Blowing agent compositions of hydrofluoroolefins and hydrochlorofluoroolefins

Abstract

The present invention relates to blowing agent compositions comprising (1) at least one hydrofluoroolefin (HFO) and (2) at least one hydrochlorofluoroolefin (HCFO) used in the preparation of foamable thermoplastic compositions. The HFOs of component (1) include, but are not limited too, 3,3,3-trifluoropropene (HFO-1243zf), 1,2,3,3,3-pentafluoropropene (HFO-1225ye), cis- and/or trans-1,3,3,3-tetrafluoropropene (HFO-1234ze), and 2,3,3,3-tetrafluoropropene (HFO 1234yf), and mixtures thereof. The HCFOs of component (2) include, but are not limited to, 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd), 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) and mixtures thereof. 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 (1) at least one hydrofluoroolefin and (2) at least one hydrochlorofluoroolefin. 
   
   
       2 . The blowing agent composition of  claim 1  comprising about 2 wt % to about 90 wt % of said (2) at least one hydrochlorofluoroolefin. 
   
   
       3 . The blowing agent composition of  claim 1  comprising about 5 wt % to about 80 wt % of said (2) at least one hydrochlorofluoroolefin. 
   
   
       4 . The blowing agent composition of  claim 1  comprising about 10 wt % to about 70 wt % of said (2) at least one hydrochlorofluoroolefin. 
   
   
       5 . The blowing agent composition of  claim 1  comprising about 20 wt % to about 65 wt % of said (2) at least one hydrochlorofluoroolefin. 
   
   
       6 . The blowing agent composition of  claim 1  comprising about 30 wt % to about 60 wt % of said (2) at least one hydrochlorofluoroolefin. 
   
   
       7 . The blowing agent composition of  claim 1  further comprising a hydrofluorocarbon, alkane, carbon dioxide, methyl formate, inert gas, atmospheric gas, alcohol, ether, fluorinated ether, unsaturated fluorinated ether, ketone, fluoroketone, water, and mixtures thereof 
   
   
       8 . The blowing agent composition of  claim 1  wherein said hydrofluoroolefin is selected from C3 through C5 fluorinated alkene or mixtures thereof. 
   
   
       9 . The blowing agent composition of  claim 8  wherein said C3 through C5 fluorinated alkene is selected from trifluoropropene, tetrafluoropropene, pentafluoropropene, or mixtures thereof. 
   
   
       10 . The bowing agent composition of  claim 9  wherein said trifluoropropene is 3,3,3-trifluoropropene. 
   
   
       11 . The blowing agent composition of  claim 9  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. 
   
   
       12 . The blowing agent composition of  claim 9  where the pentafluoropropene is E-1,2,3,3,3-pentafluoropropene, Z-1,2,3,3,3-pentafluoropropene, and mixtures thereof. 
   
   
       13 . The blowing agent composition of  claim 1  wherein said hydrochlorofluoroolefin contains three or more carbons atoms. 
   
   
       14 . 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, 1,1-dichloro-3,3,3-trifluoropropene, 1,2-dichloro-3,3,3-trifluoropropene, or mixtures thereof. 
   
   
       15 . The blowing agent composition of  claim 14  where said 1-chloro-3,3,3-trifluoropropene comprises greater than 75% of the trans-isomer. 
   
   
       16 . The blowing agent composition of  claim 7  wherein said hydrofluorocarbon is selected from HFC-32, HFC-161, HFC-152, HFC-152a, HFC-143, HFC-143a, HFC-134, HFC-134a, HFC-125, HFC-245fa, HFC-365mfc, HFC-227ea, or mixtures thereof. 
   
   
       17 . The blowing agent composition of  claim 16  wherein said hydrofluorocarbon is selected from HFC-134a, HFC-152a, HFC-32, HFC-143a, HFC-245fa, or mixtures thereof. 
   
   
       18 . The blowing agent composition of  claim 7  wherein said alkane is selected from propane, butane, pentane, or hexane. 
   
   
       19 . The blowing agent composition of  claim 18  wherein said pentane is selected from n-pentane, cyclopentane, iso-pentane or mixtures thereof. 
   
   
       20 . The blowing agent composition of  claim 7  wherein said alcohol is selected from ethanol, iso-propanol, butanol, ethyl hexanol, methanol, or mixtures thereof. 
   
   
       21 . The blowing agent composition of  claim 7  wherein said ether is selected from dimethyl ether, diethyl ether, methylethyl ether, or mixtures thereof. 
   
   
       22 . The blowing agent composition of  claim 7  wherein said ketone is selected from acetone, methyl ethyl ketone, or mixtures thereof. 
   
   
       23 . The blowing agent composition for thermoplastic foam of  claim 1  wherein said thermoplastic is selected from polystyrene, polyethylene, polypropylene, or mixtures thereof. 
   
   
       24 . A foamable resin composition comprising a thermoplastic resin and a blowing agent comprising (1) at least one hydrofluoroolefin and (2) at least one hydrochlorofiuoroolefin. 
   
   
       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 .