Polyisocyanurate
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Polyisocyanurate (), also referred to as PIR, polyiso, or ISO, is a
thermoset In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening (" curing") a soft solid or viscous liquid prepolymer ( resin). Curing is induced by heat or suitable radiation ...
plastic typically produced as a foam and used as rigid thermal insulation. The starting materials are similar to those used in
polyurethane Polyurethane (; often abbreviated PUR and PU) refers to a class of polymers composed of organic units joined by carbamate (urethane) links. In contrast to other common polymers such as polyethylene and polystyrene, polyurethane is produced from ...
(PUR) except that the proportion of
methylene diphenyl diisocyanate Methylene diphenyl diisocyanate (MDI) is an aromatic diisocyanate. Three isomers are common, varying by the positions of the isocyanate groups around the rings: 2,2′-MDI, 2,4′-MDI, and 4,4′-MDI. The 4,4′ isomer is most widely used, and i ...
(MDI) is higher and a polyester-derived polyol is used in the reaction instead of a
polyether In organic chemistry, ethers are a class of compounds that contain an ether group—an oxygen atom connected to two alkyl or aryl groups. They have the general formula , where R and R′ represent the alkyl or aryl groups. Ethers can again be ...
polyol In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, thr ...
. The resulting chemical structure is significantly different, with the
isocyanate In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...
groups on the MDI trimerising to form isocyanurate groups which the polyols link together, giving a complex polymeric structure.


Manufacturing

The reaction of (MDI) and polyol takes place at higher temperatures compared with the reaction temperature for the manufacture of PUR. At these elevated temperatures and in the presence of specific catalysts, MDI will first react with itself, producing a stiff, ring molecule, which is a reactive intermediate (a tri-isocyanate isocyanurate compound). Remaining MDI and the tri-isocyanate react with polyol to form a complex poly(urethane-isocyanurate) polymer (hence the use of the abbreviation PUI as an alternative to PIR), which is foamed in the presence of a suitable blowing agent. This isocyanurate polymer has a relatively strong molecular structure, because of the combination of strong
chemical bonds A chemical bond is a lasting attraction between atoms or ions that enables the formation of molecules and crystals. The bond may result from the electrostatic force between oppositely charged ions as in ionic bonds, or through the sharing of ...
, the ring structure of isocyanurate and high cross link density, each contributing to the greater stiffness than found in comparable polyurethanes. The greater bond strength also means these are more difficult to break, and as a result a PIR foam is chemically and thermally more stable: breakdown of isocyanurate bonds is reported to start above 200 °C, compared with urethane at 100 to 110 °C. PIR typically has an MDI/polyol ratio, also called its index (based on isocyanate/polyol stoichiometry to produce urethane alone), higher than 180. By comparison PUR indices are normally around 100. As the index increases material stiffness the brittleness also increases, although the correlation is not linear. Depending on the product application greater stiffness,
chemical A chemical substance is a form of matter having constant chemical composition and characteristic properties. Some references add that chemical substance cannot be separated into its constituent elements by physical separation methods, i.e., w ...
and/or
thermal stability In thermodynamics, thermal stability describes the stability of a water body and its resistance to mixing.Schmidt, W. 1928. Über Temperatur und Stabilitätsverhältnisse von Seen. Geogr. Ann 10: 145 - 177. It is the amount of work needed to t ...
may be desirable. As such PIR manufacturers can offer multiple products with identical densities but different indices in an attempt to achieve optimal end use performance.


Uses

PIR is typically produced as a foam and used as rigid thermal insulation. Its
thermal conductivity The thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by k, \lambda, or \kappa. Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal ...
has a typical value of 0.023 W/(m·K) (0.16 BTU·in/(hr·ft2·°F)) depending on the perimeter:area ratio. PIR foam panels laminated with pure embossed
aluminium Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. I ...
foil are used for fabrication of pre-insulated duct that is used for heating, ventilation and air conditioning systems. Prefabricated PIR sandwich panels are manufactured with corrosion-protected, corrugated steel facings bonded to a core of PIR foam and used extensively as roofing insulation and vertical walls (e.g. for warehousing, factories, office buildings etc.). Other typical uses for PIR foams include industrial and commercial pipe insulation, and carving/machining media (competing with expanded polystyrene and rigid polyurethane foams). Effectiveness of the insulation of a
building envelope A building envelope is the physical separator between the conditioned and unconditioned environment of a building including the resistance to air, water, heat, light, and noiseSyed, Asif. ''Advanced building technologies for sustainability''. Hoboke ...
can be compromised by gaps resulting from shrinkage of individual panels. Manufacturing criteria require that shrinkage be limited to less than 1% (previously 2%). Even when shrinkage is limited to substantially less than this limit, the resulting gaps around the perimeter of each panel can reduce insulation effectiveness, especially if the panels are assumed to provide a vapor/infiltration barrier. Multiple layers with staggered joints, ship lapped or tongue & groove joints greatly reduce these problems. Polyisocyanurates of isophorone diisocyanate are also used in the preparation of polyurethane coatings based on acrylic polyols and polyether polyols.


Health hazards

PIR insulation can be a mechanical irritant to skin, eyes, and upper respiratory system during fabrication (such as dust). No statistically significant increased risks of respiratory diseases have been found in studies.


Fire risk

PIR is at times stated to be
fire retardant A fire retardant is a substance that is used to slow down or stop the spread of fire or reduce its intensity. This is commonly accomplished by chemical reactions that reduce the flammability of fuels or delay their combustion. Fire retardants m ...
, or contain fire retardants, but these describe the results of "small scale tests" and "do not reflect llhazards under real fire conditions"; the extent of hazards from fire include not just resistance to fire but the scope for toxic byproducts from different fire scenarios. A 2011 study of fire toxicity of insulating materials at the University of Central Lancashire's Centre for Fire and Hazard Science studied PIR and other commonly used materials under more realistic and wide-ranging conditions representative of a wider range of fire hazard, observing that most fire deaths resulted from toxic product inhalation. The study evaluated the degree to which toxic products were released, looking at toxicity, time-release profiles, and lethality of doses released, in a range of flaming, non-flaming, and poorly ventilated fires, and concluded that PIR generally released a considerably higher level of toxic products than the other insulating materials studied (PIR > PUR > EPS > PHF; glass and stone wools also studied). In particular, hydrogen cyanide is recognised as a significant contributor to the fire toxicity of PIR (and PUR) foams. PIR insulation board (cited as the FR4000 and the FR5000 products of Celotex, a
Saint-Gobain Compagnie de Saint-Gobain S.A. () is a French multinational corporation, founded in 1665 in Paris and headquartered on the outskirts of Paris, at La Défense and in Courbevoie. Originally a mirror manufacturer, it now also produces a variety of ...
company) was proposed to be used externally in the refurbishment of
Grenfell Tower Grenfell Tower is a derelict 24-storey residential tower block in North Kensington in London, England. The tower was completed in 1974 as part of the first phase of the Lancaster West Estate. The tower was named after Grenfell Road, which ran to ...
, London, with vertical and horizontal runs of 100 mm and 150 mm thickness respectively; subsequently "Ipswich firm Celotex confirmed it provided insulation materials for the refurbishment." On 14 June 2017 the block of flats, within 15 minutes, was enveloped in flames from the fourth floor to the top 24th floor. The public inquiry into the fire determined that the Celotex cladding material was one of the primary causes of the rapid spread of the fire, as they were much more flammable than permitted by building regulations. Celotex deceived regulators about the fire performance of the cladding by secretly adding fire retardant materials to the cladding panels that were used during safety testing.


References


External links

{{commons category, Polyisocyanurate insulation boards
Polyisocyanurate Insulation Manufacturers AssociationPolyisocyanurate Insulation energy savings, by Center for the Polyurethanes IndustryContinuous Insulation
Resources for several types of rigid foam continuous insulation Plastics Polyurethanes Building insulation materials Thermosetting plastics