NOVEL POLYMER POLYOLS BASED ON NATURAL OILS POLYOLS
This invention relates to stable, low-viscosity polymer polyols and to a process for preparing these stable, low-viscosity polymer polyols. These polymer polyols comprise (a) a base polyol component that comprises a natural oil base polyol having a mean hydroxyl functionality of 1.7 to 5.0, a number average molecular weight of about 350 to about 725, and an OH number of 190 to 500.
1 . A stable, low-viscosity polymer polyol comprising the free-radical polymerization product of:
(a) a clear liquid base polyol component comprising a natural oil base polyol having a mean hydroxyl functionality of 1.7 to 5.0, a number average molecular weight of about 350 to about 725 and an OH number of 190 to 500, and which comprises the transesterification/alkoxylation product of
(i) at least one initiator comprising at least one Zerewitinoff-active hydrogen atom;
(ii) a natural oil component or a mixture of natural oil components;
and
(iii) at least one alkylene oxide;
in the presence of:
(iv) at least one alkaline catalyst;
wherein said alkylene oxide is completely reacted;
(b) at least one ethylenically unsaturated monomer;
and, optionally,
(c) a preformed stabilizer;
in the presence of:
(d) a free-radical polymerization initiator;
and, optionally,
(e) a chain transfer agent.
2 . The stable, low-viscosity polymer polyol of claim 1 , wherein (a) (iii) said alkaline catalyst comprises one or more of the compounds potassium hydroxide, sodium hydroxide, sodium methoxide, potassium methoxide, sodium stearate, calcium oxide and N-methyl imidazole.
3 . The stable, low-viscosity polymer polyol of claim 1 , wherein (a) (iii) said alkaline catalyst comprises potassium hydroxide in vacuum glycerin start medium.
4 . The stable, low-viscosity polymer polyol of claim 1 , wherein (a) said clear liquid base polyol has a mean hydroxyl functionality of 2.4 to 4.4, a number average molecular weight of 400 to 600, and an OH number of 300 to 400.
5 . The stable, low-viscosity polymer polyol of claim 1 , wherein (a) (i) said initiator comprising at least one Zerewitinoff-active hydrogen atom is selected from the group consisting of a hydroxyl group containing compound, an amine group containing compound, mixtures thereof and alkoxylates thereof.
6 . The stable, low-viscosity polymer polyol of claim 1 , wherein (a) (ii) said natural oil component comprises soybean oil.
7 . The stable, low-viscosity polymer polyol of claim 1 , wherein (b) said ethylenically unsaturated monomer is selected from the group consisting of styrene, acrylonitrile and mixtures thereof.
8 . The stable, low-viscosity polymer polyol of claim 1 , wherein (d) said free radical polymerization initiator is selected from the group consisting of peroxides, azo compounds and mixtures thereof.
9 . A process for preparing a stable, low-viscosity polymer polyol comprising:
(1) free-radically polymerizing:
(a) a clear liquid base polyol component comprising a natural oil base polyol having a functionality of 1.7 to 5.0, a molecular weight of about 350 to about 725 and an OH number of 190 to 500, and which comprises the transesterification/alkoxylation product of
(i) at least one initiator comprising at least one Zerewitinoff active hydrogen atom;
(ii) a natural oil component or a mixture of natural oil components;
and
(iii) at least one alkylene oxide;
in the presence of
(iv) at least one basic catalyst;
wherein said alkylene oxide is completely reacted;
(b) at least one ethylenically unsaturated monomer;
and, optionally,
(c) a preformed stabilizer;
in the presence of:
(d) a free-radical polymerization initiator;
and, optionally,
(e) a chain transfer agent.
10 . The process of claim 9 , wherein (a) (iii) said alkaline catalyst comprises one or more of the compounds potassium hydroxide, sodium hydroxide, sodium methoxide, potassium methoxide, sodium stearate, calcium oxide and N-methyl imidazole.
11 . The process of claim 9 , wherein (a) (iii) said alkaline catalyst comprises potassium hydroxide in vacuum glycerin start medium.
12 . The process of claim 9 , wherein (a) said clear liquid base polyol has a mean hydroxyl functionality of 2.4 to 4.4, a number average molecular weight of 400 to 600, and an OH number of 300 to 400.
13 . The process of claim 9 , wherein (a) (i) said initiator comprising at least one Zerewitinoff-active hydrogen atom is selected from the group consisting of a hydroxyl group containing compound, an amine group containing compound, mixtures thereof and alkoxylates thereof.
14 . The process of claim 9 , wherein (a) (ii) said natural oil component comprises soybean oil.
15 . The process of claim 9 , wherein (b) said ethylenically unsaturated monomer is selected from the group consisting of styrene, acrylonitrile and mixtures thereof.
16 . The process of claim 9 , wherein (d) said free radical polymerization initiator is selected from the group consisting of peroxides, azo compounds and mixtures thereof.
17 . A process for preparing a polyurethane foam comprising reacting a polyisocyanate component with an isocyanate-reactive component, in the presence of at least one blowing agent, at least one catalyst, and at least one surfactant, wherein said isocyanate-reactive component comprises the polymer polyol of claim 1 .
18 . A polyurethane foam comprising the reaction product of a polyisocyanate component with an isocyanate-reactive component, in the presence of at least one blowing agent, at least one catalyst and at least one surfactant, wherein said isocyanate-reactive component comprises the polymer polyol of claim 1 .