Methods of making foams exhibiting desired properties from aromatic polyester polyether polyols derived from polyethylene terephthalates and foams made therefrom

Abstract

The disclosure relates to methods of making foams comprising aromatic polyester polyether polyol materials derived from the transesterification of polyethylene terephthalate with either glycerin or trimethylolpropane, wherein each of these triols, independently, has a degree of ethoxylation of from 1 to 9. Uses of the foams are further disclosed. The disclosure further relates to selection of blowing agents suitable to generate a selected end use case. Yet further, the disclosure relates to selection of end uses, properties, and environmental profiles of the foams generated according to the methods herein, and selecting formulation variables suitable to obtain the foams.

What is claimed is: 
     
         1 . A method of generating a polyurethane foam material comprising:
 a. selecting a use case for a polyurethane foam material;   b. providing an aromatic polyurethane polyether polyol material having the structure that is either:
 i. based on a glycerol backbone, the structure represented by a formula: 
   
       
         
           
           
               
               
           
         
         
            wherein each of R 1 , R 2 , and R 3  is independently selected from hydroxyl and a structure represented by a formula: 
         
       
       
         
           
           
               
               
           
         
         
            wherein m has a value such that the polyol has a Brookfield Cone and Plate Viscosity of less than about 5 Poise carried out using Spindle #4 at 100 rpm and 60° C.; 
            and wherein each of n 1 , n 2 , and n 3  is an integer independently selected from 0, 1, 2, 3, 4, 5, 6, 7, 8, and 9, provided that a sum of the values for n 1 , n 2 , and n 3  is 1 to 9; 
         
         or
 ii. based on a trimethylolpropane backbone, the structure represented by a formula: 
 
       
       
         
           
           
               
               
           
         
          wherein each of R 1 , R 2 , and R 3  is independently selected from hydroxyl and a structure represented by a formula: 
       
       
         
           
           
               
               
           
         
          wherein m has a value such that the polyol has a Brookfield Cone and Plate Viscosity of less than about carried out using Spindle #4 at 100 rpm and 60° C.; 
          and wherein each of n 1 , n 2 , and n 3  is an integer independently selected from 0, 1, 2, 3, 4, 5, 6, 7, 8, and 9, provided that a sum of the values for n 1 , n 2 , and n 3  is 1 to 9; 
         c. selecting a blowing agent suitable for generating a polyurethane foam for the identified use case when the aromatic polyester polyether polyol and blowing agent are used with a suitable amount of an isocyanate material under urethane reaction conditions; 
         d. combining the selected blowing agent, aromatic polyester polyether polyol, optional cell size regulator, and the isocyanate under urethane reaction conditions; and 
         e. reacting the mixture to generate a polyurethane reaction product, thereby generating a polyurethane foam suitable for use in the selected use case.