A Novel Nucleating Agent-Based Technology Resulting in Low Density Rigid Polyurethane Foam for Appliances with Reduced Energy Consumption

Emulsion technology has proven to offer improvements to the performance of rigid polyurethane foam both in terms of general physical properties as well as for insulation performance. The presence of insoluble liquid materials generates a very fine celled structure leading to the above mentioned advantages. Earlier technological developments made in this direction made use of fully or highly fluorinated materials, an approach which became jeopardised because of the unfavourable environmental properties (especially the very high GWP) of this type of materials. A new approach has now been identified which via a similar process, results in polyurethane foam showing improved physical properties, but which doesn't offer negative environmental properties. The improved physical properties include a 10% reduction in minimum stable density in comparison to actual systems available in the market. This paper describes all aspects of this new approach, both in terms of its physical and environmental properties, as well as the final physical properties of the PU foam produced. The overall environmental impact of the different options identified using this approach also will be discussed. Several aspects of the effect of the emulsion technology on the general processing of the foam system will be highlighted. Sourcing, availability and cost impact of the new technology options will also be discussed.