Polyurethane foams comprising oligomeric polyols

Abstract

The invention relates to polyurethane foams comprising oligomeric polyols. In embodiments of the invention, the polyurethane foams comprise the reaction product of: (a) a polyisocyanate; and (b) an active-hydrogen containing composition comprising an oligomeric polyol having a hydroxyl number of about 45 to about 65 mg KOH/g, a number average hydroxyl functionality (Fn) of less than about 2.7, and about 40% weight or greater oligomers. The polyurethane foams of the invention may be slabstock foams or molded foams. Also disclosed are low odor polyols and polyurethane compositions.

1 . A polyurethane foam comprising the reaction product of:
 (a) a polyisocyanate; and   (b) an active-hydrogen containing composition comprising an oligomeric polyol having a hydroxyl number of about 45 to about 65 mg KOH/g, a number average hydroxyl functionality of less than about 2.7, and about 40% weight or greater oligomers.   
     
     
         2 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has from about 55% to about 65% weight oligomers. 
     
     
         3 . (canceled) 
     
     
         4 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a number average hydroxyl functionality less than about 2.5. 
     
     
         5 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a number average hydroxyl functionality less than about 2.0. 
     
     
         6 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has an acid value that is less than about 1.0 mg KOH/gram. 
     
     
         7 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a number average molecular weight (Mn) of about 1000 to 5000 grams/mole. 
     
     
         8 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a weight average molecular weight (Mw) of about 5000 to 50,000 grams/mole. 
     
     
         9 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a viscosity of about 0.5 to about 10 Pa·s at 25° C. 
     
     
         10 . (canceled) 
     
     
         11 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol has a residual epoxy oxygen content of about 0.01% to about 5.0%. 
     
     
         12 . The polyurethane foam of  claim 1 , wherein the oligomeric polyol is made from an epoxidized natural oil. 
     
     
         13 . The polyurethane foam of  claim 12 , wherein the natural oil is selected from soybean oil, safflower oil, linseed oil, corn oil, sunflower oil, olive oil, canola oil, sesame oil, cottonseed oil, palm-based oil, rapeseed oil, tung oil, peanut oil, fish oil, lard, tallow, and combinations thereof. 
     
     
         14 . The polyurethane foam of  claim 13 , wherein the natural oil comprises soybean oil. 
     
     
         15 . The polyurethane foam of  claim 13 , wherein the palm-based oil comprises palm-olein. 
     
     
         16 . The polyurethane foam of  claim 1 , wherein the active-hydrogen containing composition further comprises a petroleum-derived polyol. 
     
     
         17 . The polyurethane foam of  claim 16 , wherein the petroleum-derived polyol is a triol. 
     
     
         18 . The polyurethane foam of  claim 16 , wherein the petroleum-derived triol has a molecular weight of about 3000 grams/mole. 
     
     
         19 . The polyurethane foam of  claim 16 , wherein the active-hydrogen containing composition comprises about 45% to about 90% weight petroleum-derived polyol and about 10% to about 60% weight oligomeric polyol. 
     
     
         20 . The polyurethane foam of  claim 1 , wherein the polyisocyanate is toluene diisocyanate, 4,4′-diphenylmethane diisocyanate, polymeric 4,4′-diphenylmethane, or a mixture thereof. 
     
     
         21 . The polyurethane foam of  claim 1 , wherein the active-hydrogen containing composition comprises about 10% to about 50% weight of the oligomeric polyol. 
     
     
         22 . (canceled) 
     
     
         23 . The polyurethane foam of  claim 1 , wherein the polyurethane foam is flexible slabstock foam. 
     
     
         24 . The polyurethane foam of  claim 1 , wherein the polyurethane foam is a molded foam. 
     
     
         25 . The polyurethane foam of  claim 1 , wherein the polyurethane foam has a density of about 0.5 to about 5.0 lbs/ft 3 . 
     
     
         26 . The polyurethane foam of  claim 1 , wherein the wherein the active hydrogen-containing composition comprises at least 10 PPH oligomeric polyol, and wherein the polyurethane foam exhibits a percent tensile strength reduction relative to a control formulation that is less than or equal to formula (I):
   percent tensile strength reduction=0.89×(PPH oligomeric polyol)  (I)   
       for polyurethane foam having a density of about 1.5 lb/ft 3  and a 25% IFD of about 23 N/323 cm 3 . 
     
     
         27 . The polyurethane foam of  claim 26 , wherein formula (I) equals:
   percent tensile strength reduction=1.0×(PPH oligomeric polyol)  (I).   
     
     
         28 . The polyurethane foam of  claim 1 , wherein the active hydrogen-containing composition comprises at least 10 PPH oligomeric polyol, and wherein the polyurethane foam exhibits a tear strength reduction relative to a control formulation that is less than or equal to formula (II):
   percent tear strength reduction=1.40×(PPH of oligomeric polyol)  (II)   
       for polyurethane foam having a density of about 1.5 lb/ft 3  and a 25% IFD of about 23 N/323 cm 2 . 
     
     
         29 . The polyurethane foam of  claim 1 , wherein the active-hydrogen containing composition comprises at least 10 PPH oligomeric polyol, and wherein the polyurethane foam exhibits a percent elongation reduction that is less than or equal to formula (III):
   percent elongation reduction=1.36×(PPH of oligomeric polyol)  (III)   
       for polyurethane foam having a density of about 1.5 lb/ft 3  and a 25% IFD of about 23 N/323 cm 2 . 
     
     
         30 - 52 . (canceled) 
     
     
         53 . A polyurethane foam comprising the reaction product of:
 a polyisocyanate; and
 an active hydrogen containing composition comprising at least 10 PPH of an oligomeric polyol having a number average hydroxyl functionality less than about 2.7, wherein a polyurethane foam having a density of about 1.5 lb/ft 3  foam has a tensile strength of at least about 85 kPa. 
   
     
     
         54 . The polyurethane foam of  claim 53 , wherein the foam has an elongation of at least about 90%. 
     
     
         55 . The polyurethane foam of  claim 53 , wherein the foam has a tear of at least about 150 N/m. 
     
     
         56 . The polyurethane foam of  claim 53 , wherein the foam has a 90% compression set of less than about 20%. 
     
     
         57 - 63 . (canceled) 
     
     
         64 . The polyurethane foam of  claim 53 , wherein the oligomeric polyol has a hydroxyl number from about 45 to about 65 mg KOH/g. 
     
     
         65 - 76 . (canceled) 
     
     
         77 . The polyurethane foam of  claim 53 , wherein the foam, upon exposure to light under ambient conditions for a period of 6 weeks in the absence of an ultraviolet stabilizer, has a reflectance specular included color characterized by an (L) value of at least 70 units. 
     
     
         78 . The polyurethane foam of  claim 53 , wherein the foam, upon exposure to light under ambient conditions for a period of 6 weeks in the absence of an ultraviolet stabilizer, has a reflectance specular included color characterized by an (L) value of at least 80 units. 
     
     
         79 - 84 . (canceled)