U.S. patent application number 09/974301 was filed with the patent office on 2005-06-09 for method of producing a bio-based carpet material.
Invention is credited to Kreifels, Les P., Kurth, Richard A., Kurth, Thomas M., Turner, Robert B..
Application Number | 20050121134 09/974301 |
Document ID | / |
Family ID | 46278307 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050121134 |
Kind Code |
A9 |
Kurth, Thomas M. ; et
al. |
June 9, 2005 |
METHOD OF PRODUCING A BIO-BASED CARPET MATERIAL
Abstract
The present invention includes a method for making a bio-based
carpet material by providing tufts, a backing, a pre-coat, and a
backing material wherein the pre-coat includes the reaction product
of a pre-coat A-side having a pre-coat isocyanate and a pre-coat
B-side and the backing material includes the reaction product of a
backing material A-side having a backing material B-side. The
pre-coat B-side and the backing material B-side may include a
petroleum based polyol; a vegetable oil, cross-linker, and a
catylst; or a transesterified poylol.
Inventors: |
Kurth, Thomas M.;
(Princeton, IL) ; Kurth, Richard A.; (Walnut,
IL) ; Turner, Robert B.; (Georgetown, TX) ;
Kreifels, Les P.; (Marseilles, IL) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
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Prior
Publication: |
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Document Identifier |
Publication Date |
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US 0121328 A1 |
September 5, 2002 |
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Family ID: |
46278307 |
Appl. No.: |
09/974301 |
Filed: |
October 10, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09974301 |
Oct 10, 2001 |
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09646356 |
Sep 14, 2000 |
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6465569 |
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09974301 |
Oct 10, 2001 |
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09944212 |
Aug 31, 2001 |
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09646356 |
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PCT/US99/21511 |
Sep 17, 1999 |
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09944212 |
Aug 31, 2001 |
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09154340 |
Sep 17, 1998 |
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6180686 |
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60239161 |
Oct 10, 2000 |
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60251068 |
Dec 4, 2000 |
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60251068 |
Dec 4, 2000 |
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60239161 |
Oct 10, 2000 |
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60230463 |
Sep 6, 2000 |
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Current U.S.
Class: |
156/72 ;
156/309.6; 156/322 |
Current CPC
Class: |
C08G 18/4288 20130101;
Y10T 428/23979 20150401; C08G 2110/0008 20210101; C08G 18/36
20130101; C08G 2110/0025 20210101; C08G 18/10 20130101; D06N
2203/068 20130101; Y10T 428/23993 20150401; C08G 2110/0033
20210101; C08G 18/6696 20130101; C08G 2110/0016 20210101; C08G
2110/0083 20210101; C08G 18/664 20130101; C08G 18/3206 20130101;
C08G 18/7671 20130101; D06N 2205/20 20130101; D06N 7/0086 20130101;
C08G 18/10 20130101; C08G 18/36 20130101 |
Class at
Publication: |
156/072 ;
156/322; 156/309.6 |
International
Class: |
A46D 001/00 |
Claims
The invention claimed is:
1. A method of making a carpet material comprising: providing
tufts, a backing, a pre-coat, and a backing material wherein the
pre-coat comprises the reaction product of a pre-coat A-side
comprising a pre-coat isocyanate and a pre-coat B-side comprising a
petroleum based polyol, a pre-coat cross-linking agent, and a
pre-coat catalyst and wherein the backing material comprises the
reaction product of a backing material A-side comprising an
isocyanate and a backing material comprising B-side, a vegetable
oil, a cross-linker agent and a catalyst; engaging the tufts and
the primary backing thereby forming griege goods having a top and
bottom surface; applying the pre-coat onto the bottom surface of
the griege goods; curing the pre-coat; and applying the backing
material to the bottom surface of the griege goods.
2. The method of claim 1 further comprising curing the backing
material.
3. The method of claim 1, wherein the pre-coated carpet material is
cured using a curing oven.
4. The method of claim 3, wherein the curing oven temperature is
about 180.degree. F. to about 220.degree. F.
5. The method of claim 3, wherein the curing oven generates heat
electrically.
6. The method of claim 3, wherein the curing oven generates heat
using a fossil fuel.
7. The method of claim 1 further comprising subjecting the griege
goods to a bow and weft straightening station thereby straightening
the tufts.
8. The method of claim 1, wherein the application of the pre-coat
is applied by spraying the pre-coat A-side and the pre-coat B-side
onto the bottom surface of the griege goods.
9. The method of claim 1, wherein the backing material is applied
by spraying the backing material A-side and the backing material
B-side on the bottom surface of the griege goods.
10. The method of claim 1, wherein the vegetable oil comprises a
blown vegetable oil.
11. The method of claim 1, wherein the vegetable oil comp rises a
vegetable oil chosen from palm oil, safflower oil, sunflower oil,
canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut
oil.
12. The method of claim 1, wherein the cross-linker comprises a
cross-linker chosen from ethylene glycol, 1,4 butanediol, diethanol
amines, ethanol amines, tripropylene glycol, aliphatic amine
tetrol, or mixtures thereof.
13. The method of making a carpet material comprising providing
tufts, a primary backing, a pre-coat and a backing material wherein
the pre-coat comprises the reaction product of a pre-coat A-side
comprising a pre-coat isocyanate and a pre-coat B-side comprising a
pre-coat petroleum based polyol and wherein the backing material
comprises the reaction product of a backing material A-side
comprising a backing material isocyanate and a backing material
B-side comprising the reaction product of an esterified polyol and
a backing material vegetable oil wherein the esterified polyol
comprises the reaction product of a first multifunctional compound
and a second multifunctional compound; engaging the tufts and the
primary backing thereby forming griege goods having a top surface
and a bottom surface; applying the pre-coat onto the bottom surface
of the griege goods; curing the pre-coat; and applying the backing
material to the bottom surface of the griege goods.
14. The method of claim 13 further comprising curing the backing
material.
15. The method of claim 13, wherein the pre-coat is cured using a
curing oven.
16. The method of clam 15, wherein the curing oven temperature is
about 180.degree. F. to about 220.degree. F.
17. The method of claim 15, wherein the curing oven generates heat
electrically.
18. The method of claim 15, wherein the curing oven generates heat
using a fossil fuel.
19. The method of claim 13 further comprising subjecting the griege
goods to a bow and weft straightening station thereby straightening
the tufts.
20. The method of claim 13, wherein the pre-coat comprising
spraying the pre-coat A-side and the pre-coat B-side onto the
bottom surface of the griege goods.
21. The method of claim 13, wherein the backing material is applied
by spraying the backing material A-side and the backing material
B-side onto the bottom surface of the griege goods.
22. The method of claim 13, wherein a bed plate and doctor blade
level the pre-coat backing material after the pre-coat backing
material is applied to the bottom surface of the griege goods.
23. The method of claim 13, wherein the first multifunctional
compound comprises a multifunctional alcohol chosen from glycerin,
butanediol, ethylene glycol, tripropylene glycol, dipropylene
glycol, and aliphatic amine tetrol.
24. The method of claim 23, wherein the second multifunctional
compound comprises a saccharide compound.
25. The method of claim 24, wherein the saccharide compound
comprises a saccharide compound chosen from monosaccharides,
disaccharides, oligosaccharides, sugar alcohols, and honey.
26. The material of claim 25, wherein the saccharide compound
comprises a saccharide compound chosen from glucose, sorbitol, and
cane sugar.
27. The method of claim 13, wherein the backing material vegetable
oil comprises a blown vegetable oil.
28. The method of claim 27, wherein the backing material vegetable
oil comprises a blown vegetable oil chosen from blown palm oil,
blown safflower oil, blown sunflower oil, blown canola oil, blown
rapeseed oil, blown cottonseed oil, blown linseed oil, and blown
coconut oil.
29. The method of claim 13, wherein the pre-coat B-side comprises a
cross-linking agent and a catalyst.
30. The method of claim 13, wherein the backing material B-side
comprises a cross-linking agent and a catalyst.
31. The method of claim 13 further comprising substantially
leveling the backing material using a bed plate and doctor
blade.
32. The method of claim 13, wherein an adhesive is applied to the
bottom surface of the griege goods after the pre-coat.
33. The method of claim 32, wherein the backing material is
pre-formed and the backing material is engaged to the bottom
surface of the griege goods by the adhesive.
34. The method of claim 33, wherein the backing material is applied
to the bottom surface of the griege goods by pressure rolling the
backing material into contact with the adhesive.
35. The method of claim 13, wherein the top surface of the griege
goods comprises exposed tufts.
36. A method of making a carpet material comprising: providing
tufts, a primary backing material, and a pre-coat wherein the
pre-coat material comprises the reaction product of a pre-coat
A-side comprising a pre-coat isocyanate and a pre-coat B-side
comprising a pre-coat vegetable oil, a pre-coat cross-linker, and a
pre-coat catalyst; engaging the tufts and the primary backing
thereby forming griege goods having a top and bottom surface;
applying the pre-coat onto the bottom surface of the griege goods;
and curing the pre-coat.
37. The method of claim 36 further comprising: providing a backing
material wherein the backing material comprises the reaction
product of a backing material A-side comprising a backing material
isocyanate and a backing material B-side comprising a backing
material vegetable oil, a backing material cross-linker and a
backing material catalyst; and applying the backing material to the
bottom surface of the griege goods.
38. The method of claim 37 further providing curing the backing
material.
39. The method of claim 37, wherein the pre-coat material is cured
using a curing oven.
40. The method of claim 39, wherein the curing oven temperature is
about 180.degree. F. to about 220.degree. F.
41. The method of claim 39, wherein the curing oven generates heat
electrically.
42. The method of claim 39, wherein the curing oven generates heat
using a fossil fuel.
43. The method of claim 38, comprising subjecting the griege goods
to a bow and weft straightening station thereby straightening the
tufts.
44. The method of claim 37, wherein the application of the pre-coat
is applied to the griege goods by spraying of the pre-coat A-side
and the pre-coat B-side onto the bottom surface of the griege
goods.
45. The method of claim 36, wherein the pre-coat vegetable oil
comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
46. The method of claim 36, wherein the pre-coat vegetable oil
comprises a blown vegetable oil.
47. The method of claim 36, wherein the backing material vegetable
oil comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
48. The method of claim 37, wherein the backing material vegetable
oil comprises a blown vegetable oil.
49. The method of claim 36, wherein the pre-coat cross-linker
comprises a cross-linker chosen from ethylene glycol, 1,4
butanediol, diethanol amines, ethanol amines, tripropylene glycol,
aliphatic amine tetrol, or mixtures thereof.
50. The method of claim 49, wherein the backing material
cross-linker comprises a cross-linker chosen from ethylene glycol,
1,4 butanediol, diethanol amines, ethanol amines, tripropylene
glycol, aliphatic amine tetrol, or mixtures thereof.
51. The method of claim 37, wherein a first bed plate and a first
doctor blade level the pre-coat.
52. The method of claim 51, wherein a second bed plate and a second
doctor blade level the backing material.
53. The method of claim 37, wherein the application of the pre-coat
comprises spraying the pre-coat A-side and the pre-coat B-side onto
the bottom surface of the griege goods.
54. The method of claim 53, wherein the application of the backing
material comprises spraying the backing material A-side and the
backing material B-side onto the bottom surface of the griege
goods.
55. The method of claim 37, wherein an adhesive is applied to the
bottom surface of the griege goods.
56. The method of claim 55, wherein the backing material is
pre-formed and the backing material is engaged to the bottom
surface of the griege goods by the adhesive.
57. The method of claim 56, wherein the backing material is applied
to the bottom surface of the griege goods by pressure rolling the
backing material into contact with the adhesive.
58. The method of claim 36 further comprising: providing a backing
material wherein the backing material comprises the reaction
product of a backing material A-side comprising a backing material
isocyanate and a backing material B-side comprising a petroleum
based polyol; and applying the backing material to the bottom
surface of the griege goods.
59. The method of claim 58 further providing curing the backing
material.
60. The method of claim 58, wherein the pre-coat material is cured
using a curing oven.
61. The method of claim 60, wherein the curing oven temperature is
about 180.degree. F. to about 220.degree. F.
62. The method of claim 60, wherein the curing oven generates heat
electrically.
63. The method of claim 60, wherein the curing oven generates heat
using a fossil fuel.
64. The method of claim 58, comprising subjecting griege goods to a
bow and weft straightening station thereby straightening the
tufts.
65. The method of claim 58, wherein the application of the pre-coat
is applied to the griege goods by spraying of the pre-coat A-side
and the pre-coat B-side onto the bottom surface of the griege
goods.
66. The method of claim 58, wherein the pre-coat vegetable oil
comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
67. The method of claim 58, wherein the pre-coat vegetable oil
comprises a blown vegetable oil.
68. The method of claim 58, wherein the backing material vegetable
oil comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
69. The method of claim 58, wherein the backing material vegetable
oil comprises a blown vegetable oil.
70. The method of claim 58, wherein a first bed plate and a first
doctor blade level the pre-coat.
71. The method of claim 70, wherein a second bed plate and a second
doctor blade level the backing material.
72. The method of claim 58, wherein the application of the pre-coat
comprises spraying the pre-coat A-side and the pre-coat B-side onto
the bottom surface of the griege goods.
73. The method of claim 72, wherein the application of the backing
material comprises spraying the backing material A-side and the
backing material B-side onto the bottom surface of the griege
goods.
74. The method of claim 58, wherein the backing material B-side
further comprises a cross-linker and a catalyst.
75. The method of claim 36 further comprising: providing a backing
material comprising the reaction product of a backing material
A-side comprising a backing material isocyanate and a backing
material B-side comprising the reaction product of an esterified
polyol and a backing material vegetable oil wherein the esterified
polyol comprises the reaction product of a first multifunctional
compound and a second multifunctional compound; and applying the
backing material to the bottom surface of the griege goods.
76. The method of claim 75, wherein the backing material vegetable
oil comprises a blown vegetable oil.
77. The method of claim 75, wherein the backing material vegetable
oil comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
78. The method of claim 75, wherein the pre-coat cross-linker
comprises a cross-linker chosen from ethylene glycol, 1,4
butanediol, diethanol amines, ethanol amines, tripropylene glycol,
aliphatic amine tetrol, or mixtures thereof.
79. The method of making a carpet material comprising: providing
tufts, a primary backing material, and a pre-coat wherein the
pre-coat comprises the reaction product of a pre-coat A-side
comprising a pre-coat isocyanate and a pre-coat B-side comprising
the reaction product of a pre-coat esterified polyol and a pre-coat
vegetable oil wherein the pre-coat esterified polyol comprises the
reaction product of a first pre-coat multifunctional compound and a
second pre-coat multifunctional compound; engaging the tufts and
the primary backing thereby forming griege goods having a top and
bottom surface; applying the pre-coat onto the bottom surface of
the griege goods; and curing the pre-coat.
80. The method of claim 79 further comprising: providing a backing
material wherein the backing material comprises the reaction
product of a backing material A-side comprising a backing material
isocyanate and a backing material B-side comprising a backing
material vegetable oil, a backing material cross-linker and a
backing material catalyst; and applying the backing material to the
bottom surface of the griege goods.
81. The method of claim 80 further providing curing the backing
material.
82. The method of claim 80, wherein the pre-coat material is cured
using a curing oven.
83. The method of claim 82, wherein the curing oven temperature is
about 180.degree. F. to about 220.degree. F.
84. The method of claim 82, wherein the curing oven generates heat
electrically.
85. The method of claim 82, wherein the curing oven generates heat
using a fossil fuel.
86. The method of claim 81, comprising subjecting the griege goods
to a bow and weft straightening station thereby straightening the
tufts.
87. The method of claim 80, wherein the application of the pre-coat
is applied to the griege goods by spraying of the pre-coat A-side
and the pre-coat B-side onto the bottom surface of the griege
goods.
88. The method of claim 79, wherein the pre-coat vegetable oil
comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
89. The method of claim 79, wherein the pre-coat vegetable oil
comprises a blown vegetable oil.
90. The method of claim 79, wherein the backing material vegetable
oil comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
91. The method of claim 80, wherein the backing material vegetable
oil comprises a blown vegetable oil.
92. The method of claim 79, wherein the pre-coat cross-linker
comprises a cross-linker chosen from ethylene glycol, 1,4
butanediol, diethanol amines, ethanol amines, tripropylene glycol,
aliphatic amine tetrol, or mixtures thereof.
93. The method of claim 92, wherein the backing material
cross-linker comprises a cross-linker chosen from ethylene glycol,
1,4 butanediol, diethanol amines, ethanol amines, tripropylene
glycol, aliphatic amine tetrol, or mixtures thereof.
94. The method of claim 80, wherein a first bed plate and a first
doctor blade level the pre-coat.
95. The method of claim 94, wherein a second bed plate and a second
doctor blade level the backing material.
96. The method of claim 80, wherein the application of the backing
material comprises spraying the backing material A-side and the
backing material B-side onto the bottom surface of the griege
goods.
97. The method of claim 96, wherein the application of the pre-coat
comprises spraying the pre-coat A-side and the pre-coat B-side onto
the bottom surface of the griege goods.
98. The method of claim 80, wherein an adhesive is applied to the
bottom surface of the griege goods.
99. The method of claim 98, wherein the backing material is
pre-formed and the backing material is engaged to the bottom
surface of the griege goods by the adhesive.
100. The method of claim 80, wherein the backing material is
applied to the bottom surface of the griege goods by pressure
rolling the backing material into contact with the adhesive.
101. The method of claim 79 further comprising: providing a backing
material wherein the backing material comprises the reaction
product of a backing material A-side comprising a backing material
isocyanate and a backing material B-side comprising a petroleum
based polyol; and applying the backing material to the bottom
surface of the griege goods.
102. The method of claim 101 further providing curing the backing
material.
103. The method of claim 101, wherein the pre-coat material is
cured using a curing oven.
104. The method of claim 103, wherein the curing oven temperature
is about 180.degree. F. to about 220.degree. F.
105. The method of claim 103, wherein the curing oven generates
heat electrically.
106. The method of claim 103, wherein the curing oven generates
heat using a fossil fuel.
107. The method of claim 101, comprising subjecting griege goods to
a bow and weft straightening station thereby straightening the
tufts.
108. The method of claim 101, wherein the application of the
pre-coat is applied to the griege goods by spraying of the pre-coat
A-side and the pre-coat B-side onto the bottom surface of the
griege goods.
109. The method of claim 101, wherein the pre-coat vegetable oil
comprises a vegetable oil chosen from palm oil, safflower oil,
sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed
oil, and coconut oil.
110. The method of claim 101, wherein the pre-coat vegetable oil
comprises a blown vegetable oil.
111. The method of claim 101, wherein the backing material
vegetable oil comprises a vegetable oil chosen from palm oil,
safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed
oil, linseed oil, and coconut oil.
112. The method of claim 101, wherein the backing material
vegetable oil comprises a blown vegetable oil.
113. The method of claim 101, wherein a first bed plate and a first
doctor blade level the pre-coat.
114. The method of claim 113, wherein a second bed plate and a
second doctor blade level the backing material.
115. The method of claim 101, wherein the application of the
pre-coat comprises spraying the pre-coat A-side and the pre-coat
B-side onto the bottom surface of the griege goods.
116. The method of claim 115, wherein the application of the
backing material comprises spraying the backing material A-side and
the backing material B-side onto the bottom surface of the griege
goods.
117. The method of claim 101, wherein the backing material B-side
further comprises a cross-linker and a catalyst.
118. The method of claim 79 further comprising: providing a backing
material comprising the reaction product of a backing material
A-side comprising a backing material isocyanate and a backing
material B-side comprising the reaction product of a backing
material esterified polyol and a backing material vegetable oil
wherein the backing material esterified polyol comprises the
reaction product of a first backing material multifunctional
compound and a second backing material multifunctional compound;
and applying the backing material to the bottom surface of the
griege goods.
119. The method of claim 118 further comprising curing the backing
material.
120. The method of claim 118, wherein the pre-coat is cured using a
curing oven.
121. The method of claim 120, wherein the curing oven temperature
is about 180.degree. F. to about 220.degree. F.
122. The method of claim 120, wherein the curing oven generates
heat electrically.
123. The method of claim 120, wherein the curing oven generates
heat using a fossil fuel.
124. The method of claim 118 further comprising subjecting the
griege goods to a bow and weft straightening station thereby
straightening the tufts.
125. The method of claim 118, wherein the pre-coat comprising
spraying the pre-coat A-side and the pre-coat B-side onto the
bottom surface of the griege goods.
126. The method of claim 125, wherein the backing material is
applied by spraying the backing material A-side and the backing
material B-side onto the bottom surface of the griege goods.
127. The method of claim 118, wherein a bed plate and doctor blade
level the pre-coat backing material after the pre-coat backing
material is applied to the bottom surface of the griege goods.
128. The method of claim 118, wherein the first pre-coat
multifunctional compound and the first backing material
multifunctional compound comprise a multifunctional alcohol chosen
from glycerin, butanediol, ethylene glycol, tripropylene glycol,
dipropylene glycol, and aliphatic amine tetrol.
129. The method of claim 129, wherein the second pre-coat
multifunctional compound and the second backing material
multifunctional compound comprise a saccharide compound.
130. The method of claim 129, wherein the saccharide compound
comprises a saccharide compound chosen from monosaccharides,
disaccharides, oligosaccharides, sugar alcohols, and honey.
131. The material of claim 130, wherein the saccharide compound
comprises a saccharide compound chosen from glucose, sorbitol, and
cane sugar.
132. The method of claim 118, wherein the backing material
vegetable oil comprises a blown vegetable oil.
133. The method of claim 132, wherein the backing material
vegetable oil comprises a blown vegetable oil chosen from blown
palm oil, blown safflower oil, blown sunflower oil, blown canola
oil, blown rapeseed oil, blown cottonseed oil, blown linseed oil,
and blown coconut oil.
134. The method of claim 118, wherein the pre-coat B-side comprises
a cross-linking agent and a catalyst.
135. The method of claim 118, wherein the backing material B-side
further comprises a backing material cross-linker and a backing
material catalyst.
136. The method of claim 118 further comprising substantially
leveling the backing material using a bed plate and doctor
blade.
137. The method of claim 118, wherein an adhesive is applied to the
bottom surface of the griege goods after the pre-coat.
138. The method of claim 137, wherein the backing material is
pre-formed and the backing material is engaged to the bottom
surface of the griege goods by the adhesive.
139. The method of claim 138, wherein the backing material is
applied to the bottom surface of the griege goods by pressure
rolling the backing material into contact with the adhesive.
140. The method of claim 118, wherein the top surface of the griege
goods comprises exposed tufts.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application
Ser. No. 09/944,212, entitled TRANSESTERIFIED POLYOL HAVING
SELECTABLE AND INCREASED FUNCTIONALITY AND URETHANE MATERIAL
PRODUCTS FORMED USING THE POLYOL, by Thomas M. Kurth et al., filed
on Aug. 31, 2001), the disclosure of which is hereby incorporated
by reference, which claims priority to the following U.S.
Provisional Patent Applications: U.S. Provisional Patent
Application Ser. No. 60/251,068 entitled, "TRANSESTERIFIED POLYOL
HAVING SELECTABLE AND INCREASED FUNCTIONALITY AND URETHANE PRODUCTS
FORMED USING THE POLYOL", by Thomas M. Kurth et al., filed Dec. 4,
2000, the disclosure of which is hereby incorporated by reference;
U.S. Provisional Patent Application Ser. No. 60/239,161 entitled,
"TRANSESTERIFIED POLYOL HAVING SELECTABLE AND INCREASED
FUNCTIONALITY AND URETHANE PRODUCTS FORMED USING THE POLYOL", by
Thomas M. Kurth et al., filed Oct. 10, 2000, the disclosure of
which is hereby incorporated by reference; and U.S. Provisional
Patent Application Ser. No. 60/230,463 entitled, "TRANSESTERIFIED
POLYOL HAVING SELECTABLE AND INCREASED FUNCTIONALITY AND URETHANE
PRODUCTS FORMED USING THE POLYOL", by Thomas M. Kurth et al., filed
Sep. 6, 2000, the disclosure of which is hereby incorporated by
reference. This application also claims priority to U.S.
Provisional Patent Application Ser. No. 60/239,161 entitled,
"TRANSESTERIFIED POLYOL HAVING SELECTABLE AND INCREASED
FUNCTIONALITY AND URETHANE PRODUCTS FORMED USING THE POLYOL", by
Thomas M. Kurth et al., filed Oct. 10, 2000, the disclosure of
which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Because of their widely ranging mechanical properties and
their ability to be relatively easily machined and formed, plastic
foams and elastomers have found wide use in a multitude of
industrial and consumer applications. In particular, urethane
materials, such as foams and elastomers, have been found to be well
suited for many applications. Automobiles, for instance, contain a
number of components, such as cabin interior parts, that are
comprised of urethane foams and elastomers. Urethane foams are also
used as carpet backing. Such urethane foams are typically
categorized as flexible, semi-rigid, or rigid foams with flexible
foams generally being softer, less dense, more pliable, and more
subject to structural rebound subsequent to loading than rigid
foams.
[0003] The production of urethane foams and elastomers are well
known in the art. Urethanes are formed when isocyanate (NCO) groups
react with hydroxyl (OH) groups. The most common method of urethane
production is via the reaction of a polyol and an isocyanate, which
forms the backbone urethane group. A cross-linking agent and/or
chain extender may also be added. Depending on the desired
qualities of the final urethane product, the precise formulation
may be varied. Variables in the formulation include the type and
amounts of each of the reactants and additives.
[0004] In the case of a urethane foam, a blowing agent is added to
cause gas or vapor to be evolved during the reaction. The blowing
agent is one element that assists in creating the size of the void
cells in the final foam, and commonly is a solvent with a
relatively low boiling point or water. A low boiling solvent
evaporates as heat is produced during the exothermic
isocyanate/polyol reaction to form vapor bubbles. If water is used
as a blowing agent, a reaction occurs between the water and the
isocyanate group to form an amine and carbon dioxide (CO.sub.2) gas
in the form of bubbles. In either case, as the reaction proceeds
and the material solidifies, the vapor or gas bubbles are locked
into place to form void cells. Final urethane foam density and
rigidity may be controlled by varying the amount or type of blowing
agent used.
[0005] A cross-linking agent is often used to promote chemical
cross-linking to result in a structured final urethane product. The
particular type and amount of cross-linking agent used will
determine final urethane properties such as elongation, tensile
strength, tightness of cell structure, tear resistance, and
hardness. Generally, the degree of cross-linking that occurs
correlates to the flexibility of the final foam product. Relatively
low molecular weight compounds with greater than single
functionality are found to be useful as cross-linking agents.
[0006] Catalysts may also be added to control reaction times and to
effect final product qualities. The catalysts generally effect the
speed of the reaction. In this respect, the catalyst interplays
with the blowing agent to effect the final product density.
Preferably, for foam urethane production, the reaction should
proceed at a rate such that maximum gas or vapor evolution
coincides with the hardening of the reaction mass. The catalyst may
also effect the timing or speed of curing so that a urethane foam
may be produced in a matter of minutes instead of hours.
[0007] Polyols currently used in the production of urethanes are
petrochemicals being generally derived from propylene or ethylene
oxides. Polyester polyols and polyether polyols are the most common
polyols used in urethane production. For flexible foams, polyester
or polyether polyols with molecular weights greater than 2,500, are
generally used. For semi-rigid foams, polyester or polyether
polyols with molecular weights of 2,000 to 6,000 are generally
used, while for rigid foams, shorter chain polyols with molecular
weights of 200 to 4,000 are generally used. There is a very wide
variety of polyester and polyether polyols available for use, with
particular polyols being used to engineer and produce a particular
urethane elastomer or foam having desired particular final
toughness, durability, density, flexibility, compression set ratios
and modulus, and hardness qualities. Generally, higher molecular
weight polyols and lower functionality polyols tend to produce more
flexible foams than do lower molecular weight polyols and higher
functionality polyols. In order to eliminate the need to produce,
store, and use different polyols, it would be advantageous to have
a single, versatile, renewable component that was capable of being
used to create final urethane foams of widely varying
qualities.
[0008] Currently, one method employed to increase the reactivity of
petroleum based polyols includes propoxylation or ethoxylation.
When propoxylation or ethoxylation is done on conventional
petroleum based polyols, current industry practice is to employ
about 70% propylene oxide by weight of the total weight of the
polyol and propylene oxide is required to complete the reaction.
Due to the large amount of alkyloxide typically used, the reaction
if the alkyloxide and the petroleum based polyol is extremely
exothermic and alkyloxides can be very expensive to use, especially
in such high volumes. The exothermic nature of the reaction
requires numerous safety precautions be undertaken when the process
is conducted on an industrial scale.
[0009] Use of petrochemicals such as, polyester or polyether
polyols is disadvantageous for a variety of reasons. As
petrochemicals are ultimately derived from petroleum, they are a
non-renewable resource. The production of a polyol requires a great
deal of energy, as oil must be drilled, extracted from the ground,
transported to refineries, refined, and otherwise processed to
yield the polyol. These required efforts add to the cost of polyols
and to the disadvantageous environmental effects of its production.
Also, the price of polyols tends to be somewhat unpredictable.
Their price tends to fluctuate based on the fluctuating price of
petroleum.
[0010] Also, as the consuming public becomes more aware of
environmental issues, there are distinct marketing disadvantages to
petrochemical based products. Consumer demand for "greener"
products continues to grow. The term "bio-based" or "greener"
polyols for the purpose of this application is meant to be broadly
interpreted to mean all polyols not derived exclusively from
non-renewable resources. Petroleum and bio-based copolymers are
also encompassed by the term "bio-based". As a result, it would be
most advantageous to replace polyester or polyether polyols, as
used in the production of urethane elastomers and foams, with more
versatile, renewable, less costly, and more environmentally
friendly components.
[0011] The difficulties in the past that occurred due to the use of
vegetable oil as the polyols to produce a urethane product include
the inability to regulate the functionality of the polyol resulting
in variations in urethane product where the industry demands
relatively strict specifications be met and the fact that urethane
products, in the past, outperformed vegetable oil based products in
quality tests, such as carpet backing pull tests.
[0012] An unresolved need therefore exists for an improved
functionality, vegetable oil based polyol of increased and
selectable functionality for use in manufacturing urethane
materials such as, elastomers and foams. Also needed is a method of
producing such urethane materials, in particular, carpet materials
using the improved functionality, vegetable oil based polyol based
on a reaction between isocyanates alone or as a prepolymer, in
combination with the improved functionality polyol or a blend of
the improved functionality polyol and other polyols including
petrochemical based polyols. The products and methods of the
present invention are particularly desirable because they relate to
relatively inexpensive, versatile, renewable, environmentally
friendly materials such as, vegetable oil, blown soy oil, or
transesterified vegetable oil that forms a polyol of increased and
selectable functionality that can be a replacement for soy or
petroleum based polyether or polyester polyols typically
employed.
SUMMARY OF THE INVENTION
[0013] One aspect of the present invention includes a method of
making a carpet material providing tufts, a backing, a pre-coat,
and a backing material. The pre-coat includes the reaction product
of a pre-coat A-side having a pre-coat isocyanate and a pre-coat
B-side having a Petroleum based polyol, a pre-coat cross-linking
agent, and a pre-coat catalyst. The backing material includes the
reaction product of a backing material A-side having an isocyanate
and a backing material B-side having a vegetable oil, a
cross-linking agent and a catalyst. The tufts are engaged with the
primary backing thereby forming griege goods having a top and
bottom surface The pre-coat is applied onto the bottom surface of
the griege goods and cured. The backing material is applied to the
bottom surface of the griege goods.
[0014] Another aspect of the present invention includes the method
of making a carpet material by providing tufts, a primary backing,
a pre-coat and a backing material. The pre-coat includes the
reaction product of a pre-coat A-side having a pre-coat isocyanate
and a pre-coat B-side having a pre-coat petroleum based polyol. The
backing material includes the reaction product of a backing
material A-side having a backing material isocyanate and a backing
material B-side having the reaction product of an esterified polyol
and a backing material vegetable oil where the esterified polyol
includes the reaction product of a first multifunctional compound
and a second multifunctional compound. The tufts are engaged with
the primary backing thereby forming griege goods having a top
surface and a bottom surface. The pre-coat is applied onto the
bottom surface of the griege goods and cured. The backing material
is applied to the bottom surface of the griege goods.
[0015] In yet another aspect of the present invention, a method of
making a carpet material includes providing tufts, a primary
backing material, and a pre-coat where the pre-coat material
includes the reaction product of a pre-coat A-side having pre-coat
isocyanate and a pre-coat B-side having a pre-coat vegetable oil, a
cross-linker, and a pre-coat catalyst. The tufts are engaged with
the primary backing thereby forming griege goods having a top and
bottom surface. The pre-coat is applied onto the bottom surface of
the griege goods and cured.
[0016] In still another embodiment of the present invention, the
method of making a carpet material includes providing tufts, a
primary backing material, and a pre-coat where the pre-coat
includes the reaction product of a pre-coat A-side having a
pre-coat isocyanate and a pre-coat B-side having the reaction
product of a pre-coat esterified polyol and a pre-coat vegetable
oil. The pre-coat esterified polyol includes the reaction product
of a first pre-coat multifunctional compound and a second pre-coat
multifunctional compound. The tufts are engaged with the primary
backing thereby forming griege goods having a top and bottom
surface. The pre-coat is applied onto the bottom surface of the
griege goods and cured.
[0017] These and other features, advantages and objects of the
present invention will be further understood and appreciated by
those skilled in the art by reference to the following
specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a simplified carpet processing line diagram of one
embodiment of the present invention;
[0019] FIG. 2 is a simplified carpet processing line diagram of
another embodiment of the present invention;
[0020] FIG. 3 is a simplified carpet processing line diagram of
another embodiment of the present invention;
[0021] FIG. 4 is a simplified carpet processing line diagram of
another embodiment of the present invention; and
[0022] FIG. 5 is a flowchart of the general carpet processing
steps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] A new vegetable oil based polyol having increased and
selectable functionality has been developed. A two-stage
transesterification process produces the new vegetable oil based
polyol as the reaction product of a multifunctional alcohol and a
multifunctional component, subsequently reacted with a vegetable
oil. In the first step in the two-stage transesterification
process, glycerin, a suitable multifunctional alcohol, or other
suitable multifunctional alcohol is heated to about 230.degree. F.,
and advantageously also stirred; however, a catalyst may be used
instead of or in addition to heat. Next, a multifunctional
component having at least two hydroxyl groups preferably includes a
saccharide compound, typically a monosaccharide, disaccharide, a
polysaccharide, sugar alcohol, cane sugar, honey, or mixture
thereof is slowly introduced into the glycerin until saturated.
Currently, the preferred saccharide components are fructose and
cane sugar. Cane sugar provides greater tensile strength and
fructose provides greater elongation of the carbon chain of the
polyol. Preferably, 2 parts of the saccharide compound is added to
1 part of the multifunctional alcohol, by weight. Glycerin is a
carrier for the saccharide compound component, although it does add
some functional hydroxyl groups. The saccharide component is slowly
added until no additional saccharide component can be added to the
glycerin solution.
[0024] It is believed that the multifunctional alcohol and the
saccharide component undergo an initial transesterification to form
new ester products (precursors). As such, the functionality of the
new polyol is selectable. The greater the functionality of the
alcohol, the greater the functionality of the final new polyol.
[0025] Next, from about 200 to 300 grams (experimental amount) of
vegetable oil, preferably soy oil, and most preferably blown soy
oil, is heated to at least about 180.degree. F. However, the
temperature may be any temperature from about 180.degree. F. until
the oil is damaged. Blown soy oil provides superior results to
regular vegetable oil; however, any vegetable oil or blown
vegetable oil will work. Other vegetable oils that may be utilized
in the present invention include, but should not be limited to,
palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil,
cottonseed oil, linseed, and coconut oil. When these vegetable oils
are used, they too are preferably blown. However, the vegetable
oils may be crude vegetable oils or crude vegetable oils that have
had the soap stock and wax compound in the crude oil removed.
[0026] Once the blown soy oil has been heated, it is slowly reacted
with the heated glycerin/saccharide ester, the first
transesterification reaction product. The vegetable oil and the
first transesterification product undergo a second
transesterification reaction that increases the functionality of
the resulting polyol. Lowering the amount of the saccharide
component added to the vegetable oil lowers the number of
functional groups available to be cross-linked with an isocyanate
group when the polyol produced using the two-stage
transesterification process outlined above is used to create a
urethane product. In this manner, functionality of the final polyol
produced by the transesterification process of the present
invention may be regulated and engineered. Therefore, more rigid
urethane products are formed using a polyol produced by the present
invention by using increased amounts of a saccharide component. In
addition, as discussed above, the higher functionality of the
multifunctional alcohol may also increase the functionality of the
urethane products formed using the new polyol.
[0027] Also, polyols having increased functionality can not only be
made by the transesterification process discussed above alone, but
a further increase in functionality of the vegetable oil based
polyol may also be achieved by propoxylation, butyoxylation, or
ethoxylation. Applicants believe that the addition of propylene
oxide (propoxylation), ethylene oxide (ethoxylation), butylene
oxide, (butyloxylation), or any other known alkene oxides to a
vegetable oil, a crude vegetable oil, a blown vegetable oil, the
reaction product of the saccharide (multifunctional compound) and
the multifunctional alcohol, or the final vegetable oil based,
transesterified polyol produced according to the
transesterification process discussed above will further increase
the functionality of the polyol thereby formed.
[0028] Also, polyols having increased functionality can not only be
made by the transesterification process discussed above alone, but
a further increase in functionality of a vegetable oil based polyol
may also be achieved by oxylation (propoxylation, butyoxylation, or
ethoxylation). The addition of propylene oxide (propoxylation),
ethylene oxide (ethoxylation), butylene oxide, (butyloxylation), or
any other known alkene oxides to a vegetable oil, a crude vegetable
oil, a blown vegetable oil, the reaction product of the saccharide
(multifunctional compound) and the multifunctional alcohol, or the
final vegetable oil based, transesterified polyol produced
according to the transesterification process discussed above will
further increase the functionality of the polyol thereby
formed.
[0029] Applicants currently believe that bio-based oxylation
substances, such as, tetrahydrofuran (TMF), tetrahydrofurfuryl,
tetrahydrofurfural, and furfural derivatives as well as
tetrahydrofurfuryl alcohol may be used instead of or in addition to
alkyloxides in the present invention.
[0030] Moreover, Applicants believe that any substance containing
an active hydrogen may be oxylated to any desired degree and
subsequently transesterified. Once transesterified with the
vegetable oil, a compound whose active hydrogens were not fully
oxylated may be further oxylated. Some active hydrogens include OH,
SH, NH, chorohydrin, or any acid group. Compounds containing these
active hydrogens, such as ethylene diamine, may be partially
(because it contains more than one active hydrogen) or fully
oxylated and then transesterified with the multifunctional alcohol,
a crude vegetable oil, a blown vegetable oil, the reaction product
of the saccharide (multifunctional compound) and the
multifunctional alcohol, or the final vegetable oil based,
transesterified polyol produced according to the
transesterification process discussed above will further increase
the functionality of the polyol thereby formed.
[0031] When propoxylation or like reactions are done to the
vegetable oil or the transesterified polyol, an initiator/catalyst
is typically employed to start and, throughout the reaction, to
maintain the reaction of the propylene oxide and the vegetable oil
to the transesterified polyol. The resulting reaction is an
exothermic reaction. Initiators/catalysts that may be employed in
the propoxylation, ethyloxylation, or butyloxylation reaction
include triethylamine, trimethylamine, or other suitable amines as
well as potassium hydroxide or other suitable metal catalyst.
[0032] Significantly, while about 70% by weight of alkyloxides is
typically used to fully oxylate a petroleum based polyol, when
oxylation of crude, blown, or transesterified vegetable based
polyols is conducted, only about 5% to about 10% of the oxylation
compound is necessary. As a result, Applicants have found that, in
experimental amounts, the reaction is not nearly as exothermic as a
"typical" oxylation reaction using a petroleum based product. As a
result, Applicants believe this will be a significant safety
benefit when done at production scale. Applicants have suprisingly
found that adding heat to the oxylation reaction employing a
vegetable based polyol is preferred. On an industrial scale, this
may provide the additional benefit of regulating reaction time.
Obviously, since significantly less oxylation raw material is used
when oxylation is done to the vegetable based polyol of the present
invention, significant cost savings result as well. Additionally
and probably most significantly, oxylation of the vegetable based
polyols of the present invention, either blown or transesterified,
results in a vegetable oil based polyol with improved reactive and
chemical properties.
[0033] In practice, the alkyloxide or bio-based oxylation compound
and a suitable catalyst/initiator are added to a vegetable oil,
preferably a blown or transesterified vegetable oil and mixed. The
resultant mixture is then heated until the temperature reaches
about 100.degree. C. The temperature is held at about 100.degree.
C. for about one to about two hours. The mixture is then cooled to
ambient temperature while pulling a vacuum to remove any excess
alkyloxide or bio-based oxylation compound.
[0034] Moreover, it has been contemplated that the above described
transesterification process may be performed on crude or non-blown
vegetable (soy) oil prior to blowing the vegetable (soy) oil to
form a pre-transesterified vegetable (soy) oil. The
pre-transesterified vegetable (soy) oil may then be blown, as
known, to increase its functionality. Thereafter, the
transesterification process discussed above may optionally be
carried out again on the blown pre-transesterified vegetable (soy)
oil.
[0035] A transesterification catalyst such as tetra-2-ethylhexyl
titonate, which is marketed by DuPont.RTM. as Tyzor.RTM. TOT, may
be used, instead of or in addition to heat. Also, known acids and
other transesterification catalysts known to those of ordinary
skill may also be used.
[0036] The preparation of urethanes is well known in the art. They
are generally produced by the reaction of petrochemical polyols,
either polyester or polyether, with isocyanates. The flexibility or
rigidity of the foam is dependent on the molecular weight and
functionality of the polyol and isocyanate used.
[0037] Petrochemical polyol based polyurethanes can be prepared
when what is known in the art as an A-side reactant is combined
with what is known in the art as a B-side reactant. The A-side
reactant of the urethane of the invention comprises an isocyanate,
typically a diisocyanate such as: 4,4' diphenylmethane
diisocyanate; 2,4 diphenylmethane diisocyanate; and modified
diphenylmethane diisocyanate. Typically, a modified diphenylmethane
diisocyanate is used. Mondur MR Light.RTM., an aromatic polymeric
isocyanate based on diphenylmethane-diisocyanate, and Mondur.RTM.
MA-2903, a new generation MDI prepolymer, manufactured by
Bayer.RTM. Corporation, are two specific examples of possible
isocyanates that can be used. It should be understood that mixtures
of different isocyanates may also be used. The particular
isocyanate or isocyanate mixture used is not essential and can be
selected for any given purpose or for any reason as desired by one
of ordinary skill in the art.
[0038] The A-side of the reaction may also be a prepolymer
isocyanate. The prepolymer isocyanate is the reaction product of an
isocyanate, preferably a diisocyanate, and most preferably some
form of diphenylmethane diisocyanate (MDI) and a vegetable oil. The
vegetable oil can be any of the vegetables discussed previously or
any other oil having a suitable number of reactive hydroxyl (OH)
groups. Soy oil is particularly advantageous to use. To create the
prepolymer diisocyanate, the vegetable oil, the transesterified
vegetable oil or a mixture of vegetable oils and transesterified
vegetable oils are mixed and allowed to react until the reaction
has ended. There may be some unreacted isocyanate (NCO) groups in
the prepolymer. However, the total amount of active A-side material
has increased through this process. The prepolymer reaction reduces
the cost of the A-side component by decreasing the amount of
isocyanate required and utilizes a greater amount of inexpensive,
environmentally friendly vegetable (soy) oil. Alternatively, after
the A-side prepolymer is formed, additional isocyanates may be
added.
[0039] The B-side material is generally a solution of a petroleum
based polyester or polyether polyol, cross-linking agent, and
blowing agent. A catalyst is also generally added to the B-side to
control reaction speed and effect final product qualities. As
discussed infra, the use of a petrochemical such as, a polyester or
polyether polyol is undesirable for a number of reasons.
[0040] It has been discovered that urethane materials of high
quality can be prepared by substituting the petroleum based polyol
in the B-side preparation with the increased and selectable
functionality polyol produced by the transesterification process
outlined above. Using Applicants' method permits substantial
regulation of the functionality of the resulting polyol thereby
making the polyols produced by Applicants' new process more
desirable to the industry. Previously, the functionality of
vegetable oil based polyols varied dramatically due to, for
example, genetic or environmental reasons.
[0041] In addition to the increased and selectable functionality
polyol produced by the transesterification process outlined above,
the B-side of the urethane reaction may include a cross-linking
agent. Surprisingly, a cross-linking agent is not required when
using the new transesterified polyol to form a urethane product.
Typically, a blowing agent and a catalyst are also used in the
B-side of the reaction. These components are also optional, but are
typically used to form urethane product, especially foams.
[0042] A currently preferred blown soy oil typically has the
following composition; however, the amounts of each component vary
over a wide range. These values are not all inclusive. Amounts of
each components of the oil vary due to weather conditions, type of
seed, soil quality and various other environmental conditions:
1 100% Pure Soybean Oil Air Oxidized Moisture 1.15% Free Fatty Acid
1-6%, typically .apprxeq.3% Phosphorous 50-200 ppm Peroxide Value
50-290 Meq/Kg Iron .apprxeq.6.5 ppm (naturally occurring amount)
Hydroxyl Number 42-220 mg KOH/g Acid Value 5-13 mg KOH/g Sulfur
.apprxeq.200 ppm Tin <.5 ppm
[0043] Blown soy oil typically contains a hydroxyl value of about
100-180 and more typically about 160, while unblown soy oil
typically has a hydroxyl value of about 30-40. The infrared
spectrum scans of two samples of the type of blown soy oil used in
the present invention are shown in FIGS. 1 and 2. Blown soy oil and
transesterified soy oil produced according to the present invention
have been found to have a glass transition at about -137.degree. C.
to about -120.degree. C. depending on the saccharide component used
and whether one is used at all. The glass transition measures the
first signs of molecular movement in the polymer at certain
temperatures. The glass transition can be measured using a Dynamic
Mechanical Thermal (DMT) analysis machine. Rheometric Scientific is
one manufacturer of DMT machines useful with the present invention.
Applicants specifically utilize a DMTA5 machine from Rheometric
Scientific.
[0044] Applicants have also found that soybean oil and most other
vegetable oils have C.sub.3 and C.sub.4 acid groups, which cause
bitter smells when the vegetable polyols are reacted with
isocyanates. In order to remove these acid groups and the resultant
odor from the end use product, Applicants have also developed a way
to effectively neutralize these lowering acids with the
functionality of the polyol.
[0045] Applicants blow nitrogen (N.sub.2) through a solution of
about 10% ammonium hydroxide. Nitrogen gas was selected because it
does not react with the ammonium hydroxide. Any gas that does not
react with the ammonium hydroxide while still mixing the ammonium
hydroxide through the vegetable oil would be acceptable. The
ammonium hydroxide neutralizes acid groups that naturally occur in
the vegetable oil. The pH of transesterified, blown, and crude
vegetable oil typically falls within the range of from about
5.9-6.2. Vegetable oil neutralized by the above-identified process
has a typical pH range of from about 6.5 to about 7.2, but more
typically from about 6.7 to 6.9. The removal of these C.sub.3 and
C.sub.4 acid groups results in a substantial reduction in odor when
the neutralized polyols are used to form isocyanates.
[0046] Except for the use of the transesterified polyol replacing
the petroleum based polyol, the preferred B-side reactant used to
produce urethane foam is generally known in the art. Accordingly,
preferred blowing agents, which may be used for the invention, are
those that are likewise known in the art and may be chosen from the
group comprising 134A HCFC, a hydrochloroflurocarbon refrigerant
available from Dow Chemical Co. of Midland, MI; methyl isobutyl
ketone (MIBK); acetone; a hydroflurocarbon; cyclopentane; methylene
chloride; any hydrocarbon; and water or mixtures thereof.
Presently, a mixture of cyclopentane and water is preferred.
Another possible blowing agent is ethyl lactate, which is derived
from soybeans and is bio-based. At present, water is the preferred
blowing agent when a blowing agent is used. The blowing agents,
such as water, react with the isocyanate (NCO) groups, to produce a
gaseous product. The concentrations of other reactants may be
adjusted to accommodate the specific blowing agent used in the
reaction.
[0047] As discussed above, when blown soy oil is used to prepare
the transesterified polyol of the B-side, the chain extender
(cross-linking agent) may be removed from the B-side of the
urethane reactions and similar properties to urethane products
produced using soy oil according to the teachings of WO 00/15684
and U.S. Pat. No. 6,180,686, the disclosures of which are hereby
incorporated by reference, are achieved.
[0048] If cross-linking agents are used in the urethane products of
the present invention, they are also those that are well known in
the art. They must be at least di-functional (a diol). The
preferred cross-linking agents for the foam of the invention are
ethylene glycol; 1,4 butanediol; diethanol amines; ethanol amines;
tripropylene glycol, however, other diols and triols or greater
functional alcohols may be used. It has been found that a mixture
of tripropylene glycol; 1,4 butanediol; and diethanol amines are
particularly advantageous in the practice of the present invention.
Dipropylene glycol may also be used as a cross-linking agent.
Proper mixture of the cross-linking agents can create engineered
urethane products of almost any desired structural
characteristics.
[0049] In addition to the B-side's vegetable oil, the optional
blowing agent(s), and optional cross-linking agents, one or more
catalysts may be present. The preferred catalysts for the urethanes
of the present invention are those that are generally known in the
art and are most preferably tertiary amines chosen from the group
comprising DABCO 33-LV.RTM. comprised of 33% 1,4
diaza-bicyclco-octane (triethylenediamine) and 67% dipropylene
glycol, a gel catalyst available from the Air Products Corporation;
DABCO.RTM. BL-22 blowing catalyst available from the Air Products
Corporation; POLYCAT.RTM. 41 trimerization catalyst available from
the Air Products Corporation; Dibutyltin dilaurate; Dibutyltin
diacetate; stannous octane; Air Products' DBU.RTM. (1,8
Diazabicyclo [5.4.0] dibutyltin dilaurate); and Air Products'
DBU.RTM. (1,8 Diazabicyclo [5.4.0] dibutyltin diacetate). Other
amine catalysts, including any metal catalysts, may also be used
and are known by those of ordinary skill in the art.
[0050] Also as known in the art, when forming foam urethane
products, the B-side reactant may further comprise a silicone
surfactant which functions to influence liquid surface tension and
thereby influence the size of the bubbles formed and ultimately the
size of the hardened void cells in a final urethane foam product.
This can effect foam density and foam rebound (index of elasticity
of foam). Also, the surfactant may function as a cell-opening agent
to cause larger cells to be formed in the foam. This results in
uniform foam density, increased rebound, and a softer foam.
[0051] A molecular sieve may further be present to absorb excess
water from the reaction mixture. The preferred molecular sieve of
the present invention is available under the trade name
L-paste.TM..
[0052] The urethane materials (products) of the present invention
are produced by combining the A-side reactant with the B-side
reactant in the same manner as is generally known in the art.
Advantageously, use of the transesterified polyol to replace the
petroleum based polyol does not require significant changes in the
method of performing the reaction procedure. Upon combination of
the A and B side reactants, an exothermic reaction ensues that may
reach completion in anywhere from a few seconds (approximately 2-4)
to several hours or days depending on the particular reactants and
concentrations used. Typically, the reaction is carried out in a
mold or allowed to free rise. The components may be combined in
differing amounts to yield differing results, as will be shown in
the Examples presented below.
[0053] A petroleum based polyol such as polyether polyol (i.e.,
Bayer corporation's Multranol.RTM. 3901 polyether polyol and
Multranol.RTM. 9151 polyether polyol), polyester polyol, or
polyurea polyol may be substituted for some of the transesterified
polyol in the B-side of the reaction, however, this is not
necessary. This preferred B-side formulation is then combined with
the A-side to produce a urethane material. The preferred A-side, as
discussed previously, is comprised of methylenebisdiphenyl
diisocyanate (MDI) or a prepolymer comprised of MDI and a vegetable
oil, preferably soy oil or a prepolymer of MDI and the
transesterified polyol.
[0054] Flexible urethane foams may be produced with differing final
qualities by not only regulating the properties of the
transesterified polyol, but by using the same transesterified
polyol and varying the particular other reactants chosen. For
instance, it is expected that the use of relatively high molecular
weight and high functionality isocyanates will result in a less
flexible foam than will use of a lower molecular weight and lower
functionality isocyanate when used with the same transesterified
polyol. Likewise, as discussed earlier, the higher the
functionality of the polyol produced by the transesterification
process, the more rigid the foam produced using it will be.
Moreover, it has been contemplated that chain extenders may also be
employed in the present invention. For example, butanediol, in
addition to acting as a cross-linker, may act as a chain
extender.
[0055] Urethane elastomers can be produced in much the same manner
as urethane foams. It has been discovered that useful urethane
elastomers may be prepared using the transesterified polyol to
replace some of or all of the petroleum based polyester or the
polyether polyol. The preferred elastomer of the invention is
produced using diphenylmethane diisocyanate (MDI) and the
transesterified polyol. A catalyst may be added to the reaction
composition. The resulting elastomer has an approximate density of
about 52 lb. to about 75 lb. per cubic foot.
[0056] The following examples are the preparation of
transesterified polyol of the present invention, as well as foams
and elastomers of the invention formed using the transesterified
polyol. The examples will illustrate various embodiments of the
invention. The A-side material in the following examples is
comprised of modified diphenylmethane diisocyanate (MDI), unless
otherwise indicated; however, any isocyanate compound could be
used.
[0057] Also, "cure," if used in the following examples, refers to
the final, cured urethane product taken from the mold. The soy oil
used in the following examples is blown soy oil. Catalysts used
include "DABCO 33-LV.RTM.," comprised of 33%
1,4-diaza-bicyclo-octane and 67% dipropylene glycol available from
the Air Products Urethanes Division; "DABCO.RTM. BL-22," a tertiary
amine blowing catalyst also available from the Air Products
Urethanes Division; "POLYCAT.RTM. 41" (n, n', n",
dimethylamino-propyl-hexahydrotriazine tertiary amine) also
available from the Air Products Urethanes Division; dibutyltin
dilaurate (T-12); dibutyltin diacetate (T-1); and Air Products
DBU.RTM. (1,8 Diazabicyclo [5.4.0]). The structures of the Air
Products DBU.RTM.'s (1,8 Diazabicyclo [5.4.0]) used in the present
invention are shown in FIG. 4.
[0058] A blowing catalyst in the following examples effects the
timing of the activation of the blowing agent. Some of the examples
may include "L-paste.TM.," which is a trade name for a molecular
sieve for absorbing water. Some may also contain "DABCO.RTM.
DC-5160" or "Air Products DC193.RTM.", both are silicone
surfactants available from Air Products Urethane Division.
EXAMPLES
[0059] All percentages referred to in the following examples refer
to weight percent, unless otherwise noted.
Example 1
[0060]
2 Transesterification 2.5% Glycerin 5.0% Sorbitol 92.5% Polyurea
polyol and Blown soy oil mixture Elastomer Formation B-side: 97 g
Transesterified polyol formed above Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 3% Butanediol
(cross-linker) A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0061] The B-side was combined with the A-side in a ratio of 55
parts A-side to 100 parts B-side.
Example 2
[0062]
3 Transesterification 2.5% Glycerin 5.0% Sorbitol 92.5% Polyurea
polyol and Blown soy oil Elastomer Formation B-side: 97%
Transesterified polyol formed above Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 3% Dipropylene glycol
(chain extender) A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0063] The B-side was combined with the A-side in a ratio of 46
parts A-side to 100 parts B-side.
Example 3
[0064]
4 Transesterification 2.5% Glycerin 5.0% Sorbitol 92.5% Blown soy
oil Elastomer Formation B-side: 97% Transesterified polyol formed
above Air Products DBU .RTM. = urethane catalyst (1,8 Diazabicyclo
[5.4.0]) 3% Dipropylene glycol A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0065] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side.
Example 4
[0066]
5 Transesterification 5.0% Glycerin 10.0% Sorbitol 85.0% Blown soy
oil Elastomer Formation B-side: 97% Transesterified polyol formed
above Air Products DBU .RTM. = urethane catalyst (1,8 Diazabicyclo
[5.4.0]) 3% Dipropylene glycol A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0067] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side.
Example 5
[0068]
6 Transesterification 10.0% Glycerin 20.0% Sorbitol 70.0% Blown soy
oil Elastomer Formation B-side: Transesterified polyol formed above
Air Products DBU .RTM. = urethane catalyst (1,8 Diazabicyclo
[5.4.0]) 3.0 g Dipropylene glycol A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0069] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side.
Example 6
[0070]
7 Transesterification 12.0% Glycerin 24.0% Sorbitol 12.0% Polyurea
polyol 52.0% Blown soy oil Elastomer Formation B-side:
Transesterified polyol formed above Heat (190.degree. F.) was used
to catalyze the reaction Butanediol (cross-linker) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
Example 7
[0071]
8 Transesterification 5.0% Glycerin 10.0% Sorbitol 85% Polyurea
polyol and Blown soy oil mixture Elastomer Formation B-side: 40.0 g
Transesterified polyol formed above 0.3 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 10.0 g Polyether
polyol (Bayer Multranol .RTM. 9151) 3.0 g Dipropylene glycol
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0072] The B-side was combined with the A-side in a ratio of 38
parts A-side to 100 parts B-side.
Example 8
[0073]
9 Transesterification 5.0% Glycerin 10.0% Sorbitol 85% Polyurea
polyol and Blown soy oil mixture Elastomer Formation B-side: 30.0 g
Transesterified polyol formed above 20.0 g Polyether polyol (Bayer
Multranol .RTM. 9151) 3.0 g Air Products DBU .RTM. = urethane
catalyst (1,8 Diazabicyclo [5.4.0]) 3.0 g Dipropylene glycol
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0074] The B-side was combined with the A-side in a ratio of 31
parts A-side to 100 parts B-side.
Example 9
[0075]
10 Transesterification 5.0% Glycerin 10.0% Sorbitol 85.0% Blown soy
oil Elastomer Formation B-side: 50.0 g Transesterified polyol
formed above 0.4 g Air Products DBU .RTM. = urethane catalyst (1,8
Diazabicyclo [5.4.0]) 3.0 g Dipropylene glycol A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0076] The B-side was combined with the A-side in a ratio of 60
parts A-side to 100 parts B-side.
Example 10
[0077]
11 Transesterification 5.0% Glycerin 10.0% Sorbitol 5.0% Polyurea
polyol 80.0% Blown soy oil Elastomer Formation B-side: 40.0 g
Transesterified polyol formed above 0.4 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 2.4 g Dipropylene
glycol A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0078] The B-side was combined with the A-side in a ratio of 40
parts A-side to 100 parts B-side.
Example 11
[0079]
12 Transesterification 5.0% Glycerin 10.0% Sorbitol 5.0% Polyurea
polyol 80.0% Blown soy oil Elastomer Formation B-side: 40.0 g
Transesterified polyol formed above 0.4 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 2.4 g Dipropylene
glycol A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0080] The B-side was combined with the A-side in a ratio of 100
parts A-side to 100 parts B-side.
Example 12
[0081]
13 Transesterification 5.0% Glycerin 10.0% Sorbitol 12.0% Polyurea
polyol 73.0% Blown soy oil Elastomer Formation B-side: 50.0 g
Transesterified polyol formed above 0.4 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) 3.0 g Dipropylene
glycol A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0082] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side and cured at a temperature of
162.degree. F.
Example 13
[0083]
14 Transesterification 5.0% Glycerin 10.0% Sorbitol 85.0% Blown soy
oil Elastomer Formation B-side: 50.0 g Transesterified polyol
formed above 0.4 g Air Products DBU .RTM. = urethane catalyst (1,8
Diazabicyclo [5.4.0]) 3.0 g Dipropylene glycol A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0084] The B-side was combined with the A-side in a ratio of 80
parts A-side to 100 parts B-side and cured at a temperature of
166.degree. F.
Example 14
[0085]
15 Transesterification 5.0% Glycerin 10.0% Sorbitol 85.0% Blown soy
oil Elastomer Formation B-side: 50.0 g Transesterified polyol
formed above 0.4 g Dibutyltin diacetate (T-1) - catalyst 3.0 g
Dipropylene glycol A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0086] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side and cured at a temperature of
153.degree. F.
Example 15
[0087]
16 Transesterification 1.0% (6.66 g) Glycerin 3.0% (13.4 g)
Sorbitol 400.0 g Blown soy oil
[0088] This mixture was heated at 196.degree. F. for 1.5 hours.
Example 16
[0089] 20.0 g of Glycerin heated and stirred at 178.degree. F.
[0090] Introduced 40.0 g sorbitol slowly for about 4 minutes
[0091] Stayed milky until about 15 minute mark
[0092] At temperatures above 120.degree. F., the solution was very
fluid and clear. At temperatures under 120.degree. F., the solution
was clear; however, it was very viscous.
[0093] Added this mixture to 200.0 g of blown soy oil
[0094] 200.0 g of blown soy oil heated to 178.degree. F.
[0095] Introduced sorbitol, glycerin mixture as follows:
[0096] Added 10.0 g turned very cloudy within 30 seconds. Could not
see the bottom of the beaker
[0097] Still very cloudy after 5 minutes and added 10.0 g
[0098] Viscosity increased and had to reduce paddle speed after 10
minutes
[0099] Viscosity reduced somewhat after about 18 minutes
[0100] A further reduction in viscosity after about 21 minutes
[0101] This was mixed in a 500 ML beaker with a magnetic paddle.
The scientists were not able to see through the beaker. After about
21 minutes, a vortex appended in the surface indicating a further
reduction in viscosity. At this time, the mixture lightened by a
visible amount. Maintained heat and removed.
[0102] Reacted the new polyol with Modified Monomeric MDI,
NCO-19.
17 New Polyol 100% DBU 0.03% MDI 50 p to 100 p of about Polyol
Reaction: Cream time about 30 seconds Tack free in about 45 seconds
Good physical properties after about 2 minutes
[0103] The reaction looked good, the material showed no signs of
blow and seemed to be a good elastomer. It does however exhibit
some signs of too much crosslinking and did not have the amount of
elongation that would be optimal.
[0104] A comparative reaction run along side with the unmodified
blown soy oil was not tack free at 24 hours.
Example 17
[0105]
18 Transesterification 1.0% Glycerin 3.0% Sorbitol 96.0% Blown soy
oil Elastomer Formation B-side: 50.0 g Transesterified polyol
formed as in Example 15 0.5 g Dibutyltin diacetate (T1) - catalyst
3.0 g Dipropylene glycol A-side: Modified monomeric MDI (Mondur
.RTM. MA-2903)
[0106] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side and cured at a temperature of
154.degree. F. for 4 minutes.
Example 18
[0107]
19 hz,1/32 B-side: 50.0 g Transesterified polyol formed from 20 g
Dipropylene Glycol, 5 g Glycerin, and 20 g sorbitol blended with
200 g blown soy oil 0.3 g Air Products DBU .RTM. = urethane
catalyst (1,8 Diazabicyclo [5.4.0]) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0108] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side.
Example 19
[0109]
20 Transesterification 750 g Blown soy oil 150 g Glycerin 75 g Cane
sugar
Example 20
[0110]
21 B-side: 40.0 g Transesterified polyol formed as in Example 19
10.0 g Polyether polyol (Bayer Multranol .RTM. 9151) 1.5 g
Dipropylene Glycol 1.5 g Butanediol 0.6 g Dibutyltin diacetate
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0111] The B-side was combined with the A-side in a ratio of 57
parts A-side to 100 parts B-side and was set up on 20 seconds.
Example 21
[0112]
22 B-side: 50.0 g Transesterified polyol formed as in Example 19
10.0 g Polyether polyol (Bayer Multranol .RTM. 9151) 1.5 g
Dipropylene Glycol 1.5 g Butanediol 0.6 g Dibutyltin diacetate (T1)
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0113] The B-side was combined with the A-side in a ratio of 71
parts A-side to 100 parts B-side.
Example 22
[0114]
23 B-side: 40.0 g Transesterified polyol formed as in Example 19
10.0 g Polyether polyol (Bayer Multranol .RTM. 9151) 1.5 g
Dipropylene Glycol 1.5 g Butanediol 0.6 g Dibutyltin diacetate (T1)
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0115] The B-side was combined with the A-side in a ratio of 45
parts A-side to 100 parts B-side.
Example 23
[0116]
24 B-side: 100.0 g Transesterified polyol formed as in Example 19
20.0 g Polyether polyol (Bayer Multranol .RTM. 9151) 3.0 g
Dipropylene Glycol 3.0 g Butanediol 0.7 g Dibutyltin diacetate (T1)
228.6 calcium carbonate filler A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0117] The B-side was combined with the A-side in a ratio of 25
parts A-side to 100 parts B-side.
Example 24
[0118]
25 B-side: 20.0 g Transesterified polyol formed as in Example 19
5.0 g Transesterification from Example 25 0.6 g Dipropylene Glycol
0.7 g Air Products DBU .RTM. = urethane catalyst (1,8 Diazabicyclo
[5.4.0]) A-side: Modified monomeric MDI (Mondur .RTM. MA-2903).
[0119] The B-side was combined with the A-side in a ratio of 57
parts A-side to 100 parts B-side and was set up on 20 seconds.
Example 25
[0120]
26 Transesterification 100 g Blown soy oil 27 g 63% glycerin and
37% cane sugar reaction product mixture
[0121] The above was heated at a temperature of 230.degree. F. and
mixed for 15 minutes.
Example 26
[0122]
27 Transesterification 100.0 g Blown soy oil 13.5 g 63% glycerin
and 37% cane sugar reaction product mixture
[0123] The above was heated at a temperature of 220.degree. F.
Example 27
[0124]
28 Transesterification 400 g Blown soy oil 12 g 33% Glycerin and
66% Sorbitol
[0125] The glycerin and sorbitol product was preheated to
195.degree. F. The total mixture was heated for 15 minutes at
202.degree. F.
Example 28
[0126]
29 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol 0.5 g Dibutyltin diacetate (T1) - catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0127] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 134.degree. F.
for 4 minutes.
Example 29
[0128]
30 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol 0.8 g Dibutyltin diacetate (T1) - catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0129] The B-side was combined with the A-side in a ratio of 67
parts A-side to 100 parts B-side.
Example 30
[0130]
31 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol 1.5 g Water 0.8 g Dibutyltin diacetate
(T1)--catalyst A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0131] The B-side was combined with the A-side in a ratio of 90
parts A-side to 100 parts B-side.
Example 31
[0132]
32 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol l.5 g Water 0.8 g Dibutyltin diacetate
(T1)--catalyst 0.2 g Silicon surfactant (Air Products .RTM. DC193)
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0133] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side.
Example 32
[0134]
33 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol 1.5 g Water 0.6 g Dibutyltin diacetate
(T1)--catalyst 0.3 g Tertiary block amine catalyst A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0135] The B-side was combined with the A-side in a ratio of 74
parts A-side to 100 parts B-side.
Example 33
[0136]
34 B-side: 50.0 g Transesterified polyol formed as in Example 27
3.0 g Dipropylene glycol 1.5 g Water 0.2 g Silicon surfactant (Air
Products .RTM. DC 193) 1.1 g Dibutyltin diacetate (T1)--catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0137] The B-side was combined with the A-side in a ratio of 55
parts A-side to 100 parts B-side.
Example 34
[0138]
35 Transesterification: 50.0 g Blown soy oil 6.0 g 33% Glycerin and
66% Sorbitol reaction product mixture
Example 35
[0139]
36 B-side: 50.0 g Transesterified polyol formed as in Example 34
3.0 g Dipropylene glycol 0.6 g Dibutyltin diacetate (T1)--catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0140] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 148.degree. F.
for 3 minutes.
Example 36
[0141]
37 Transesterification 20.0 g Glycerin 40.0 g Brown cane sugar
[0142] The above was heated at a temperature of 250.degree. F. and
mixed. 30 g of wet mass was recovered in a filter and removed.
Example 37
[0143]
38 B-side: 50.0 g Transesterified polyol formed as in Example 36
3.0 g Dipropylene glycol 1.0 g Dibutyltin diacetate (T1)--catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0144] The B-side was combined with the A-side in a ratio of 67
parts A-side to 100 parts B-side at a temperature of 171.degree. F.
for one minute.
Example 38
[0145]
39 B-side: 50.0 g Transesterified poiyoi formed as in Example 36
3.0 g Dipropylene glycol 1.0 g Dibutyltin diacetate (T1)--catalyst
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0146] The B-side was combined with the A-side in a ratio of 67
parts A-side to 100 parts B-side at a temperature of 146.degree. F.
for 1.5 minutes.
Example 39
[0147]
40 B-side: 50.0 g Transesterified polyol formed as in Example 36
3.0 g Dipropylene glycol 0.5 g Dibutyltin diacetate (T1)--catalyst
A-side: Mondur .RTM. MR light
[0148] The B-side was combined with the A-side in a ratio of 20
parts A-side to 100 parts B-side at a temperature of 141.degree. F.
for 2 minutes.
Example 40
[0149]
41 B-side: 50.0 g Transesterified polyol formed as in Example 36
3.0 g Dipropylene glycol 1.0 g Dibutyltin diacetate (T1) - catalyst
A-side: Mondur .RTM. MR light
[0150] The B-side was combined with the A-side in a 1:1 ratio
A-side to B-side at a temperature of 152.degree. F. and for 1
minute.
Example 41
[0151]
42 Transesterification 350.0 g Blown soy oil 60.0 g Glycerin 35.0 g
White cane sugar
[0152] The above was heated at a temperature of 240.degree. F.
Example 42
[0153]
43 B-side: 50.0 g Transesterified polyol formed as in Example 41
(preheated to 101.degree. F.) 3.0 g Dipropylene glycol 1.0 g
Dibutyltin diacetate (T1) - catalyst A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0154] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 193.degree. F.
for 30 seconds.
Example 43
[0155]
44 B-side: 50.0 g Transesterified polyol formed as in Example 42
(preheated to 101.degree. F.) 3.0 g Dipropylene glycol 0.8 g
Dibutyltin diacetate (T1) - catalyst A-side: Mondur .RTM. MR
light
[0156] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side and reached a temperature of
227.degree. F. for 20 seconds.
Example 44
[0157]
45 Transesterification 35.9 g Glycerin 6.9 g Cane sugar 20.0 g
Trimethylolpropane (preheated to 190.degree. F.)
[0158] 30 g of the above mixture was combined with 300 g of blown
soy oil.
Example 45
[0159]
46 Step 1 Heated 60 g trimethylolpropane (melting point of about
58.degree. C., about 136.4.degree. F.) to liquid Step 2 Heated 30 g
water and added 30 g cane sugar Step 3 Added 60 g water and cane
sugar to 60 g trimethylolpropane and slowly raised the heat over 3
hours to 290.degree. F.. This drove off the water.
Example 46
[0160]
47 B-side: 20.0 g Transesterified polyol formed as in Example 44
0.5 g Dibutyltin diacetate (T1) - catalyst A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0161] The B-side was combined with the A-side in a ratio of 40
parts A-side to 100 parts B-side.
Example 47
[0162]
48 Transesterification 1000 g Glycerin 500 g Cane sugar
[0163] The above was mixed at a temperature of 230.degree. F. for
20 minutes.
Example 48
[0164]
49 Transesterification: 22.3 g Reaction product formed as in
Example 47 100.0 g Blown soy oil
[0165] The above mixture was heated at a temperature of 227.degree.
F. for 20 minutes.
Example 49
[0166]
50 50 g Water 50 g Cane sugar
[0167] The above was mixed and heated at a temperature of
85.degree. F. for 20 minutes.
Example 50
[0168]
51 Transesterification 20 g Reaction mixture formed as in Example
53 100 g Blown soy oil
[0169] The above was heated at a temperature of 185.degree. F. for
20 minutes, then heated to a temperature of 250.degree. F. for 80
minutes.
Example 51
[0170]
52 B-side: 20.0 g Transesterified poiyol formed as in Example 50
0.4 g Dibutyltin diacetate (T1)--catalyst A-side: Mondur .RTM. MR
light
[0171] The B-side was combined with the A-side in a ratio of 56
parts A-side to 100 parts B-side.
Example 52
[0172]
53 B-side: 20.0 g Transesterified polyol formed as in Example 50
0.8 g Dibutyltin diacetate (T1)--catalyst A-side: Mondur .RTM. MR
light
[0173] The B-side was combined with the A-side in a ratio of 54
parts A-side to 100 parts B-side.
Example 53
[0174]
54 Transesterification 3200 g Blown soy oil (5 % sugar by volume)
48 g 67% Glycerin and 37% Cane sugar mixture
Example 54
[0175]
55 B-side: 60.0 parts by weight Transesterified polyol formed as in
Example 19 40.0 parts by weight Polyether Polyol (Bayer .RTM.
Multranol .RTM. 3901) 5.0 parts by weight Dipropylene Glycol 2.0
parts by weight Dibutyltin diacetate (T1)--catalyst 2.1 parts by
weight Water 109.0 parts by weight Calcium Carbonate (filler)
A-side: Mondur .RTM. MR light
[0176] The B-side was combined with the A-side in a ratio of 56
parts A-side to 100 parts B-side.
Example 55
[0177]
56 B-side: 50.0 g Transesterified poiyol formed as in Example 19
3.0 g Dipropylene glycol 1.0 g Water 0.8 g Dibutyltin diacetate
(T1)--catalyst 54.7 g Calcium Carbonate (filler) A-side: Bayer
Corporation's Mondur .RTM. MA-2901 (Isocyanate)
[0178] The B-side was combined with the A-side in a ratio of 40
parts A-side to 100 parts B-side.
Example 56
[0179]
57 B-side: 40.0 g Transesterified polyol formed as in Example 53
10.0 g Polyether polyol 1.5 g Dipropylene glycol 1.5 g Butanediol
1.0 g Water 55 g Calcium Carbonate (filler) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
Example 57
[0180]
58 Transesterification 70.0 g Trimethylolpropane 33.0 g
Pentaethertrol 60.0 g Sugar
[0181] The above was heated to a temperature of 237.degree. F. and
added 15.0 g of this reaction product to 100.0 g of blown soil
oil.
Example 58
[0182]
59 B-side: 50.0 g Transesterified polyol formed as in Example 53
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0183] The B-side was combined with the A-side in a ratio of 41
parts A-side to 100 parts B-side at a temperature of 151.degree. F.
for 1 minute.
Example 59
[0184]
60 B-side: 50.0 g Transesterified polyol formed as in Example 53
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0185] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 177.degree. F.
for 1 minute.
Example 60
[0186]
61 B-side: 50.0 g Transesterified polyol formed as in Example 53
3.0 g Dipropylene glycol 3.0 g Dibutyltin diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0187] The B-side was combined with the A-side in a ratio of 45
parts A-side to 100 parts B-side at a temperature of 165.degree. F.
for 10 seconds.
Example 61
[0188]
62 Transesterification 200 g Blown soy oil 20 g
Trimethylolpropane
[0189] The above was heated to a temperature of 220.degree. F. for
30 minutes.
Example 62
[0190]
63 B-side: 50.0 g Transesterified polyol formed as in Example 61
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0191] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 168.degree. F.
for 35 seconds.
Example 63
[0192]
64 Transesterification: 200 g Blown soy oil 20 g
Trimethylolpropane
[0193] The above was heated at a temperature of 325.degree. F. for
1 hour. The trimethylolpropane did not dissolve completely.
Example 64
[0194]
65 B-side: 50.0 g Transesterified polyol formed as in Example 63
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0195] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 151.degree. F.
for 1 minute.
Example 65
[0196]
66 Transesterification 100.0 g Blown soy oil 5.9 g
Trimethylolpropane
[0197] The above was heated at a temperature of 235.degree. F.
Example 66
[0198]
67 B-side: 50.0 g Transesterified polyol formed as in Example 65
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0199] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 162.degree. F.
for 1 minute.
Example 67
[0200]
68 B-side: 50.0 g Transesterified polyol formed as in Example 65
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0201] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 166.degree. F.
for 1 minute.
Example 68
[0202]
69 Transesterification 2000 g Blown soy oil 100 g
Trimethylolpropane
[0203] The above was heated at a temperature of 200.degree. F. for
2 hours.
Example 69
[0204]
70 B-side: 50.0 g Transesterified polyol formed as in Example 68
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0205] The above was heated at a temperature of 166.degree. F. for
1 minute.
Example 70
[0206]
71 B-side: 50.0 g Transesterified polyol formed as in Example 68
4.0 g Dipropylene Glycol 1.4 g Dibutyltin Diacetate (T1) 1.3 g
Water A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
Example 71
[0207]
72 B-side: 50.0 g Transesterified polyol formed as in Example 68
3.0 g Dipropylene Glycol 1.0 g Dibutyltin Diacetate (T1) A-side:
Modified monomeric MDI (Mondur .RTM. MA-2903)
[0208] The B-side was combined with the A-side in a ratio of 61
parts A-side to 100 parts B-side at a temperature of 172.degree. F.
for 1 minute.
Example 72
[0209]
73 B-side: 50.0 g Transesterified polyol formed as in Example 68
2.0 g Dibutyltin diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0210] The above was heated at a temperature of 135.degree. F.
Example 73
[0211]
74 Transesterification 200.0 g Blown soy oil 4.0 g
Trimethylolpropane
[0212] The above was heated at a temperature of 205.degree. F.
Example 74
[0213]
75 B-side: 50.0 g Transesterified polyol formed as in Example 73
2.0 g Dibutyltin diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0214] The B-side was combined with the A-side in a ratio of 45
parts A-side to 100 parts B-side at a temperature of 126.degree.
F.
Example 75
[0215]
76 Transesterification 400 g Blown soy oil 62 g 66.7% Glycerin and
33.3% cane sugar mixture
[0216] The above mixture was heated at an average temperature of
205.degree. F.
Example 76
[0217]
77 B-side: 40.0 g Transesterified polyol formed as in Example 53
1.5 g Dipropylene Glycol 1.5 g Butanediol 0.4 g Dibutyltin
Diacetate (T1) 10.0 g Polyether Polyol (Bayer Multranol .RTM. 3901)
.RTM. 3901 A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0218] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 77
[0219]
78 B-side: 40.0 g Transesterified polyol formed as in Example 53
1.5 g Dipropylene Glycol 1.5 g Butanediol 0.4 g Dibutyltin
Diacetate (T1) 10.0 g Polyether Polyol (Bayer Multranol .RTM. 9151)
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0220] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 78
[0221]
79 B-side: 40.0 g Transesterified polyol formed as in Example 75
1.5 g Dipropylene Glycol 1.5 g Butanediol 0.4 g Dibutyltin
Diacetate (T1) A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0222] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side.
Example 79
[0223]
80 B-side: 20.0 g Transesterified polyol formed as in Example 75
0.4 g Dibutyltin Diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0224] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side.
Example 80
[0225]
81 B-side: 100.0 g Transesterified polyol formed as in Example 75
2.9 g Dibutyltin Diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0226] The B-side was combined with the A-side in a ratio of 44
parts A-side to 100 parts B-side.
Example 81
[0227]
82 Transesterification 350 g Blown soy oil 52 g 66.7% Glycerin and
33.3% cane sugar mixture
[0228] The above was heated at a temperature of 194.degree. F. for
4 hours.
Example 82
[0229]
83 B-side: 40.0 g Transesterified polyol formed as in Example 53
1.5 g Dipropylene Glycol 1.5 g Butanediol 0.3 g Dibutyltin
Diacetate (T1) 10.0 g Polyether Polyol (Bayer .RTM. Multranol .RTM.
3901) 97.0 g Calcium Carbonate (filler) A-side: Modified monomeric
MDI (Mondur .RTM. MA-2903)
[0230] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 83
[0231]
84 B-side: 20.0 g Transesterified polyol formed as in Example 53
1.5 g Dipropylene Glycol 1.5 g Butanediol 0.4 g Dibutyltin
Diacetate (T1) 0.4 g Dibutyltin Dilaurate (T12) 8.0 g Polyether
Polyol (Bayer .RTM. Multranol .RTM. 3901) A-side: Mondur .RTM. MR
Light
[0232] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 84
[0233]
85 Transesterification 400.0 g Blown soy oil 6.0 g Vinegar (to add
acidic proton); hydrogen chloride may also be added 60.0 g 66.7%
Glycerin and 33.3% Cane sugar mixture
[0234] The above was heated at a temperature of 210.degree. F. for
1 hour.
Example 85
[0235]
86 B-side: 40.0 g Transesterified polyol formed as in Example 84
0.8 g Dibutyltin Diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0236] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side.
Example 86
[0237]
87 B-side: 40.0 g Transesterified polyol formed as in Example 84
0.8 g Dibutyltin Diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0238] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 87
[0239]
88 Transesterification First step: 80.0 g 66.7% Glycerin and 33.3%
Cane sugar 0.8 g Vinegar
[0240] The above was heated at a temperature of 260.degree. F. for
30 minutes.
[0241] Second step:
[0242] 60 g of the above reaction product was reacted with 400 g
blown soy oil and mixed for 30 minutes.
Example 88
[0243]
89 B-side: 50.0 g Transesterified polyol formed as in Example 87
1.0 g Dibutyltin diacetate (T1) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0244] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side.
Example 89
[0245]
90 B-side: 20.0 g Transesterified polyol formed as in Example 87
0.5 g Dibutyltin diacetate (T1) 20.0 g Bayer .RTM. Multranol .RTM.
A-side: Mondur .RTM. MR Light
[0246] The B-side was combined with the A-side in a ratio of 92
parts A-side to 100 parts B-side at a temperature of 240.degree. F.
for 20 seconds.
Example 90
[0247]
91 B-side: 50.0 g Blown soy oil 1.7 g Dibutyltin diacetate (T1)
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0248] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side.
Example 91
[0249]
92 Transesterification 50.0 g Blown soy oil 100.0 g Bayer .RTM.
Multranol .RTM. 9185
[0250] The above was heated to a temperature of 100.degree. F. for
5 hours.
Example 92
[0251]
93 B-side: 50.0 g Transesterified polyol formed as in Example 91
0.7 g Dibutyltin diacetate (T1) A-side: Mondur .RTM. MR Light
[0252] The B-side was combined with the A-side in a ratio of 56
parts A-side to 100 parts B-side.
Example 93
[0253]
94 Transesterification 80.0 g Blown soy oil 20.0 g Polyether Polyol
Bayer .RTM. Multranol .RTM. 3901
[0254] The above was heated to a temperature of 100.degree. C.
Example 94
[0255]
95 B-side: 50.0 g Blown soy oil 0.8 g Dibutyltin Dilaurate (T12)
5.0 g Butanediol A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0256] The B-side was combined with the A-side in a ratio of 64
parts A-side to 100 parts B-side at a temperature of 167.degree. F.
for 90 seconds.
Example 95
[0257]
96 B-side: 50.0 g Blown soy oil 15.0 g Butanediol 0.8 g Dibutyltin
Dilaurate (T12) A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0258] The B-side was combined with the A-side in a ratio of 131
parts A-side to 100 parts B-side at a temperature of 224.degree. F.
for 20 seconds.
Example 96
[0259]
97 2000 g Transesterified polyol formed as in Example 80 6 g
Dipropylene glycol 6 g Butanediol 40 g Polyether Polyol (Bayer
.RTM. Multranol .RTM. 3901)
Example 97
[0260]
98 B-side: 50.0 g Transesterified prepolymer polyol formed as in
Example 96 0.3 g Dibutyltin Dilaurate (T12) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0261] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side for 120 seconds.
Example 98
[0262]
99 B-side: 50.0 g Transesterified prepolymer polyol formed as in
Example 96 0.2 g Dibutyltin Dilaurate (T12) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0263] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side for 160 seconds.
Example 99
[0264]
100 B-side: 50.0 g Transesterified prepolymer polyol formed as in
Example 96 0.4 g Dibutyltin Dilaurate (T12) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0265] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side for 80 seconds.
Example 100
[0266]
101 B-side: 40.0 g Transesterified prepolymer polyol formed as in
Example 96 0.2 g Dibutyltin Dilaurate (T12) A-side: Mondur .RTM. MR
Light mixed with 15% blown soy oil for 120 seconds.
[0267] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 101
[0268]
102 Transesterification 400 g Blown soy oil 60 g 66.7% Glycerin and
33% Cane sugar mixture
[0269] The above was heated at a temperature of 198.degree. F. for
5 hours.
Example 102
[0270]
103 B-side: 50.0 g Transesterified polyol formed as in Example 101
0.8 g Dibutyltin Dilaurate (T12) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0271] The B-side was combined with the A-side in a ratio of 42
parts A-side to 100 parts B-side at a temperature of 149.degree. F.
for 260 seconds.
Example 103
[0272]
104 B-side: 40.0 g Transesterified polyol formed as in Example 81
0.9 g Dibutyltin Dilaurate (T12) 10.0 g Bayer .RTM. Multranol .RTM.
A-side: Mondur .RTM. MR Light
[0273] The B-side was combined with the A-side in a ratio of 56
parts A-side to 100 parts B-side at a temperature of 189.degree. F.
for 190 seconds.
Example 104
[0274]
105 B-side: 40.0 g Transesterified polyol formed as in Example 81
3.0 g Butanediol 0.9 g Dibutyltin Dilaurate (T12) 10.0 g Bayer
.RTM. Multranol .RTM. A-side: Mondur .RTM. MR Light
[0275] The above was heated at a temperature of 220.degree. F. for
116 seconds.
Example 105
[0276]
106 Transesterification 400 g Blown soy oil 60 g 66.7% Glycerin and
33.3% Cane Sugar
Example 106
[0277]
107 B-side: 50.0 g Transesterified polyol formed as in Example 81
0.8 g Dibutyltin Dilaurate (T12) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0278] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 107
[0279]
108 B-side: 50.0 g Transesterified polyol formed as in Example 101
0.9 g Dibutyltin Dilaurate (T12) A-side: Modified monomeric MDI
(Mondur .RTM. MA-2903)
[0280] The B-side was combined with the A-side in a ratio of 14
parts A-side to 100 parts B-side.
Example 108
[0281]
109 Transesterification 200.0 g Blown soy oil 14.3 g Honey
[0282] The above was heated at a temperature of 200.degree. F. for
3 hours.
Example 109
[0283]
110 B-side: 50.0 g Transesterified polyol formed as in Example 81
0.1 g Dibutyltin Dilaurate (T12) 10.0 g Polyether Polyol (Bayer
.RTM. Multranol .RTM. 3901) 1.5 g Dipropylene glycol 1.5 g
Butanediol A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0284] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 110
[0285]
111 B-side: 40.0 g Transesterified polyol formed as in Example 81
0.2 g Dibutyltin Dilaurate (T12) 10.0 g Polyether Polyol (Bayer
.RTM. Multranol .RTM. 3901) 1.5 g Dipropylene glycol 1.5 g
Butanediol 0.2 g Air Products DBU .RTM. = urethane catalyst (1,8
Diazabicyclo [5.4.0]) A-side: Modified monomeric MDI (Mondur .RTM.
MA-2903)
[0286] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 111
[0287]
112 B-side: 80.0 g Transesterified polyol formed as in Example 81
20.0 g Polyether Polyol (Bayer .RTM. Multranol .RTM. 3901) 3.0 g
Dipropylene glycol 3.0 g Butanediol 0.4 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0288] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 112
[0289]
113 B-side: 80.0 g Transesterified polyol formed as in Example 81
20.0 g Polyether Polyol (Bayer .RTM. Multranol .RTM. 3901) 3.0 g
Dipropylene glycol 3.0 g Butanediol 0.6 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) A-side: Modified
monomeric MDI (Mondur .RTM. MA-2903)
[0290] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 113
[0291]
114 B-side: 50.0 g Transesterified polyol formed as in Example 81
0.8 g Dibutyltin Dilaurate (T12) 10.0 g Polyether Polyol (Bayer
.RTM. Multranol .RTM. 3901) 62.0 g Calcium Carbonate filler A-side:
Mondur .RTM. MR Light
[0292] The B-side was combined with the A-side in a ratio of 56
parts A-side to 100 parts B-side.
Example 114
[0293]
115 B-side: 50.0 g Transesterified polyol formed as in Example 81
0.2 g Dibutyltin Dilaurate (T12) 0.2 g Air Products DBU .RTM. =
urethane catalyst (1,8 Diazabicyclo [5.4.0]) A-side: 20% Modified
monomeric MDI (Mondur .RTM. MA-2903) 80% Mondur .RTM. MR Light
[0294] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 115
[0295]
116 Transesterification 389.0 g Blown soy oil 13.0 g Dipropylene
glycol 31.6 g Polyether Polyol (Bayer .RTM. Multranol .RTM. 3901)
381.5 g Dibutyltin Dilaurate (T12)
Example 116
[0296]
117 B-side: 40.0 g Transesterified polyol formed as in Example 81
10.0 g Polyether Polyol (Bayer .RTM. Multranol .RTM. 9196) 0.4 g
Dibutyltin Dilaurate (T12) A-side: 20.0 g Modified monomeric MDI
(Mondur .RTM. MA-2903) 80.0 g Mondur .RTM. MR Light
[0297] The B-side was combined with the A-side in a ratio of 82
parts A-side to 100 parts B-side.
Example 117
[0298]
118 B-side: 40.0 g Transesterified polyol formed as in Example 101
0.1 g Dibutyltin Dilaurate (T12) 1.5 g Dipropylene glycol 10.0 g
Polyether Polyol (Bayer .RTM. Multranol .RTM. 3901) 0.4 g Air
Products DBU .RTM. = urethane catalyst (1,8 Diazabicyclo [5.4.0])
A-side: Modified monomeric MDI (Mondur .RTM. MA-2903)
[0299] The B-side was combined with the A-side in a ratio of 72
parts A-side to 100 parts B-side.
Example 118
[0300]
119 B-side: 50.0 g Transesterified polyol formed as in Example 81
0.5 g Dibutyltin Dilaurate (T12) 2.0 g Butanediol 20.0 g Polyether
Polyol (Bayer .RTM. Multranol .RTM. 9196) A-side: 20% Modified
monomeric MDI (Mondur .RTM. MA-2903) 80% Mondur .RTM. MR Light
[0301] The B-side was combined with the A-side in a ratio of 88
parts A-side to 100 parts B-side.
Example 119
[0302]
120 B-side: 50.0 g Transesterified polyol formed as in Example 81
20.0 g Polyether Polyol (Bayer .RTM. Multranol .RTM. 9196) 0.5 g
Dibutyltin Dilaurate (T12) 2.0 g Dipropylene Glycol A-side: 20 g
Modified monomeric MDI (Mondur .RTM. MA-2903) 80 g Mondur .RTM. MR
Light
Example 120
Water Blown TDI Seating-type Foam
[0303]
121 B-side: 50.0 g Transesterified blown soy oil 50.0 g
Conventional polyol (3 Functional, 28 OH, 6000 Molecular weight,
1100 viscosity) 0.8 g Non-acid blocked Dibutyltin dilaurate
catalyst 0.8 g Flexible blowing catalyst (Bis(N,N,
dimethylaminoethyl)ether), 1.0 g Flexible foam silicon surfactant
1.0 g Water A-side: 2,4-Toluene Diisocyanate (TDI)
[0304] The B-side was combined with the A-side in a ratio of 40
parts A-side to 100 parts B-side.
Example 121
Hydrocarbon Blown TDI Seating-type Foam
[0305]
122 B-side: 50.0 g Transesterified blown soy oil 50.0 g
Conventional polyol (3 Functional, 28 OH, 6000 Molecular weight,
1100 viscosity) 0.8 g Non-acid blocked Dibutyltin Dilaurate
catalyst 0.8 g Flexible blowing catalyst
(Bis(N,N,dimethylaminoethyl)ether) 1.0 g Flexible foam silicone
surfactant 4.0 g Cyclopentane, or other suitable blowing agents
A-side: 2,4-Toluene Diisocyanate (TDI)
[0306] The B-side was combined with the A-side in a ratio of 40
parts A-side to 100 parts B-side.
Example 122
Water Blown MDI Seating-type Foam
[0307]
123 B-side: 100.0 g Transesterified blown soy oil 1.0 g Flexible
foam surfactant 1.6 g Non-acid blocked Dibutyltin Dilaurate
catalyst 3.0 g Water A-side: 100% Isocyanate terminated PPG
(polypropylene ether glycol) Prepolymer (19% NCO, 400 Viscosity,
221 Equivalent weight, 2 Functional)
[0308] The B-side was combined with the A-side in a ratio of 65
parts A-side to 100 parts B-side.
Example 123
Hydrocarbon Blown MDI Seating-type Foam
[0309]
124 B-side: 100.0 g Transesterified blown soy oil 1.0 g Flexible
foam surfactant 1.6 g Non-acid blocked Dibutyltin Dilaurate
catalyst 6.0 g Cyclopentane, or other suitable blowing agent
A-side: 100% Isocyanate terminated PPG (polypropylene ether glycol)
Prepolymer (19% NCO, 400 Viscosity, 221 Equivalent weight, 2
Functional)
[0310] The B-side was combined with the A-side in a ratio of 65
parts A-side to 100 parts B-side.
Example 124
Water Blown Higher Rebound MDI Searing-type Foam
[0311]
125 B-side: 50.0 g Transesterified blown soy oil 50.0 g
Conventional polyol (3-functional, 28 OH, 6000 molecular weight,
1100 viscosity) 1.0 g Flexible foam surfactant 0.3 g Non-acid
blocked Dibutyltin Dilaurate catalyst 0.4 g Non-acid blocked
Alkyltin mercaptide catalyst 3.0 g Water A-side: 100% Isocyanate
terminated PPG (polypropylene ether glycol) Prepolymer (19% NCO,
400 Viscosity, 221 Equivalent weight, 2 Functional)
[0312] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 125
Hydrocarbon Blown Higher Rebound MDI Searing-type Foam
[0313]
126 B-side: 50.0 g Transesterified blown soy oil 50.0 g
Conventional polyol (3 Functional, 28 OH, 6000 Molecular weight,
1100 Viscosity) 1.0 g Flexible foam surfactant 0.3 g Non-acid
blocked Dibutyltin Dilaurate catalyst 0.4 g Non-acid blocked
Alkyltin mercaptide catalyst 6.0 g Cyclopentane, or other suitable
blowing agents A-side: 100% Isocyanate terminated PPG
(polypropylene ether glycol) Prepolymer (19% NCO, 400 Viscosity,
221 Equivalent weight, 2 Functional)
[0314] The B-side was combined with the A-side in a ratio of 62
parts A-side to 100 parts B-side.
Example 126
Water Blown Lightweight Rigid Urethane Material
[0315]
127 B-side: 50.0 g Transesterified blown soy oil 1.2 g Non-acid
blocked Dibutyltin Dilaurate catalyst 1.0 g Water A-side: 100%
Polymeric MDI (Methylenebisdipenyl diisocyanate) (31.9% NCO, 200
Viscosity, 132 Equivalent weight, 2.8 Functional)
[0316] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 127
Hydrocarbon Blown Lightweight Rigid Urethane Material
[0317]
128 B-side: 100.0 g Transesterified blown soy oil 1.2 g Non-acid
blocked Dibutyltin Dilaurate catalyst 3.0 g Cyclopentane, or other
suitable blowing agents A-side: 100% Polymeric MDI
(Methylenebisdipenyl diisocyanate) (31.9% NCO, 200 Viscosity, 132
Equivalent weight, 2.8 Functional)
[0318] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 128
Dense Rigid Urethane Material
[0319]
129 B-side: 100.0 g Transesterified blown soy oil 1.2 g Non-acid
blocked Dibutyltin Dilaurate catalyst A-side: 100% Polymeric MDI
(Methylenebisdipenyl diisocyanate) (31.9% NCO, 200 Viscosity, 132
Equivalent weight, 2.8 Functional)
[0320] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 129
Very Dense Rigid Urethane Material
[0321]
130 B-side: 100.0 g Transesterified blown soy oil 1.2 g Non-acid
blocked Dibutyltin Dilaurate catalyst A-side: 100% Polymeric MDI
(Methylenebisdipenyl diisocyanate) (31.9% NCO, 200 Viscosity, 132
Equivalent weight, 2.8 Functional)
[0322] The B-side was combined with the A-side in a ratio of 110
parts A-side to 100 parts B-side.
Example 130
Semi-flexible Carpet Backing Material
[0323]
131 B-side: 80.0 g Transesterified blown soy oil 20.0 g
Conventional polyol (2 Functional, 28 OH, 4000 Molecular weight,
820 Viscosity) 0.2 g Non-acid blocked Dibutyltin Dilaurate catalyst
0.5 g Non-acid blocked Alkyltin mercaptide catalyst 4.0 g
Dipropylene glycol A-side: 100% Monomeric MDI (methylenebisdiphenyl
diisocyanate) (23% NCO, 500 Viscosity, 183 Equivalent weight, 2
Functional)
[0324] The B-side was combined with the A-side in a ratio of 45
parts A-side to 100 parts B-side.
Example 131
Semi-flexible Carpet Backing Material
[0325]
132 B-side: 80.0 g Blown soy oil 20.0 g Conventional polyol (2
Functional, 28 OH, 4000 Molecular weight, 820 Viscosity) 0.2 g
Non-acid blocked Dibutyltin Dilaurate catalyst 0.5 g Non-acid
blocked Alkyltin mercaptide catalyst 4.0 g Dipropylene glycol
A-side: 50% 4,4-MDI (methylenebisdiphenyl diisocyanate) Isocyanate
50% 2,4-MDI (methylenebisdiphenyl diisocyanate)Isocyanate mixture
(33.6% NCO, 10 Viscosity, 125 Equivalent weight, 2 Functional)
[0326] The B-side was combined with the A-side in a ratio of 34
parts A-side to 100 parts B-side.
Example 132
Flexible Carpet Padding Material
[0327]
133 B-side: 85.0 g Transesterified blown soy oil 7.5 g Conventional
polyol (3 Functional, 28 OH, 4000 Molecular weight, 1100 Viscosity)
7.5 g Conventional polyol (4 Functional, 395 OH, 568 Molecular
weight, 8800 Viscosity) 0.1 g Non-acid blocked Dibutyltin Dilaurate
catalyst 0.2 g Non-acid blocked Alkyltin mercaptide catalyst 2.0 g
Dipropylene glycol A-side: 100% Isocyanate terminated PPG
(polypropylene ether glycol) Prepolymer (19% NCO, 400 Viscosity,
221 Equivalent weight, 2 Functional)
[0328] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side.
Example 133
Fast-set Hard Skin Coating Material
[0329]
134 B-side: 100.0 g Transesterified blown soy oil 1.0 g Flexible
foam surfactant 0.8 g Non-acid blocked Dibutyltin Dilaurate
catalyst 0.8 g Fast acting Amicure DBU .RTM. (Bicyclic Amidine)
catalyst A-side: 100% Isocyanate terminated PPG (polypropylene
ether glycol) Prepolymer (19% NCO, 400 Viscosity, 221 Equivalent
weight, 2 Functional)
[0330] The B-side was combined with the A-side in a ratio of 68
parts A-side to 100 parts B-side.
Example 134
Wood Molding Substitute Material
[0331]
135 B-side: 100.0 g Transesterified blown soy oil 2.0 g
Trimethylolpropane 1.0 g Non-acid blocked Dibutyltin Dilaurate
catalyst A-side: 100% Polymeric MDL (methylenebisdiphenyl
diisocyanate) (31.9% NCO, 200 Viscosity, 132 Equivalent weight, 2.8
Functional)
[0332] The B-side was combined with the A-side in a ratio of 80
parts A-side to 100 parts B-side.
Example 135
Semi-rigid Floral Foam Type Material
[0333]
136 B-side: 100.0 g Transesterified blown soy oil 0.5 g Non-acid
blocked Dibutyltin Dilaurate catalyst 0.5 g Fast acting Amicure DBU
(Bicyclic amidine) catalyst 5.0 g Water A-side: 100% Polymeric MDI
(methylenebisdiphenyl diisocyanate) (31.9% NCO, 200 Viscosity, 132
Equivalent weight, 2.8 Functional)
[0334] The B-side was combined with the A-side in a ratio of 70
parts A-side to 100 parts B-side. A colorant (green) may be added
if desired.
[0335] While vegetable oil based transesterified polyols are
preferred in urethane production, an alternative embodiment of the
present invention includes a cellular material that is the reaction
product of an A-side and a B-side, where the A-side is comprised of
a diisocyanate and the B-side comprises a vegetable oil, or a blown
vegetable oil, a cross-linking agent comprised of a
multi-functional alcohol, and a catalyst. This alternative further
comprises a method for preparing a cellular material comprising the
reactive product of an A-side comprised of a prepolymer
diisocyanate and a B-side. The B-side comprises a first vegetable
oil, a cross-linking agent comprised of a multifunctional alcohol,
a catalyst, and a blowing agent.
[0336] There are several methods of application and production
available for either the vegetable oil based transesterified
polyurethane or the alternative non-transesterified vegetable
oil-based polyurethane. As shown in FIG. 1 (the simplified
processes shown in FIGS. 1-4 proceed from left to right), the
tuft/primary backing assembly, commonly referred to as griege
goods, is metered to bow and weft straightening station where the
bow and weft are straightened to the alignment fibers. Griege goods
are then conveyed to bed plate pre-coat applicators where pre-coat
polyurethane carpet backing application are then applied and then
sized through doctor blades. As in other polyurethane applications,
the pre-coat polyurethane carpet backing application acts as an
adhesive thereby holding the tuft of carpet so the tufts remain
engaged with the polypropylene primary backing.
[0337] The pre-coat polyurethane carpet backing application
comprises the reaction product of a pre-coat A-side comprising an
isocyanate and a pre-coat B-side. As discussed previously, the
A-side pre-coat may also comprise a pre-coat prepolymer of crude
vegetable oil, blown vegetable oil, or transesterified vegetable
oil. The pre-coat B-side may comprise any of the aforementioned
bio-based urethane systems. In one embodiment of the present
invention, the pre-coat B-side comprises a petroleum based polyol.
In another embodiment, the pre-coat B-side comprises a pre-coat
vegetable oil, a pre-coat cross-linking agent, and a pre-coat
catalyst. In yet another embodiment, the pre-coat B-side comprises
the reaction product of a pre-coat esterified polyol and a backing
material vegetable oil where the pre-coat esterified polyol
comprises the reaction product of a first pre-coat multifunctional
compound and a second pre-coat multifunctional compound.
[0338] The carpet material is then transported to an electric or a
gas preheat oven, which serves to cure the pre-coat. Next, the
carpet material is conveyed to a backing material applicator.
[0339] At this point, a backing material is applied. The backing
material is typically a foam cushioning material. The backing
material comprises the reaction product of a backing material
A-side comprising a backing material isocyanate and a backing
material B-side. As with the pre-coat B-side, any of the
aforementioned bio-based urethane systems may be employed or
petroleum based systems. In one embodiment of the present
invention, the backing material B-side comprises a petroleum based
polyol. In yet another embodiment, the backing material B-side
comprises a backing material vegetable oil, a backing material
cross-linker (chain extender), and a backing material catalyst. In
another embodiment of the present invention, backing material
B-side comprises the reaction product of a backing material
vegetable oil and a backing material esterified polyol where the
backing material esterified polyol comprises the reaction product
of a first backing material multifunctional compound and a second
backing material multifunctional compound.
[0340] The carpet material is next sized through a final doctor
blade. The final doctor blade is used to set off, or even out, the
carpet material, where the carpet material is then transported
toward and through a second electric or gas curing oven to finally
cure the pre-coat and the backing material.
[0341] An additional method of application is to position the
carpet material so the tufts are facing upward, as shown in FIG. 2.
The process shown in FIG. 2 is very similar to the process shown in
FIG. 1 as described above, but with some distinctions. First, while
the pre-coat may be applied from above, as shown in the production
line depicted in FIG. 1, the pre-coat may also be applied from
below the production line. In either case, the pre-coat is applied
to the bottom surface of the griege goods. Second, once the
pre-coat has been cured, an adhesive may be applied to the pre-coat
and previously formed backing material, adhered to the bottom
surface of the griege goods preferably by pressure rolling the
previously formed backing material into contact with the
adhesive.
[0342] FIG. 3 shows another variation of the carpet processing line
where the pre-coat is applied to the bottom surface of the griege
goods and the previously formed backing material is adhered to the
bottom surface of the griege goods preferably by pressure rolling
the previously formed backing material into contact with the
adhesive.
[0343] FIG. 4 shows yet another variation of the carpet processing
line, which is similar to the process described with respect to
FIG. 1, but where the pre-coat and backing material are applied
from above the production line.
[0344] With the particularly advantageous features of the bio-based
polyurethane of the present invention, it has been found that
specific characteristics, such as padding, resilience, padding
density, and other dimensional characteristics may be obtained in a
very highly selective and particularly advantageous manner, as
opposed to polyurethanes of the prior art. For example, several
carpets of the prior art utilize calcium carbonate or other similar
material as a filler to add weight to the carpet, whereas the
bio-based polyurethane carpets of the present invention do not.
When calcium carbonate is added, the calcium carbonate is added to
the B-side mixture from about 15 minutes to about 2 days before the
B-side utilizing the calcium carbonate is used. The calcium
carbonate is preferably agitated to keep it properly in suspension.
Additionally, there are advantages in the application methods
utilized in making and applying the bio-based polyurethane. Another
significant advantage of manufacturing the bio-based carpet
material as opposed to petroleum based polyurethanes relates to
curing oven temperatures. The ovens typically used in the prior art
(petroleum based carpet process) process reach a temperature of
about 300.degree. F., which consumes approximately 3.5 million BTUs
per hour. When the present invention is employed, the curing ovens
typically only need to reach a temperature of from about
180.degree. F., which, by contrast, only consumes approximately
1-1.5 million BTUs per hour.
[0345] The above description is considered that of the preferred
embodiments only. Modifications of the invention will occur to
those skilled in the art and to those who make or use the
invention. Therefore, it is understood that the embodiments shown
in the drawings and described above are merely for illustrative
purposes and not intended to limit the scope of the invention,
which is defined by the following claims as interpreted according
to the principles of patent law, including the doctrine of
equivalents.
* * * * *