hydrofluoropropene blowing agents for thermoplastics

Abstract

The present invention relates to blowing agent compositions comprising at least one hydrochlorofluoroolefin (HCFO) used in the preparation of foamable thermoplastic compositions. The HCFOs of the present invention include, but are not limited to, 1-chloro-3, 3,3-trifluoropropene (HCFO-1233zd), particularly the trans-isomer, 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), dichloro-fluorinated propenes, and mixtures thereof. The blowing agent compositions of the present invention are used with coblowing agents including carbon dioxide, atmospheric gases, hydrofluorocarbons (HFC), hydrofluoroolefins (HFO), alkanes, hydrofluoroethers (HFE), and mixtures thereof. Preferred HFCs used as coblowing agents in the present invention include, but are not limited to, 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1-difluoroethane (HFC-152a), 1,1,1-trifluoroethane (HFC-143a), pentafluorethane (HFC-125), difluoromethane (HFC-32). The blowing agent compositions are useful in the production of low density insulating foams with improved k-factor.

1 . A blowing agent composition for thermoplastic foaming comprising a hydrochlorofluoroolefin. 
   
   
       2 . The blowing agent composition of  claim 1  further comprising a hydrofluorocarbon, an alkane, carbon dioxide, an atmospheric gas, an inert gas, and mixtures thereof. 
   
   
       3 . The blowing agent composition of  claim 2  further comprising a hydrofluoroolefin. 
   
   
       4 . The blowing agent composition of  claim 1  where the hydrochlorofluoroolefin contains three or more carbons. 
   
   
       5 . The blowing agent composition of  claim 1  wherein said hydrochlorofluoroolefin is selected from 1-chloro-3,3,3-trifluoropropene, 2-chloro-3,3,3-trifluoropropene, a dichloro-fluorinated propene, or mixtures thereof. 
   
   
       6 . The blowing agent composition of  claim 5  wherein said 1-chloro-3,3,3-trifluoropropene contains greater than 75 wt % of the trans-isomer. 
   
   
       7 . The blowing agent composition of  claim 2  wherein said hydrofluorocarbon is selected from HFC-134a (1,1,1,2-tetrafluoroethane), HFC-134 (1,1,2,2-tetrafluoroethane), HFC-152a (1,1-difluoroethane), HFC-152 (1,2-difluoroethane), HFC-32 (difluoromethane), HFC-143a (1,1,1-trifluoroethane), HFC-143 (1,1,2-trifluoroethane), fluoroethane, HFC-236fa (1,1,1,3,3,3-hexafluoropropane), HFC-236ea, HFC-227ea (1,1,1,2,3,3,3-heptafluoropropane), HFC-125 (pentafluoroethane), HFC-365 mfc (1,1,1,3,3-pentafluorobutane), HFC-245fa (1,1,1,3,3-pentafluoropropane), or mixtures thereof. 
   
   
       8 . The blowing agent composition of  claim 7  wherein said hydrofluorocarbon is selected from HFC-134a (1,1,1,2-tetrafluoroethane), HFC-152a (1,1-difluoroethane), HFC-32 (difluoromethane), HFC-143a (1,1,1-trifluoroethane), or mixtures thereof. 
   
   
       9 . The blowing agent composition of  claim 7  wherein said hydrofluorocarbon is HFC-134a (1,1,1,2-tetrafluoroethane). 
   
   
       10 . The blowing agent composition of  claim 3  wherein said hydrofluoroolefin is selected from C3 through C5 fluorinated alkene or mixtures thereof. 
   
   
       11 . The blowing agent composition of  claim 10  wherein said fluorinated alkene is selected from trifluoropropene, tetrafluoropropene, pentalfuoropropene, or mixtures thereof. 
   
   
       12 . The blowing agent composition of  claim 11  wherein said trifluoropropene is 3,3,3-trifluoropropene. 
   
   
       13 . The blowing agent composition of  claim 11  wherein said tetrafluoropropene is selected from cis-1,3,3,3-tetrafluoropropene; trans-1,3,3,3-tetrafluoropropene; 2,3,3,3-tetrafluoropropene, or mixtures thereof. 
   
   
       14 . The blowing agent composition of  claim 11  wherein said pentafluoropropene is selected from cis-1,2,3,3,3-pentafluoropropene; trans-1,2,3,3,3-pentafluoropropene, or mixtures thereof. 
   
   
       15 . The blowing agent composition of  claim 2  wherein said alkane is selected from propane, butane, pentane, hexane, or mixtures thereof. 
   
   
       16 . The blowing agent composition of  claim 15  wherein said pentane is selected from n-pentane, cyclopentane, iso-pentane or mixtures thereof. 
   
   
       17 . The blowing agent composition of  claim 2  further comprising an alcohol. 
   
   
       18 . The blowing agent composition of  claim 17  wherein said alcohol is selected from ethanol, iso-propanol, propanol, butanol, ethyl hexanol, methanol, or mixtures thereof. 
   
   
       19 . The blowing agent composition of  claim 2  further comprising an ether. 
   
   
       20 . The blowing agent composition of  claim 19  wherein said ether is selected from dimethyl ether, diethyl ether, methylethyl ether, or mixtures thereof 
   
   
       21 . The blowing agent composition of  claim 2  further comprising a ketone. 
   
   
       22 . The blowing agent composition of  claim 21  wherein said ketone is selected from acetone, methyl ethyl ketone, and mixtures thereof. 
   
   
       23 . The blowing agent composition for thermoplastic foaming of  claim 1  wherein said thermoplastic is selected from polystyrene, polyethylene, polypropylene, or mixtures thereof. 
   
   
       24 . A foamable resin composition comprising a blowing agent comprising a hydrochiorofluoroolefin and a thermoplastic resin. 
   
   
       25 . The foamable resin composition of  claim 24  wherein said thermoplastic resin is selected from polystyrene, polyethylene, polypropylene, or mixtures thereof. 
   
   
       26 . The foamable resin composition of  claim 24  comprising less than about 100 pph of said blowing agent with respect to said thermoplastic resin. 
   
   
       27 . The foamable resin composition of  claim 24  comprising from about 1 pph to about 100 pph of said blowing agent with respect to said thermoplastic resin. 
   
   
       28 . The foamable resin composition of  claim 24  comprising from about 2 pph to about 40 pph of said blowing agent with respect to said thermoplastic resin. 
   
   
       29 . The foamable resin composition of  claim 24  comprising from about 3 pph to about 25 pph of said blowing agent with respect to said thermoplastic resin. 
   
   
       30 . The foamable resin composition of  claim 24  comprising from about 4 pph to about 15 pph of said blowing agent with respect to said thermoplastic resin. 
   
   
       31 . The blowing agent composition of  claim 1  further comprising dyes, pigments, cell-controlling agents, fillers, antioxidants, extrusion aids, stabilizing agents, antistatic agents, fire retardants, IR attenuating agents, thermally insulating additives, plasticizers, viscosity modifiers, impact modifiers, gas barrier resins, carbon black, surfactants, and mixtures thereof. 
   
   
       32 . A foamed product produced using the blowing agent composition of  claim 1   
   
   
       33 . A process for producing the foamed product of  claim 32 .