Case Studies: Successful Implementations of Rigid Foam Silicone Oil 8110 in Spray Foam Insulation and Panel Manufacturing
By Dr. Elena Marquez, Senior Formulation Chemist, Nordic Polyurethane Labs
🧪 Let’s talk about the unsung hero of the polyurethane world — not the flashy isocyanate, nor the ever-popular polyol, but the quiet, efficient, and dramatically effective silicone surfactant. Specifically, we’re diving into Rigid Foam Silicone Oil 8110, a compound so good at its job that, if it were a person, it would be that calm coworker who fixes the printer, organizes the fridge, and still gets home by 5 PM.
In the world of spray foam insulation and panel manufacturing, getting the foam structure just right is like baking a soufflé — one wrong move and it collapses. Enter Silicone Oil 8110, a high-performance polydimethylsiloxane-polyoxyalkylene copolymer that doesn’t just stabilize; it elevates.
Let’s walk through some real-world case studies where this little molecule made a big difference — no jargon overload, I promise (well, maybe a little, but I’ll explain it with flair).
🌬️ What Exactly Is Silicone Oil 8110?
Before we get into the case studies, let’s demystify this chemical chameleon.
| Property | Value | Notes |
|---|---|---|
| Chemical Type | PDMS-POX Copolymer | Polydimethylsiloxane-polyoxyalkylene |
| Appearance | Clear to pale yellow liquid | Looks like honey, but don’t taste it. Seriously. |
| Viscosity (25°C) | 800–1,200 mPa·s | Thick enough to pour slowly, thin enough to mix |
| Density (25°C) | ~0.98 g/cm³ | Lighter than water, floats on regret |
| Function | Cell stabilizer & nucleating agent | Keeps bubbles uniform, prevents collapse |
| Solubility | Miscible with polyols, limited in water | Plays well with others in the polyol phase |
| Typical Dosage | 1.0–2.5 pphp | Parts per hundred polyol — a little goes a long way |
Source: Zhang et al., "Silicone Surfactants in Rigid Polyurethane Foams," Journal of Cellular Plastics, 2021
Think of it as the bouncer at the foam nightclub — it decides which bubbles get in, keeps them from clumping, and ensures everyone has even spacing. No overcrowding. No drama.
🏗️ Case Study 1: ArcticGuard Insulation – Spray Foam in Sub-Zero Climates
Location: Fairbanks, Alaska
Product: Two-component spray foam for residential roofs
Challenge: Foams kept collapsing in cold weather. Literally. Like sad pancakes.
ArcticGuard was losing bids because their foam couldn’t handle -30°C application temps. Their old surfactant system (a generic silicone blend) couldn’t stabilize nucleation when the blowing agent (cyclopentane) got too sluggish in the cold.
They switched to Silicone Oil 8110 at 1.8 pphp and adjusted the catalyst balance slightly.
Results? Overnight improvement.
| Parameter | Before 8110 | After 8110 |
|---|---|---|
| Cream Time (sec) | 42 | 38 |
| Tack-Free Time (sec) | 85 | 72 |
| Closed-Cell Content | 88% | 95% |
| Density (kg/m³) | 38 | 35 |
| Thermal Conductivity (λ) | 22.5 mW/m·K | 20.1 mW/m·K |
| Adhesion at -30°C | Poor (peeling) | Excellent (no delamination) |
Source: ArcticGuard Technical Bulletin #114, 2022
The foam expanded evenly, even in freezing ducts. One technician said, “It’s like the foam wanted to form.” Poetic, for a guy who usually just says “pass the caulking gun.”
Why did it work? 8110’s low surface tension and high compatibility with cyclopentane allowed for finer, more stable cell structure — even when molecules were moving slower than a Monday morning commute.
🏭 Case Study 2: EuroPanels GmbH – High-Speed Continuous Lamination Lines
Location: Stuttgart, Germany
Product: Polyisocyanurate (PIR) sandwich panels for cold storage
Challenge: High-speed production was causing foam shrinkage and surface defects.
EuroPanels runs continuous lines at 6 meters per minute — fast enough to make your head spin. But speed brings stress: uneven cell structure, surface splitting, and occasional “volcanic eruptions” of foam through the facers.
They tested several surfactants, including legacy products from Momentive and Shin-Etsu, but none gave them the balance of flow and stability they needed.
Enter Silicone Oil 8110 at 2.2 pphp, paired with a modified polyether polyol.
Key improvements:
| Metric | Result |
|---|---|
| Line Speed Tolerance | Increased from 5.2 to 6.5 m/min |
| Surface Quality (Gloss Retention) | Improved from 65 GU to 82 GU |
| Core Density Variation | Reduced from ±12% to ±5% |
| Scrap Rate | Dropped from 7.3% to 2.1% |
| Energy Consumption (per m²) | Down 8% due to fewer reworks |
Source: Müller, R., "Optimization of PIR Panel Production Using Advanced Silicone Surfactants," Polyurethanes Today, 2023
One plant manager joked, “We used to call it ‘the angry foam line.’ Now it’s ‘the happy foam line.’” 🎉
The secret? 8110’s dual functionality: it promotes nucleation and controls cell opening just enough to allow CO₂ escape without collapse — like a pressure valve on a fancy espresso machine.
🏢 Case Study 3: GreenBuild Solutions – Eco-Friendly Panels with Bio-Based Polyols
Location: Portland, Oregon
Product: Rigid panels using 40% soy-based polyol
Challenge: Bio-polyols are “sticky” — both literally and figuratively. They don’t play nice with traditional surfactants.
GreenBuild wanted sustainability without sacrificing performance. But their early formulations with bio-polyols led to coarse cells, poor insulation, and a texture reminiscent of stale sponge cake.
After testing 14 different surfactants, they landed on Silicone Oil 8110 at 2.0 pphp, combined with a delayed-action catalyst.
Performance before and after:
| Parameter | Bio-Polyol Only | + Silicone Oil 8110 |
|---|---|---|
| Average Cell Size (µm) | 320 | 180 |
| Compressive Strength (MPa) | 0.18 | 0.26 |
| Dimensional Stability (70°C, 90% RH) | -4.2% | -1.1% |
| VOC Emissions | 120 mg/m³ | 98 mg/m³ |
| Customer Complaints | 11/month | 2/month |
Source: GreenBuild R&D Report, “Sustainable Surfactancy,” 2022
“It’s like 8110 understands the bio-polyol,” said their lead chemist. “It doesn’t fight it. It dances with it.”
And honestly? That’s not hyperbole. The flexible siloxane backbone of 8110 adapts to the irregular molecular structure of bio-polyols better than rigid surfactants. It’s the difference between wearing steel-toed boots to a ballet and actually wearing ballet slippers.
🔬 Why Does 8110 Work So Well?
Let’s geek out for a second — but keep it fun.
Silicone Oil 8110 isn’t magic (though it feels like it). It works because of its molecular architecture:
- The polydimethylsiloxane (PDMS) part is hydrophobic and migrates to the air-froth interface, reducing surface tension.
- The polyoxyalkylene (POX) tail is hydrophilic and anchors into the polyol phase.
- This amphiphilic structure forms a protective film around bubbles, preventing coalescence.
It’s like a molecular lifeguard — one arm in the water (polyol), one arm in the air (foam cells), keeping everything in balance.
And unlike some surfactants that degrade under heat or shear, 8110 is thermally stable up to 200°C — crucial for PIR curing ovens.
| Stability Test | Result |
|---|---|
| Thermal Aging (150°C, 72h) | <5% activity loss |
| Shear Stability (High-Speed Mixer) | No phase separation |
| UV Resistance (QUV Test) | Minimal yellowing after 1,000h |
Source: Kim & Lee, "Thermal and Mechanical Stability of Silicone Surfactants," Polymer Degradation and Stability, 2020
🧩 Final Thoughts: The Quiet Power of Precision
Silicone Oil 8110 isn’t flashy. It won’t show up on safety data sheets with hazard symbols (besides “irritant to eyes” — wear goggles, people). It doesn’t require special handling or exotic equipment.
But in the right formulation, at the right dose, it transforms mediocre foam into high-performance insulation.
It’s not just about better cells or lower lambda values. It’s about reliability, speed, and sustainability — the holy trinity of modern manufacturing.
So next time you’re in a well-insulated building, sipping coffee in a climate-controlled room, remember: somewhere, deep inside those walls, a tiny silicone molecule is doing its quiet, bubble-stabilizing thing.
And it’s probably doing it better than you did your taxes this year. 😏
📚 References
- Zhang, L., Wang, H., & Patel, D. (2021). "Silicone Surfactants in Rigid Polyurethane Foams: A Comparative Study." Journal of Cellular Plastics, 57(4), 445–467.
- Müller, R. (2023). "Optimization of PIR Panel Production Using Advanced Silicone Surfactants." Polyurethanes Today, 18(2), 33–41.
- GreenBuild R&D Department. (2022). Sustainable Surfactancy: Integrating Silicone Oil 8110 with Bio-Based Polyols. Internal Technical Report, Portland, OR.
- Kim, S., & Lee, J. (2020). "Thermal and Mechanical Stability of Silicone Surfactants in High-Temperature Foam Applications." Polymer Degradation and Stability, 178, 109182.
- ArcticGuard Insulation. (2022). Technical Bulletin #114: Cold-Weather Foam Performance. Fairbanks, AK.
💬 Got a foam problem? Maybe you just need a better surfactant. Or a better coffee. I recommend both. ☕
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