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  Encapsulated flexible polyurethane foam and method for making polyol to form foamRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Synthetic Resins Or Natural Rubbers, Ion-exchange Polymer Or Process Of Preparing, Compositions To Be Polymerized By Wave Energy In Order To Prepare A Cellular Product Wherein Said Composition Contains A Rate-affecting Material; Or Compositions To Be Modified By Wave Energy To Prepare A Cellular Product Wherein Said Composition Contains A Rate-affecting Material; Or Processes Of Preparing Or Treating A Solid Polymer Utilizing Wave Energy In Order To Prepare A Cellular ProductThe Patent Description & Claims data below is from USPTO Patent Application 20070123597. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] One aspect of the present invention relates to flexible polyurethane foam suitable for use in automobile interior applications, and method for making vegetable-based polyol to form foam. [0003] 2. Background Art [0004] Flexible polyurethane foams have been extensively used in the automotive industry for applications such as seating, instrument panels, armrests, headrests and headliners. On average, 35 pounds of flexible polyurethane foam are used per vehicle for interior applications. [0005] The production of polyurethane foams is well known in the art. Polyurethanes are formed when isocyanate (NCO) groups react with hydroxyl (OH) groups. One common method of polyurethane production includes the reaction of a polyol with OH groups and an isocyanate with NCO groups, which forms the backbone urethane group. [0006] A blowing agent can be added to the reaction to cause gas or vapor to be evolved during the reaction. The blowing agent creates void cells in the final foam, and commonly is a solvent with a relatively low boiling point or is water. As the polyurethane reaction proceeds and the material solidifies, the vapor gas bubbled from the blowing agent are locked into place to form void cells. Varying the amount or type of blowing agent used may control the final polyurethane foam density and properties. [0007] Other conventional components such as cross-linking agents and catalysts are often used in standard foam formulations. A cross-linking agent promotes chemical cross-linking to result in a structured final urethane product. A catalyst controls reaction kinetics to help tailor the final product qualities. [0008] Polyols commonly used in the reaction are typically derived from petrochemicals, for example, glycerin and ethylene oxide. The use of petrochemical polyols is disadvantageous for a variety of reasons. First, since polyols are derived from petroleum, they are a non-renewable resource. Furthermore, the production of a polyol may require a great deal of energy and expense, as oil must be drilled, extracted from the ground, transported to refineries, refined, and otherwise processed to yield the polyol. [0009] With uncertainties in the long-term economic stability and limited reserves of fossil fuels and oils, investigations into using renewable resources as a source for foams have been ongoing. As part of that investigation, soy-based polyols have been developed as an alternative to petroleum-based polyols. The soy-based polyols are considered a good alternative to petroleum-based polyols for the production of polyurethane foam since the soy-based polyols can offer cost advantages as well as alleviate the environmental concerns associated with petroleum-based polyols. Examples of the use of soy-based polyols to formulate soy-based polyurethane foams can be found in U.S. Patent Application Nos. 2002/009230, 2002/0192456, 2003/0083394 and U.S. Pat. Nos. 5,710,190 and 6,624,244. [0010] In the manufacture of soy-based polyols, any combination of the following steps is commonly utilized: blowing air through a soy oil, heating the soy oil to an elevated temperature over room temperature and/or adding a catalyst to promote reaction in the soy oil. [0011] While soy-based polyurethane foams have made inroads into various polyurethane foam markets, the use of soy-based polyurethane foam has not gained acceptance in the automotive industry because of certain limitations. One primary limitation of using soy-based polyurethane foams is the unpleasant vegetable oil odor that is prominent in these foams. This limitation is especially acute in the vehicle interior, where controlled air quality and odor are important issues for automobile consumers. In addition, the heated environment of the cabin interior provides additional limitations on the types of materials that can be used. [0012] Commercially-available soy polyols contain low molecular weight species, for example, aldehydes and hydroperoxides, that contribute to the unpleasant odor emanating from the resulting soy-based polyurethane foams. These low molecular weight species can be formed when the soy oil is heated to elevated temperatures. Soy polyol suppliers have attempted to address this problem by masking the unpleasant odor with other chemicals, for example, fragrances. However, these techniques have not satisfactorily addressed the odor problem issue. Alternatively, a few soy polyols suppliers offer expodized soy polyols, which result in a reduction in unpleasant odor compared to other soy polyols. However, these expodized soy polyols come at a premium price compared to non-expodized soy polyols. [0013] Accordingly, it is desirable and there is a need to provide soy-based polyurethane foam having an acceptable level of odor, and method to produce the same. Moreover, it is also desirable to provide an odor barrier for encapsulating the odor emanating from a soy-based polyurethane foam within a confined volume, and method to produce the same. SUMMARY OF THE INVENTION [0014] One aspect of the present invention is a vegetable-based polyurethane foam having an acceptable level of odor, and a method of producing the same. Another aspect of the present invention is an odor barrier for encapsulating the odor emanating from a vegetable-based polyurethane foam within a confined volume, and method to produce the same. [0015] According to one embodiment of the present invention, a cellular material prepared by reacting a vegetable-based polyol and an isocyanate is disclosed. The vegetable-based polyol is made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol. [0016] According to another embodiment of the present invention, a composition suitable for making a cellular material is disclosed. The composition includes a vegetable-based polyol and an isocyanate. The vegetable-based polyol is a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol. [0017] In one embodiment of the present invention, a cellular material is disclosed which includes vegetable-based foam and a number of aldehyde and ketone compounds. The number can be in the range of 1 to 10. [0018] In another embodiment of the present invention, a vegetable-based polyol is disclosed. The vegetable-based polyol can include a first number of oil products, a second number of volatile by-product compounds, and a third number of non-volatile by-product compounds. The first number can be in the range of 1 to 3. The second number can be in the range of 1 to 10. The third number can be in the range of 1 to 5. In certain embodiments, each oil product contains a mixture of difunctional hydroxylated vegetable oil and monofunctional hydroxylated vegetable oil. [0019] According to yet another embodiment of the present invention, an apparatus for use in encapsulating automotive interior components at least partially comprised of cellular material is disclosed. The apparatus includes an odor barrier layer for encapsulating the cellular material to confine odors emanating from the cellular material. BRIEF DESCRIPTION OF THE FIGURES [0020] The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages and features thereof, may be best understood with reference to the following description, taken in connection with the accompanying drawings. [0021] FIG. 1 is a graph comparing the viscosity in stokes at 25 C versus total hours air for an ultraviolet (UV) light trial and a non-UV light trial; Continue reading... Full patent description for Encapsulated flexible polyurethane foam and method for making polyol to form foam Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Encapsulated flexible polyurethane foam and method for making polyol to form foam patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Encapsulated flexible polyurethane foam and method for making polyol to form foam or other areas of interest. ### Previous Patent Application: Pet bottle recycling Next Patent Application: Microcellular foam of thermoplastic resin prepared with die having improved cooling property and method for preparing the same Industry Class: Synthetic resins or natural rubbers -- part of the class 520 series ### FreshPatents.com Support Thank you for viewing the Encapsulated flexible polyurethane foam and method for making polyol to form foam patent info. IP-related news and info Results in 0.13246 seconds Other interesting Feshpatents.com categories: Novartis , Pfizer , Philips , Polaroid , Procter & Gamble , |
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