1. Factors contributing to k-factor optimization with ecomate® blown foams
CPI Orlando 2007

2. How does ecomate compare?
141b
245fa
365mfc
365/227
93 / 7
n-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
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

3. How does ecomate compare in Foams ?
Handmix Pours Comparison
Molar Substitution - in same formulation
Same Index
Same Surfactant amount
Same Catalyst amount
Same molar BA content

4. BA Molar Substitution 2” thick sample, 75 ºF
0.187
0.202
0.204
Handmix Data ONLY
Results are Relative
ECOMATE ~ same as 245fa
k NOT SOLELY dependant on MW
134 60
117

5. Thermal Conductivity Not dependant solely on:
Molecular Wt
Gas λ
K-Factor at standard conditions
Depends on many additional factors, including:
Temperature
Processing
Formulation
Configuration
Protection

6. Temperature / k-factor Dependence

7. Examine Processing Effects
Hand Mix Factorial Design
Examine
Mix Time
Mix Speed
Pour Size
Surfactant Concentration

8. PROCESSING EFFECTS: HAND MIX FACTORIAL DESIGN
MIX TIME,
sec
Low 5
Mid
7.5
High 10

9. PROCESSING EFFECTS: HAND MIX FACTORIAL DESIGN
MIX TIME,
sec
MIX SPEED,
rpm
Low 5
1000
Mid
7.5
2000
High 10
3000

10. PROCESSING EFFECTS: HAND MIX FACTORIAL DESIGN
MIX TIME,
sec
MIX SPEED,
rpm
POUR SIZE, gm
Low 5
1000
150
Mid
7.5
2000
225
High 10
3000
300

11. PROCESSING EFFECTS: HAND MIX FACTORIAL DESIGN
MIX TIME,
sec
MIX SPEED,
rpm
POUR SIZE, gm
SURF CONC,
pct
Low 5
1000
150 1
Mid
7.5
2000
225
1.5
High 10
3000
300 2

12. PROCESSING EFFECTS: Handmix Results Summary
Mix Time
Mix Speed
Pour Size
Surf. Concentration
Not significant
Faster = lower λ (less BA loss)
Larger = lower λ (less surface area)
More = lower λ (less BA loss)

13. Handmix v Machine Same ecomate Formulations
Machine ALWAYS Superior !
K FACTOR

14. Examine Formulation Effects
Polyol
Type and Amount
Catalyst
Surfactant
Blowing agent
Temp Effect
Loss / Diffusion
Blends

15. Examine Polyol Effects
In a Hand Mix Factorial Design
Vary POLYOL BLEND
Hold Constant
Catalyst
Surfactant
Blowing Agent
INDEX = 120

16. POLYOL BLEND Design DESIGN Func. Eq. Wt. Visc. LO – HI LEVELS
Sucrose Glycerin 7
152
30K
25-75
EDA 4 70
17K
0-25
Ester
2.3
212
12K
0-50

17. Polyol Effect: DENSITY
25 – 75%
0 – 50%
0 – 25%
EDA faster,
- Captures more BA
- Thus Lower Density

18. Polyol Effect: THERMAL Props
EDA worse !
Strong affinity for BA
Less in vapor space

19. Polyol Results Choice of Polyol Critical - Not only affects Physicals
Faster reactivity captures more BA
Polyol Type can also affect k-factor, λ

20. Examine Catalyst Effects
Speed of reaction
Cell Orientation
Blow v Gel Cats
Gel / Rise Ratio

21. Gel Time Effects Faster = Lower k
PU Expo2002, pg 459, fig 12

22. RISE Cat Effects: Slower Faster Orientation Gellation STRETCHED
SMALL, _|_ RISE BEST
Orientation

23. Catalyst Effects Results
Speed of reaction
Cell Orientation
Gel / Rise Ratio
Faster is better
Smaller, rounder better
Gel at Rise best

24. Surfactant Effects AFFECTS TYPE – Critical ! AMOUNT – very important
Cell formation
Polyol / ISO compatibility
Strut / window thickness
Cell Windows open / closed
Fineness of Cells
Density
TYPE – Critical !
Mol Wt
Siloxane content
Degree of modification
See Degussa Paper [ref 4]
AMOUNT – very important
Optimize for each formulation

25. Examine BA Effects
Molecular Weight
Influential, not critical

26. Examine BA Effects Molecular Weight Gas λ Value
Influential, not critical

27. Examine BA Effects Molecular Weight Gas λ Value Solubility = Viscosity
Influential, not critical
Very Important on Flow

28. Examine BA Effects Molecular Weight Gas λ Value Solubility = Viscosity
Flow = Cell Orientation
Influential, not critical
Very Important on Flow
Critical to Thermal Properties

29. Examine BA Effects Molecular Weight Gas λ Value Solubility = Viscosity
Flow = Cell Orientation
Vapor pressure
Influential, not critical
Very Important on Flow
Critical to Thermal Properties
Very Important

30. Examine BA Effects Molecular Weight Gas λ Value Solubility = Viscosity
Flow = Cell Orientation
Vapor pressure
Liquid v Gas
Influential, not critical
Very Important on Flow
Critical to Thermal Properties
Very Important
Measure k at Use Temp

31. Liquid v Gaseous BA Condensation Effect

32. Liquid v Gaseous BA
GAS
Advantage of potential lower thermal properties
Lost because of higher Vapor Pressure
More Gas escapes during foaming

33. Caveat Moisture Very poor insulator Very small molecule [MW=18],
Smaller than N2 [MW=28, 78%],
Smaller than O2 [MW=32, 21%]
Ubiquitous
Penetrates foams readily
Plays havoc with K-factor

34. Diffusion
Gases want to reach equilibrium

35. Diffusion IF POROUS M2 = Rate2 M1 Graham’s Law Rate1 BA H2O M2 M1 134M2 M1
134 18
Gas
245fa
H2O
Rate1 / Rate2 =
2.73
Water 3X greater Diffusion !
Rigid Foams NOT Porous !
Fick’s Law: Solubility Factors BA
H2O

36. Blowing Agent Loss AHAM Study
Negligible!
Amount of CFC-11 Blowing Agent in Sampled Refrigerators
Sample
When Produced,
Pre-1993
At End of Life, Prior to Shredding, 2004
A-1
15.2 %
15.4 %
A-2
14.1 %
13.0 %
B-1
15.9 %
16.0 %
B-2
16.7 %
C-1
16.0 %*
C-2
13.0 – 14.0 % *
13.8 %
D-1
14.0 – 16.0 % *
15.7 %
D-2
14.3 %

37. REAL LIFE EXAMPLES BEST EVALUATIONS Run side-by-side
Use Actual CABINETS
Use Actual Conditions
Measure
Energy used
Ice melt over time
Compressor cycles, or
Temperature change w time

38. Ice Melt Tests

39. 141b 245fa BTU LOAD TEST – Refrigerated Display case, Maintain 40F
ecomate
18% more energy
20% more energy
CONTROL
ecomate, 245fa nearly same

40. 245fa ecomate DUTY CYCLE – 39” VENDOR CABINETS
5-100 watt bulbs to keep 95F
40 F CHILLER
40 F CHILLER
245fa
ecomate
%Time ON for 95 F:
%Time ON for 95 F:
37.4%
36.8%
ecomate, 245fa nearly same !

41. BLENDING BAs Ecomate very compatible Ecomate, mol%
Why spend extra money?
Ecomate / 245fa Blends
PAT APP
Exp-1
Exp-2
Exp-3
Exp-4
Ecomate, mol% 90 75 50 25
HFC 245fa, mol% 10
K-factor, init
0.165
0.161
0.158
0.153
CS// , psi 31 33 24
Dim Stab Cold, [28d,-29C, V%] 2 3 5 9

42. Handmix v Machine Same ecomate Formulations
Machine ALWAYS Superior !
Ecomate machine k values respectable
K FACTOR

43. Thermal Conductivity Not dependant solely on:MW
Gas λ
K-Factor at standard conditions
Depends on many additional factors, including:
Formulation
Processing
Configuration
Protection

44. Conclusions Thermal Improvements available Protect foams from Moisture
Thru formulation
Thru processing
Protect foams from Moisture
Ecomate nearly equals 245fa
in Hand mix data
in Side-by-side Performance Tests
Compare for Yourself!

45. Compare for Yourself !