Modeling Key Characteristics of Rigid Polyisocyanurate Foams to Improve Sandwich Panel Production Process

This study explores the optimization of rigid polyisocyanurate (PIR) foam formulations, focusing on foaming kinetics that significantly influence the foam's microstructure and thermal insulation properties. By systematically altering components such as isocyanate, polyols, catalysts, blowing agents, and additives, this research investigates their effects on key characteristics including cell density, mechanical strength, and thermal conductivity. A statistical approach known as response surface modeling (RSM) was employed to identify relationships between formulation variables and performance metrics. The optimization aimed to enhance thermal insulation while ensuring feasibility for industrial-scale production, particularly for sandwich-type PIR panels. Two distinct formulations, with isocyanate indices of 335 and 400, were developed to assess the impact of various parameters on properties like foaming start time, gel time, and density. The results indicated that the choice of blowing agents and catalysts played a pivotal role in controlling foaming kinetics and final mechanical properties. The optimized formulations exhibited competitive thermal conductivity values (around 23.7 mW/(m·K)) and adequate compression strength (0.32 MPa), aligning closely with commercially available materials. These findings affirm the potential for enhancing production efficiency and performance consistency in the manufacturing of rigid PIR foams for insulation applications.