Method of reducing odors of lipid-based polyols

Abstract

A method of reducing odors in lipid-based polyol. At least one lipid-based polyol is provided, and mixed with ricinoleic acid and/or a metal salt of ricinoleic acid. Isocyanate may be added, preferably toluene diisocyanate (TDI). The polyol, and the isocyanate when present, are reacted in the presence of the ricinoleic acid and/or a metal salt of ricinoleic acid which reduces or removes odors in the lipid-based polyol. When isocyanate is used, low, limiting levels are preferred, well below the level required to fully react with all of the polyol. Tin, zinc, sodium, and calcium ricinoleic acid metal salts are particularly preferred. Preferably the reaction takes place without added heat, at room temperature. The reaction may be performed in a chamber which is under at least a partial vacuum.

1 . A method of reducing odors in lipid-based polyol, the method comprising:
 providing at least one lipid-based polyol;   providing toluene diisocyanate (TDI) in an amount of from 0.01% to 1% of a stoichiometric amount of the TDI that would be required to react with all the available hydroxyl groups of a total amount of polyol present;   providing at least one of ricinoleic acid and a metal salt of ricinoleic acid, wherein the amount of ricinoleic acid or metal salt of ricinoleic acid provided is in the range of 0.0001-1.0 parts per hundred, by weight, relative to the total amount of polyol present;   combining the lipid-based polyol, the TDI, and the ricinoleic acid or ricinoleic acid metal salt; and   reacting the lipid based polyol and the TDI in the presence of the ricinoleic acid or ricinoleic acid metal salt, thereby reducing the odor of the lipid-based polyol.   
     
     
         2 . A method of reducing odors in lipid-based polyol, the method comprising:
 providing at least one lipid-based polyol;   providing toluene diisocyanate (TDI) in an amount of from 0.01% to 35% of a stoichiometric amount of the TDI that would be required to react with all the available hydroxyl groups of a total amount of polyol present;   providing at least one of ricinoleic acid and a metal salt of ricinoleic acid;   combining the lipid-based polyol, the TDI, and the ricinoleic acid or ricinoleic acid metal salt; and   reacting the lipid based polyol and the TDI in the presence of the ricinoleic acid or ricinoleic acid metal salt, thereby reducing the odor of the lipid-based polyol.   
     
     
         3 . The method of  claim 2 , comprising providing the toluene diisocyanate (TDI) in an amount of from 0.01% to 25% of the stoichiometric amount of the TDI that would be required to react with all the available hydroxyl groups of the total amount of polyol present. 
     
     
         4 . The method of  claim 2 , wherein the step of reacting the lipid-based polyol and the TDI in the presence of the ricinoleic acid or ricinoleic acid metal salt takes place substantially without added heat. 
     
     
         5 . The method of  claim 2 , wherein ricinoleic acid metal salt is provided in the range of 0.0001-1.0 parts per hundred, by weight, relative to the total amount of polyol present. 
     
     
         6 . The method of  claim 2 , wherein the amount of ricinoleic acid or ricinoleic acid metal salt provided is in the range of 0.001-0.75 parts per hundred, by weight, relative to the total amount of polyol present. 
     
     
         7 . The method of  claim 2 , wherein ricinoleic acid metal salt is provided, said ricinoleic acid metal salt comprising at least one of a tin, zinc, sodium, and calcium ricinoleic acid metal salt. 
     
     
         8 . The method of  claim 2 , the method further comprising introducing the lipid-based polyol, the TDI, and the ricinoleic acid or ricinoleic acid metal salt into a chamber which is under at least a partial vacuum. 
     
     
         9 . The method of  claim 2 , the method further comprising introducing the lipid-based polyol, the TDI, and the ricinoleic acid or ricinoleic acid metal salt in an airborne form into a chamber which is under at least a partial vacuum. 
     
     
         10 . A method of reducing odors in lipid-based polyol, the method comprising:
 providing at least one lipid-based polyol;   providing at least one of ricinoleic acid and a metal salt of ricinoleic acid;   optionally providing up to 35% of a stoichiometric amount of at least one isocyanate that would be required to react with all the available hydroxyl groups of a total amount of polyol present;   combining the lipid-based polyol, the ricinoleic acid or ricinoleic acid metal salt, and the isocyanate when present; and   reacting the lipid-based polyol, and the isocyanate when present, in the presence of the ricinoleic acid or ricinoleic acid metal salt, thereby reducing the odor of the lipid-based polyol.   
     
     
         11 . The method of  claim 10 , the method further comprising:
 providing at least one isocyanate in an amount of from 0.01% to 35% of the stoichiometric amount of the isocyanate that would be required to react with all the available hydroxyl groups of the total amount of polyol present;   combining the isocyanate with the lipid-based polyol and the ricinoleic acid or ricinoleic acid metal salt; and   reacting the lipid based polyol and the isocyanate in the presence of the ricinoleic acid or ricinoleic acid metal salt, thereby reducing the odor of the lipid-based polyol.   
     
     
         12 . The method of  claim 10 :
 wherein substantially no isocyanate is provided or present in said combination and reacting steps;   wherein ricinoleic acid is provided;   wherein said ricinoleic acid is combined with the lipid-based polyol; and   wherein the lipid based polyol is reacted in the presence of the ricinoleic acid, thereby reducing the odor of the lipid-based polyol.   
     
     
         13 . The method of  claim 10 , the method further comprising:
 providing isocyanate in an amount of from 0.01% to 5% of the stoichiometric amount of the isocyanate that would be required to react with all the available hydroxyl groups of the total amount of polyol present;   combining the isocyanate with the lipid-based polyol and the ricinoleic acid or ricinoleic acid metal salt; and   reacting the lipid based polyol and the isocyanate in the presence of the ricinoleic acid or ricinoleic acid metal salt, thereby reducing the odor of the lipid-based polyol.   
     
     
         14 . The method of  claim 10 , wherein the at least one lipid-based polyol comprises at least one of soy based polyol, palm based polyol, or rapeseed based polyol. 
     
     
         15 . The method of  claim 10 , the method further comprising introducing the lipid-based polyol, the ricinoleic acid or ricinoleic acid metal salt, and the isocyanate when present, into a chamber which is under at least a partial vacuum. 
     
     
         16 . The method of  claim 10 , the method further comprising:
 spraying the lipid-based polyol into a chamber which is under at least a partial vacuum; and   separately injecting the ricinoleic acid or ricinoleic acid metal salt into said chamber under at least a partial vacuum.   
     
     
         17 . The method of  claim 10 , the method further comprising introducing the lipid-based polyol and the ricinoleic acid or ricinoleic acid metal salt into a chamber which is under at least a partial vacuum;
 wherein the ricinoleic acid or ricinoleic acid metal salt are introduced into the chamber as a dispersed component in a liquid lipid-based polyol input stream.   
     
     
         18 . The method of  claim 10 , wherein the amount of ricinoleic acid or ricinoleic acid metal salt provided is in the range of 0.0001-1.0 parts per hundred, by weight, relative to the total amount of polyol present. 
     
     
         19 . The method of  claim 10 , wherein the amount of ricinoleic acid or ricinoleic acid metal salt provided is in the range of 0.001-0.75 parts per hundred, by weight, relative to the total amount of polyol present. 
     
     
         20 . The method of  claim 10 , wherein the reacting step takes place substantially without added heat.