Natural oil polyols derived from post-consumer recycle oils
AssigneeJohnson Controls Technology Company
InventorsHaifeng Ni, Jenny Dong, Yao Gu, James T. McEvoy, William Li
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Abstract
Disclosed embodiments include an open cell, molded polyurethane foam comprising the reaction product of a reaction mixture comprising: an isocyanate mixture; and a polyol formulation, comprising a glycerin-initiated, alkylene-oxide capped natural oil polyol having a molecular weight of between 3,000 and 8,000 and a polydispersity index (PDI) of between approximately 1.5 and 2.5, wherein the PDI is defined as the ratio of the weight-average molecular weight, Mw, to the number-average molecular weight, Mn.
Claims45
An open cell, molded foam produced by a process, the process comprising:
- reacting a polyol formulation with an isocyanate mixture, wherein at least one component of the polyol formulation is produced by a process comprising:
- reacting a first polyol with an acid anhydride compound to produce a monol having two or more polycarboxylic acid substituents;
- reacting the monol having two or more polycarboxylic acid substituents with an epoxidized fatty acid of a post-consumer recycle oil to produce a polyol branching agent;
- reacting the polyol branching agent with a polyol initiator to link at least two molecules of the polyol branching agent together to produce a branched polyol;
- and
- capping the branched polyol with an alkylene oxide to produce a natural oil-based polyol having a molecular weight of between 2,000 and 6,000.
A method, comprising:
- reacting a first polyol with an acid anhydride compound to produce a monol having two or more polycarboxylic acid substituents;
- reacting the monol having two or more polycarboxylic acid substituents with an epoxidized fatty acid of a post-consumer recycle oil to produce a polyol branching agent;
- extracting the polyol branching agent from a reaction mixture produced from the monol having two or more polycarboxylic acid substituents and the epoxidized fatty acid of a post-consumer recycle oil using one or more solvents;
- reacting the extracted polyol branching agent with a polyol initiator to link at least two molecules of the polyol branching agent together to produce a branched polyol;
- and
- capping the branched polyol with an alkylene oxide to produce a natural oil-based polyol having a molecular weight of between 2,000 and 6,000.
An open cell, molded polyurethane foam comprising the reaction product of a reaction mixture comprising:
- an isocyanate mixture;
- and
- a polyol formulation, comprising a glycerin-initiated, alkylene-oxide capped natural oil polyol having a molecular weight of between 3,000 and 8,000 and a polydispersity index (PDI) of between approximately 1.5 and 2.5, wherein the PDI is defined as the ratio of the weight-average molecular weight, Mw, to the number-average molecular weight, Mn.
A method, comprising:
- reacting a plurality of refined oils produced from used oils with an alcohol to generate a plurality of modified oils;
- oxidizing the plurality of refined oils to generate a plurality of epoxidized oils;
- and
- reducing the plurality of epoxidized oils to generate a plurality of polyhydroxylated oils;
- and
- producing a plurality of natural oil polyols from the plurality of natural oil polyols, wherein the plurality of natural oil polyols comprise primary alcohols and have a molecular weight of at least 3,000.
A method, comprising:
- treating a plurality of used oils to form a plurality of refined oils;
- subjecting the plurality of refined oils to a process that generates a plurality of modified oils;
- and
- reacting the plurality of modified oils to produce a plurality of polyhydroxylated oils;
- and
- producing a plurality of natural oil polyols from the plurality of polyhydroxylated oils, wherein the plurality of natural oil polyols comprise primary alcohols and have a molecular weight of at least 3,000.
A foam produced by a process comprising:
- reacting a polymeric polyol formulation with an isocyanate mixture, wherein one component of the polymeric polyol formulation is produced by a process comprising:
- reacting a plurality of refined oils produced from used oils with an alcohol to generate a plurality of modified oils;
- and
- oxidizing the plurality of refined oils to generate a plurality of epoxidized oils;
- reducing the plurality of epoxidized oils to generate a plurality of polyhydroxylated oils;
- and
- producing a plurality of natural oil polyols from the plurality of polyhydroxylated oils, wherein the plurality of natural oil polyols comprise primary alcohols and have a molecular weight of at least 3,000.
Dependencies are inferred from the claim text.