Foaming agents and compositions containing fluorine substituted olefins, and methods of foaming

Abstract

Various uses of fluoroalkenes, including tetrafluoropropenes, particularly (HFO-1336) in a variety of applications, including as blowing agents for integral skin foams are disclosed.

What is claimed is: 
     
         1 . A method of forming an integral skin thermoset foam comprising:
 providing a polymer foam formulation comprising a blowing agent composition comprising from about 5% by weight to about 95% by weight of a C4 fluoroalkene according to Formula I:
   XCF z R3- z   (I)
 
   where X is a C3 unsaturated, substituted radical having at least one fluorine substituent and z is 3; and   foaming said polymer foam formulation to form an integral skin foam.   
     
     
         2 . The method of  claim 1  wherein said foam comprises a polyurethane foam. 
     
     
         3 . The method of  claim 1  wherein said blowing agent further comprises a hydrofluorocarbon selected from the group consisting of difluoromethane (HFC32); 1,1,1,2,1-pentafluoroethane (HFC125); 1,1,1-trifluoroethane (HFC143a); 1,1,2,2tetrafluorothane (HFC134); 1,1,1,2-tetrafluoroethane (HFC134a); 1, I-difluoroethane (HFC152a); 1,1,1,2,3,3,3-heptafluoropropane (HFC227ea); 1,1,1,3,3pentatfluoropropane (HFC245fa); 1,1,1,3,3-pentafluorobutane (HFC365mfc). 
     
     
         4 . The method of  claim 3  wherein said hydrofluorocarbon comprises 1,I,1,2,2,3,4,5,5,5-decafluoropentane (HFC4310mee). 
     
     
         5 . The method of  claim 1  wherein said blowing agent further comprises an additive selected from the group consisting of hydrocarbons, C1 to C5 alcohols, C1 to C4 aldehydes, C1 to C4 ketones, C1 to C4 ethers, carbon dioxide, and C1 to C4 diethers. 
     
     
         6 . The method of  claim 5  wherein said hydrocarbon is selected from the group consisting of pentane isomers and butane isomers. 
     
     
         7 . A process of foaming a polyurethane integral skin foam comprising:
 (a) mixing polymer foam components capable of forming an integral skin foam with a foam blowing agent comprising a C4 fluoroalkene according to Formula I:
   XCF z R3- z   (I)
 
   where X is a C3 unsaturated, substituted radical having at least one fluorine substituent and z is 3; and   (b) forming an integral skin polyurethane foam from said polymer foam components.