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Encapsulated flexible polyurethane foam and method for making polyol to form foam

a flexible polyurethane foam and polyurethane technology, applied in the field of encapsulated flexible polyurethane foam and method for making polyol to form foam, can solve the problems of inconvenient use of petrochemical polyols, inability to meet the needs of industrial production,

Inactive Publication Date: 2007-05-31
FORD GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The use of petrochemical polyols is disadvantageous for a variety of reasons.
First, since polyols are derived from petroleum, they are a non-renewable resource.
Furthermore, the production of a polyol may require a great deal of energy and expense, as oil must be drilled, extracted from the ground, transported to refineries, refined, and otherwise processed to yield the polyol.
With uncertainties in the long-term economic stability and limited reserves of fossil fuels and oils, investigations into using renewable resources as a source for foams have been ongoing.
While soy-based polyurethane foams have made inroads into various polyurethane foam markets, the use of soy-based polyurethane foam has not gained acceptance in the automotive industry because of certain limitations.
One primary limitation of using soy-based polyurethane foams is the unpleasant vegetable oil odor that is prominent in these foams.
This limitation is especially acute in the vehicle interior, where controlled air quality and odor are important issues for automobile consumers.
In addition, the heated environment of the cabin interior provides additional limitations on the types of materials that can be used.
However, these techniques have not satisfactorily addressed the odor problem issue.

Method used

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  • Encapsulated flexible polyurethane foam and method for making polyol to form foam
  • Encapsulated flexible polyurethane foam and method for making polyol to form foam
  • Encapsulated flexible polyurethane foam and method for making polyol to form foam

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0046] In one experiment, one (1) liter of cold pressed degummed soy oil, available from the Thumb Oilseed Producers' Cooperative of Ubly, Mich., was placed in a custom blown glass column. This experiment was conducted at room temperature, about 72 F. The quartz column allowed the degummed soy oil to be exposed to all of the UV light. In a first trial, an external UV lamp, available from Philips Electronics North America of New York City, N.Y., generated UV light at a wavelength of 315 nm, which was directed at the glass column. During the UV exposure, air was blown through the degummed soy oil. The results of this trial are found in Table 1 below. A Gardner bubble viscometer was utilized to measure the viscosity in stokes at 25 C. The percent volatiles produced was measured following the Ca2c-25 test method from the American Oil Chemists Society for testing volatiles.

TABLE 1Viscosity in stokesPercent volatilesTotal hours airTotal hours UVat 25 C.produced000.501661660.8502611702.5...

example 2

[0049] In another series of experiments, one (1) liter of cold pressed degummed soy oil, available from the Thumb Oilseed Producers' Cooperative of Ubly, Mich., was placed in a PYREX column that allowed some UV light to penetrate. UV light from an external UV lamp was directed at the PYREX column. The results of these experiments are found in Tables 3-6 below.

TABLE 3PercentageUVVis. in stokesVolatiles(nm)T (F.)Hrs airHrs UVat 25 C.Produced350 nm721201201.41.54

[0050]

TABLE 4PercentageUVVis. in stokesVolatiles(nm)T (F.)Hrs airHrs UVat 25 C.Produced315 nm7228628612.14.23315 nm72309309164.88

[0051]

TABLE 5PercentageUVVis. in stokesVolatiles(nm)T (F.)Hrs airHrs UVat 25 C.Produced315 nm22220202.25—315 nm22225252.65—315 nm22243434.850.478

[0052]

TABLE 6PercentageUVVis. in stokesVolatiles(nm)T (F.)Hrs airHrs UVat 25 C.Produced315 nm17525251.25—315 nm17525 @25 @5.5—and 72175 F.175 F.and 72and 72@ 72@ 72

example 3

[0053] In yet another experiment, degummed soy oil was placed in a PYREX column that allowed the passage of some UV light. UV light at 315 nanometers from a UV lamp was directed at the PYREX column. The experiment was conducted at a temperature of about 100 F. The results of this experiment are found in Table 7 below.

TABLE 7TotalViscosity in stokesPercentageTotal hours airhours UVat 25 C.Volatiles Produced000.501201200.501441440.6501681680.850.6819819810.7522172172.51.7782892896.153.426

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Abstract

A cellular material. The cellular material can be the reaction product of a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and an isocyanate.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] One aspect of the present invention relates to flexible polyurethane foam suitable for use in automobile interior applications, and method for making vegetable-based polyol to form foam. [0003] 2. Background Art [0004] Flexible polyurethane foams have been extensively used in the automotive industry for applications such as seating, instrument panels, armrests, headrests and headliners. On average, 35 pounds of flexible polyurethane foam are used per vehicle for interior applications. [0005] The production of polyurethane foams is well known in the art. Polyurethanes are formed when isocyanate (NCO) groups react with hydroxyl (OH) groups. One common method of polyurethane production includes the reaction of a polyol with OH groups and an isocyanate with NCO groups, which forms the backbone urethane group. [0006] A blowing agent can be added to the reaction to cause gas or vapor to be evolved during the reaction. The...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C08J9/00
CPCC08G18/36C08G2101/00C08J9/142C08J2375/04
Inventor PERRY, CHRISTINEFLANIGAN, CYNTHIAMIELEWSKI, DEBORAH
Owner FORD GLOBAL TECH LLC
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