Emulsifiers for polyurethane based foam

Abstract

This invention provides stable polyol compositions at all states and these compositions are stable for at least 24 hours, in some cases for more than 6 months. There is also provided polyol mixture compositions that may be uniformly blended under manufacturing conditions within a time period of less than eight hours, typically less than two hours, i.e., stable-polyol mixtures. The invention provides a composition and a method for making stable polyurethane foams. The polyol mixture comprises at least two polyols of different polyoxyethylene content, catalyst, at least one ethoxylated alcohol of the following formula: RO(CH 2 CH 2 O) n H, wherein R is C1-C31 linear or branched alkyl, n is an integer equal to or greater than 1; and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value equal to or greater than about 3.7.

1 . A composition comprising:
 a) at least one isocyanate reactive polyol, and   b) at least one ethoxylated alcohol of the following formula:   RO(CH 2 CH 2 O) n H, wherein R is C1-C31 linear or branched alkyl,   n is an integer equal to or greater than 1 and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 15.7.   
     
     
         2 . A method to make a cellular or noncellular polyurethane by reacting the composition of  claim 1  with at least one isocyanate. 
     
     
         3 . The method of  claim 2  in which the reacting composition comprises at least one additional additive and/or an auxiliary agent from the group consisting of catalysts, carbonates, sulfates, heterocyclic aromatic amides, silicas, phase change or transfer materials, amines, renewable fillers or thermoplastic fillers. 
     
     
         4 . A polyol mixture comprising:
 a) at least two polyols of different polyoxyethylene content,   b) a catalyst, and   c) at least one ethoxylated alcohol of the following formula:   RO(CH 2 CH 2 O) n H, wherein R is C1-C31 linear or branched alkyl,   n is an integer equal to or greater than 1; and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 3.7.   
     
     
         5 . The polyol mixture of  claim 4 , wherein R is C9-C15 linear or branched alkyl, n is an integer equal to or greater than 1 and equal to or less than 10; and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 3.7 and equal to or less than 17.9. 
     
     
         6 . The polyol mixture of  claim 5 , wherein at least one polyol is derived from natural resources and a second polyol containing polyoxylene or a polymeric polyol. 
     
     
         7 . A method for preparing a polyol mixture comprising the steps of
 a) combining at least one polyoxypropylene based polyol and a polyoxyethylene based polyol and at least one ethoxylated alcohol of the following formula: RO(CH 2 CH 2 O) n H, wherein R is C1-C31 linear or branched alkyl, n is an integer equal to or greater than 1, and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 3.7; and   b) mixing the mixture of step a) until a stable one phase mixture is formed.   
     
     
         8 . The method of  claim 7 , wherein R is C9-C15 linear or branched alkyl, n is an integer equal to or greater than 1 and less than or equal to 10, and wherein the at least one ethoxylated alcohol has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 3.7 and less than or equal to 17.9. 
     
     
         9 . The method of  claim 8 , wherein the polyoxyethylene based polyol and polyoxyethylene based polyol is further combined with a natural resource based polyol. 
     
     
         10 . A polyurethane foam composition comprising the polyol mixture of  claim 4 , at least one polyisocyanate at an Isocyanate Index from about 80 to about 150, at least one blowing agent, at least one amine catalyst, at least one metal catalyst, and at least one silicone surfactant. 
     
     
         11 . The polyurethane foam composition of  claim 10  further comprising at least one additional additive and/or an auxiliary agent from the group consisting of catalysts, carbonates, sulfates, heterocyclic aromatic amides, silicas, phase change or transfer materials, amines, renewable fillers or thermoplastic fillers. 
     
     
         12 . A method for preparing polyurethane foam comprising the steps of
 a) forming a premix comprising the polyol mixture of  claim 4 , at least one blowing agent, at least one amine catalyst, at least one metal catalyst, and at least one silicone surfactant; and   b) contacting the premix with at least one isocyanate at an Isocyanate Index from about 80 to about 150.