

7 50 0 33 18

8 20 23 40 18

9 29 30 29 12

10 42 22 20 17

DESIGN RUNSRun ESTER SUCROSE MANNICH AMINE

% % % %

11 34 14 40 12

12 25 30 20 25

13 50 30 20 0

14 50 5 20 25

15 43 13 30 14

16 30 30 40 0

17 50 5 20 25

18 50 30 20 0

19 33 13 28 25

20 35 0 40 25

D-Optimal Mixture 20 RUNS Adjusted for constant DENS, REACTIVITY

EFFECTS Monitored: INDEX FLAME SPREAD SMOKE

ISOCYANATE INDEX ALL Foams 1:1 by Volume

Index range: 104 - 119 Normal for sprays

FLAME SPREADDESIGN-EXPERT Plot

FLAME SPREADDesign Points

X1 = A: ESTER: 20 - 50X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40

Actual ComponentD: AMINE = 12.50

A: ESTER67.50

B: SUCROSE47.50

C: MANNICH67.50

20.00 0.00

20.00

FLAME SPREAD

3540

45

50

55SUCROSE Levels worsen FS

SMOKEDESIGN-EXPERT Plot

SMOKE Design Points

X1 = A: ESTER: 20 - 50 X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40

Actual ComponentD: AMINE = 12.50

A: ESTER67.50

B: SUCROSE47.50

C: MANNICH67.50

20.00 0.00

20.00

SMOKE

550600

650

700

750

800

850

AMINE Levels worsen SMOKE

SMOKEDESIGN-EXPERT Plot

SMOKE Design Points

X1 = A: ESTER: 20 - 50X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40

Actual ComponentD: AMINE = 0.00

A: ESTER80.00

B: SUCROSE60.00

C: MANNICH80.00

20.00 0.00

20.00

SMOKE

450 500

550 600

650

2

AMINE Levels worsen SMOKE

DESIGN RESULTS FLAME SPREAD worse w Hi SUCROSE SMOKE worse w Hi AMINE DESIGN-EXPERT 6.0 OPTIMIZED: 45 FS / 400 SMOKE ESTER 50 SUCROSE 29 MANNICH 21 AMINE 0

POUR FOAMS ecomate system gets HIGHEST Fire Resistance FSI’s eco1 System

UL 723 – 25 FS / 300 smoke @ 6 inches [ASTM E-84] FM 4880 – Lg. Scale Corner Test – Passed

ecomate excellent for PIR Boardstock Laminator approval obtained.

System shipping possible w/o ‘Flammable’ tags Foam recycling / disposal w/o environmental

impact.

CONCLUSIONS INTEGRAL SKIN ecomate - a perfect fit

solubility, ideal BPt, Lo MW, environmentally benign

SPRAY GOOD PROPS, CLASS 1 & 2, 3+ MOs STABILITY

POUR EXCELLENT PROPS, HIGH FIRE RESISTANCE

ecomate® advantages A True LIQUID Blowing Agent SNAP Approved Good Solubility Low Volatility Good Foam Properties Good Flammability Resistance Cost Competitive TRY IT….YOU’LL LIKE IT !

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The Next Generation Blowing Agent