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.sub.2CH.sub.2O).sub.nH, 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.

Claims

1. A composition comprising: a) at least one isocyanate reactive polyol, and b) at least one ethoxylated alcohol of the following formula:
RO(CH.sub.2CH.sub.2O).sub.nH, 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.sub.2CH.sub.2O).sub.nH, 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.sub.2CH.sub.2O).sub.nH, 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 any of claims 4-6, 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 any of claims 4-6, 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.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0048] The invention relates to a polyol mixture comprising polyols of different polyoxyethylene and polyoxypropylene content, and at least one ethoxylated alcohol, shown below as formula A. The mixture may remain stable without agitation for at least 24 hours, in some cases more than 6 months or a longer time period. Foam prepared with ethoxylated alcohol of formula A have the added benefit of having higher air flow, better load bearing properties, improved performance on flexible foaming machinery leading to better distribution and improved reactivity.

[0049] Ethoxylated Alcohol

[0050] The at least one ethoxylated alcohol of the present invention has the following formula A:

RO(CH.sub.2CH.sub.2O).sub.nH  A

in which R is C1-C31 linear or branched alkyl, inclusive; n is an integer equal to or greater than 1 and less than or equal to 10; and the compound has a hydrophilic-lipophilic balance (HLB) value of equal to or greater than about 3.7 and less than or equal to 17.9.

[0051] The term “alkyl” used herein refers to aliphatic hydrocarbon radicals containing only saturated carbon-carbon bonds. Alkyl groups with or without branches and without unsaturated carbon-carbon bonds are suitable for the present invention.

[0052] The number “n” of ethoxy units in formula A may be any integer equal to or greater than 1. Non-limiting representative examples include n=1, n=2, n=3, n=6, n=10.

[0053] The term “hydrophilic-lipophilic balance (HLB) value” as used herein is a measure of the degree to which a compound is hydrophilic or lipophilic. HLB is calculated using molecular mass of different regions of a molecule, as described by Griffin:

HLB=20×Mh/M

wherein Mh is the molecular mass of the hydrophilic portion of the molecule, and M is the molecular mass of the entire molecule, giving a result on an arbitrary scale of 0 to 20.

[0054] An HLB value of 0 corresponds to a completely hydrophobic molecule, and a value of 20 corresponds to a completely hydrophilic molecule.

[0055] As an example, the HLB value of C.sub.13H.sub.27(CH.sub.2CH.sub.2O).sub.40H is calculated as the following:

HLB=20×Mh/M=20×1761/1944=18.1

Wherein Mh is the molecular mass of the hydrophilic part (CH.sub.2CH.sub.2O).sub.40H and M is the molecular mass of the entire molecule.

[0056] Examples of suitable HLB value for the present invention include, but not limited to HLB value equal to or greater than 3.7, 8, 15.7, 17.9.

[0057] Polyol Mixtures

[0058] Polyols of different molecular weight or polyoxyethylene and polyoxypropylene content that do not remain a stable one phase mixture may be used in this invention.

[0059] The polyol mixture comprises the following polyol (A), the following polyol (B), the following polyol (C), the following polyol (D) and the following polyol (E), and the proportion of the polyisocyanate compound to all active hydrogen-containing compounds in the material is at least 80 by isocyanate index, wherein: [0060] Polyol (A) is a polyether polyol having an average of 2-4 hydroxyl groups and a molecular weight of 2500-5000. Polyols suitable for use in the invention include, as non-limiting examples, polyether and polyester polyols. The polyalkylene ether polyol includes the poly(alkyleneoxide) polymers such as poly(ethyleneoxide) and poly(propyleneoxide) polymers and copolymers with terminal hydroxyl groups derived from polyhydric compounds, including diols and triols, These include, but are not limited to, ethylene glycol, propylene glycol, 1,3-butane diol, 1,4-butane diol, 1,6-hexane diol, neopentyl glycol, diethylene glycol, dipropylene glycol, pentaerythritol, glycerol, diglycerol, trimethylol propane, cyclohexane diol, and sugars such as sucrose. [0061] Polyol (B) is a “polymer polyol” and may be included in a polyol component for use according to the invention. Polymer polyols may be used in polyurethane foams to increase the resistance of the foam to deformation, for example to improve the load-bearing properties of the foam. Depending upon the load-bearing requirements for the polyurethane foam, polymer polyols may comprise from 0 to about 80 percent by weight of the total polyol content. Examples of polymer polyols include, but are not limited to, graft polyols and polyurea modified polyols, both of which are known in the art and are commercially available. [0062] Polyol (C) is a polyether polyol having an average of 2-3 hydroxy groups and a molecular weight between 100-2000. [0063] Polyol (D) is a polyol based on renewable natural resources. Examples of vegetable oils include those from castor, soybean, olive, peanut, rapeseed, corn, sesame, cotton, canola, safflower, linseed, palm, grapeseed, black caraway, pumpkin kernel, borage seed, wood germ, apricot kernel, pistachio, almond, macadamia nut, avocado, sea buckthorn, hemp, hazelnut, evening primrose, wild rose, thistle, walnut, sunflower, jatropha seed oils, or a combination thereof. Additionally, oils obtained from organisms such as algae may also be used. Examples of animal products include lard, beef tallow, fish oils and mixtures thereof. A combination of vegetable and animal based oils/fats may also be used. For use in the production of polyurethane foams, the natural material may be modified to give the material isocyanate reactive groups or to increase the number of isocyanate reactive groups on the material. Preferably such reactive groups are a hydroxyl group. Several chemistries can be used to prepare the natural oil based polyols. Such modifications of a renewable resource include, for example, epoxidation, hydroxylation, ozonolysis, esterification, hydroformylation, or alkoxylation. [0064] Polyol (E) is polyoxylene polypropylene polyol containing 40-80% polyoxylene content with a molecular weight between 3000 and 6000 and a functionality between 2 and 4.

[0065] In one embodiment of the invention the polyol mixture comprises about greater than 0 to about 90 pphp of Polyol A optionally with 0 to 60 pphp of Polyol B optionally with 10 to 40 pphp Polyol D; optionally about 10 to about 90 pphp of Polyol A, or about 10 to about 40 pphp Polyol B with Polyol D at about 20 to about 40 pphp

[0066] In another embodiment of the invention the polyol mixture comprises about greater than 0 to 90 pphp Polyol A with optionally about 5 to about 50 pphp Polyol C with optionally 20 to 70 pphp Polyol E; or about 10 to about 20 pphp Polyol A optionally with about 5 to 25 pphp Polyol C and optionally about 25 to 60 pphp Polyol E.

[0067] In another embodiment of the invention the polyol mixture comprises about greater than 0 to about 90 pphp of Polyol A optionally with 0 to 60 pphp of Polyol B optionally with 10 to 40 pphp Polyol D; optionally about 10 to about 90 pphp of Polyol A, or about 10 to about 40 pphp Polyol B with Polyol D at about 20 to about 40 pphp

[0068] In another embodiment of the invention the polyol mixture described above is combined with an effective amount of ethoxylated alcohol and mixed until a uniform mixture is formed. Any conventional mixing method, such as mechanical stirring or shaking may be employed. The order of adding polyol and ethoxylated alcohol into polyol does not impact the formation of the stable mixture.

[0069] In another embodiment of the invention the method for producing a flexible polyurethane foam which comprises reacting a polyol mixture and an ethoxylated alcohol of the invention described above with a polyisocyanate compound in the presence of a urethane-forming catalyst, a blowing agent and a foam stabilizer.

[0070] The polyol mixture is placed still at room temperature (20-25° C.) and its appearance is closely observed. A stable mixture means a mixture without appreciable layer separation to a naked-eye.

[0071] An “effective” amount of ethoxylated alcohol is an amount needed to keep the polyol mixture stable for at least 24 hours, in some cases more than 6 months. A polyol mixture may comprise at least about 0.5 pphp, at least about 2.0 pphp or at least about 4.0 pphp ethoxylated alcohol.

[0072] Typical manufacturing conditions involve contacting polyol, and ethoxylated alcohol solution of formula A in a blending tank with a capacity of 20 m.sup.3 and mixing with a 30 watt mechanical stirrer at about 1800 revolutions per minute (rpm).

[0073] Preparation of Foams

[0074] Foams or cellular material of any of the various types known in the polyurethane art may be made using the methods of this invention. Typical components of a cellular or noncellular polyurethane formulation include at least one isocyanate reactive polyol or mixtures of it, at least one blowing agent such as water, at least one polyisocyanate, at least one amine catalyst, at least one metal catalyst and at least one silicone surfactant. Other additives and/or an auxiliary agent may be included depending on the types and applications of the polyurethane including, but not limited to, catalysts, carbonates, sulfates, heterocyclic aromatic amides, silicas, phase change or transfer materials, amines, renewable fillers or thermoplastic fillers. For example, flexible polyurethane foams will typically comprise the components shown in Table 1, in the amounts indicated. The components shown in Table 1 will be discussed in detail later.

TABLE-US-00001 TABLE 1 Polyurethane Components Component pphp Polyol A  0-99 Polyol B  1-60 Polyol C  1-50 Polyol D 10-40 Polyol E 25-65 Water  0-10 Ethoxylated alcohol 0.5-4 8 Silicone surfactant  0-10 Blowing agent  0-40 Crosslinker 0-2 Amine catalyst   0-1.0 Metal catalyst   0-1.0 Polyisocyanate To provide NCO index = 70-150

[0075] The amount of polyisocyanate used in polyurethane formulations according to the invention is not limited, but it will typically be within those ranges known to those of skill in the art. An exemplary range is given in the above table, indicated by reference to “NCO Index” (isocyanate index). As is known in the art, the NCO index is defined as the number of equivalents of isocyanate, divided by the total number of equivalents of active hydrogen, multiplied by 100. The NCO index is represented by the following formula:

NCO index=[NCO/(OH+NH)]×100

[0076] In some embodiments of the invention, the catalyst, the blowing agent, the crosslinker, the surfactant and optionally one or more other additives commonly used in polyurethane formation may be combined into the polyol mixture. Such mixtures may subsequently be contacted with an organic isocyanate to form a polyurethane foam, again optionally in the presence of other additives known in the art.

[0077] In addition to making flexible foams, the invention may also be used to prepare semi-flexible foams, such as are commonly utilized for many applications in the automotive industry (e.g., instrument panels, headliners and interior trims).

[0078] Although specific exemplary types of polyurethane foams are discussed above and elsewhere herein, it is to be understood that polyurethane foams of any type may be prepared according to the invention.

[0079] Catalysts

[0080] The polyurethane formulation disclosed herein can contain any of the catalysts, and combination of catalysts, known or used for the production of polyurethane foams. Examples of useful catalysts include sodium hydroxide, sodium acetate, tertiary amines or materials which generate tertiary amines such as trimethylamine, triethylene diamine, bis-(dimethylaminoethyl)ether, bis-(dimethyl-(amino-N-propyl)-methylamine, N-methyl morpholine, N,N-dimethyl cyclohexylamine, and N,N-dimethylaminoethanol. Also applicable are metal compounds such as tin alkyl carboxylates, dibutyl tin diacetate, dibutyl tin dioctoate, dibutyl tin dilaurate and stannous octoate. Exemplary catalysts are DABCO 33LV® (Evonik Corp.) and DABCO® T-9 (Evonik Corp.). Many other kinds of catalysts can be substituted for those listed above, if desired. Typically, the loading of catalyst(s) for making a foam according to the invention will be in the range of from greater than 0 to about 2 pphp, more typically from greater than 0 to about 1 pphp, and most typically from greater than 0 to about 0.5 pphp. However, any effective amount may be used. The term “pphp” means weight parts per hundred weight parts of the polyol.

[0081] Blowing Agents

[0082] Polyurethane foam production may be aided by the inclusion of a blowing agent to produce voids in the polyurethane matrix during polymerization. Any blowing agent known in the art may be used. Suitable blowing agents include compounds with low boiling points which are vaporized during the exothermic polymerization reaction. Such blowing agents are generally inert and therefore do not decompose or react during the polymerization reaction. Examples of inert blowing agents include, but are not limited to, methylene chloride, carbon dioxide, chlorofluorocarbons, hydrogenated fluorocarbons, hydrogenated chlorofluorocarbons, acetone, and low-boiling hydrocarbons such as cyclopentane, isopentane, n-pentane, and their mixtures. Other suitable blowing agents include compounds, for example water, that react with isocyanate compounds to produce a gas.

[0083] Organic Isocyanates

[0084] Suitable organic isocyanate compounds include, but are not limited to, hexamethylene diisocyanate (HDI), phenylene diisocyanate (PDI), toluene diisocyanate (TDI), and 4,4′-diphenylmethane diisocyanate (MDI). In one aspect of the invention, 2,4-TDI, 2,6-TDI, or any mixture thereof is used to produce polyurethane foams. Other suitable isocyanate compounds are diisocyanate mixtures known commercially as “crude MDI.” One example is marketed by Dow Chemical Company under the name PAPI, and contains about 60% of 4,4′-diphenylmethane diisocyanate along with other isomeric and analogous higher polyisocyanates.

[0085] Also suitable are “prepolymers” of these isocyanate compounds, comprising a partially pre-reacted mixture of a polyisocyanate and a polyether or polyester polyol to convert one or more hydroxyls on the polyester polyol to substituted carbamate groups. Suitable prepolymers derived from polyether and polyester polyols are well known in the art.

[0086] Other Optional Components

[0087] A variety of other ingredients may be included in the formulations for making foams according to the invention. Examples of optional components include, but are not limited to, cell stabilizers, crosslinking agents, chain extenders, pigments, fillers, prepolymerised reaction products and combinations of any of these.

[0088] Practice of this invention may allow polyurethane manufacturers to realize one or more advantages. These may include a) reduced time and energy required to form polyol mixtures that may be readily used in polyurethane production; b) stable polyol mixtures that allow more time for processing other components for making polyurethane; c) polyurethane foam produced with this invention demonstrates higher airflow d) other physical properties of the produced foam are not adversely affected by employing this invention.

[0089] The invention is further described in the context of the following Examples, which are presented by way of illustration, not of limitation.

[0090] The present invention is directed to a composition comprising a) at least one isocyanate reactive polyol, and b) at least one ethoxylated alcohol of the following formula: RO(CH.sub.2CH.sub.2O).sub.nH, 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.

[0091] The present invention is also directed to a method to make a cellular or noncellular polyurethane by reacting the composition with at least one isocyanate.

[0092] Preferably, 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.

[0093] The present invention is also directed to 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.sub.2CH.sub.2O).sub.nH, 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.

[0094] Preferably, 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.

[0095] Preferably, at least one polyol is derived from natural resources and a second polyol containing polyoxylene or a polymeric polyol.

[0096] The present invention is also directed to 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.sub.2CH.sub.2O).sub.nH, 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.

[0097] Preferably, 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.

[0098] Preferably, the polyoxyethylene based polyol and polyoxyethylene based polyol is further combined with a natural resource based polyol.

[0099] The present invention is also directed to a polyurethane foam composition comprising 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.sub.2CH.sub.2O).sub.nH, 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; 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.

[0100] Preferably, the polyurethane foam composition comprises a polyol mixture 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.

[0101] Preferably, the polyurethane foam composition comprises a polyol mixture wherein at least one polyol is derived from natural resources and a second polyol containing polyoxylene or a polymeric polyol.

[0102] Preferably, the polyurethane foam composition further 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.

[0103] The present invention is also directed to a method for preparing polyurethane foam comprising the steps of a) forming a premix comprising the polyol mixture of any of claims 4-6, 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.

EXAMPLES

Example 1

Stability of Natural Oil-Polyol and Polyether Polyol Mixtures

[0104] Natural oil polyol and polyether polyol mixtures were prepared using the following procedure at room temperature (20-25° C.). To a beaker of 1000 mL was added 20-80 g polyol (A), 0-60 g polyol B, 20-80 g of polyol (D), catalyst, surfactant, and various amounts ethoxylated alcohols being tested. The amounts of the components are shown in Table 2. The mixture was then stirred using a mechanical stirrer with a diameter of 90 mm at 1150 rpm for 60 seconds or until a uniform mixture was formed. The mixture was then transferred to a glass vial of 20 mL and the vial was placed still for up to 6 months. The vial was visually checked periodically for any layer separation in the mixture. If any of the above phenomena were observed, the dispersion would be recorded as unstable; otherwise, the dispersion was recorded as stable. The stability results are listed in Table 3.

TABLE-US-00002 TABLE 2 Raw Material pphp Polyol A 60-90 Polyol B  0-60 Polyol D 10-40 SH301 0.6 DEOA-LF 1.5 DC5164 0.4 33LX 0.3 BLX11 0.08 Water 2.8 Ethoxylate alcohol 1-4

TABLE-US-00003 TABLE 3 Stability Results Polyol A/ Ethoxylated Avg. Amount Polyol D Mixture Stable Mixture stable Sample Alcohol R n HLB (pphp) ratio after 24 hours after 6 months 1 Tomadol ® 901 C9-C11 12 2.0 3/2 Yes Yes 2 Tomadol ® 23-1 C12-C13 1 3.7 2.0 2/3 Yes Yes 3 Tomadol ® 91-2.5 C9-C11 2.7 8.5 2.0 3/2 Yes Yes 4 Tomadol ® 1-3 C11 3 8.7 4.0 3/2 Yes Yes 5 Exxal 13 C12-C13 0 4.0 3/2 No No 6 PEG 200 18 3/2 No No 7 SPAN 80 4 3/2 No No

Example 2

Stability Test of Polyols with Different Molecular Weights and Polyoxylene Content

[0105] Ethoxylated alcohols with different alkyl groups, ethoxy units and therefore distinct HLB values were employed to prepare polyol mixtures according to the procedure of Example 1. The amounts of the components in the polyol mixture are shown in Table 4. The effects of the ethoxylated alcohols on the stability of the formed mixtures were compared following the visual check method of Example 1 and the results are listed in Table 5. All ethoxylated alcohols tested fit the following formula:

RO(CH.sub.2CH.sub.2O).sub.nH,

in which R is a linear or branched alkyl and n is an integer equal to or greater than 1 and equal to or less than 10.

TABLE-US-00004 TABLE 4 Formulation Component pphp Polyol C  5-50 Polyol E 25-65 Polyol A 10-40 Chain extender 0.75 Water 1.5-4   Silicone Surfactant 0.5-1.5 Dabco ® BL11 0.07 Dabco 33LV ® 0.2 T9 0.05 Ethoxylated alcohol 0.5-4  

TABLE-US-00005 TABLE 5 Stability of Hydrophobic and Hydrophilic Polyol Mixtures with Ethoxylated Alcohols Polyol Polyol Ethoxylated Avg. Amount Stable Stable Sample Alcohol R n HLB (pphp) 24 hours 3 weeks Control — — — — — No No 1 Tomadol ® 23-1 C12-C13 1 3.7 0.5-2.0 Yes Yes 2 Tomadol ® 1-3 C11-C13 3 8.7 0.5-2.0 Yes Yes 3 Tomadol ® 901 C9-C11 12 0.5-2.0 Yes Yes 4 Tomadol 900 C9-C11 13.1 2 Yes Yes 5 Propetal 160 Fatty alcohol 0.5-2.0 Yes No polyalkylene glycol ether 6 PEG 200 C8 0.5-2.0 Yes No 7 Neodol 91 0.5-2.0 Yes No 8 Genapol PF 20 EO/PO block 4 0.5-2.0 No No copolymer 40% 9 Genapol LA70 C12-C14 Fatty 13 0.5-2.0 No No alcohol ethoxylate with 10 Disperbyk Anionic agent 0.5-2.0 Yes No 11 Genapol O 20 C6-C10 Fatty 5 0.5-2.0 No No Alcohol indicates data missing or illegible when filed

[0106] Tomadol® 23-1, Tomadol® 1-3, Tomadol® 900 and Tomadol® 901 were from Evonik Corp. Propetal 160 a Fatty alcohol polyalkylene glycol ether was from Zschimmer and Schwarz, Polyethylene glycol polymer with MW from 200-5000, and Neodol 91 was from Shell Chemical. Samples 1˜4 may contain mixtures of compounds with structures falling within the scope of the specified “R” and “Avg. n”. “R” designates the range of carbon numbers of the linear alkyl group and “Avg. n” is the range or average number of ethoxy units in each sample. Genapol types were products of Clairant.

[0107] A polyol mixture without any ethoxylated alcohol became unstable in less than 2 hours. Other compounds, such as CARBOWAX™ Polyethylene Glycol (PEG) 200 from Dow Chemical with a formula of HO—(CH.sub.2CH.sub.2O).sub.4H did not stabilize polyol mixtures when combined thereinto.

[0108] This example illustrates that only ethoxylated alcohols satisfying certain structural requirements may stabilize hydrophobic and hydrophilic polyol dispersions for at least 24 hours.

Example 3

Physical Properties of Polyurethane Foams Made with and without Ethoxylated Alcohols

[0109] Physical properties were measured according to ASTM 3574. Physical properties of Sample 1 of Example 1 were measured and are presented in Table 6.

TABLE-US-00006 TABLE 6 Physical Properties of Polyurethane Sample 1 Measurement (units) No Additive 2 pphp 4 pphp 6 pphp Airflow (L/M) 70.0 74.7 88.4 90.1 Core Density (kg/m.sup.3) 41.0 41.4 41.9 42.0 Tensile (kPa) 114.8 116.8 111.1 112.6 Elongation (%) 107.0 108.0 113.7 111.4 Tear (N/m) 237.3 239.9 253.8 245.0

[0110] The data in Table 6 indicates that the inclusion of ethoxylated alcohol of the invention does not affect foaming kinetics. It also does not adversely affect the physical properties of the resulted polyurethane foams.

Example 4

[0111] Ethoxylated alcohols with different alkyl groups, ethoxy units and therefore distinct HLB values were employed to prepare a polyol mixture of 50 wt % Polyol A and 50 wt % Polyol C according to the procedure of Example 1. Their effects on the stability of the formed mixtures were compared following the visual check method of Example 1 and the results are listed in Table 7. All ethoxylated alcohols tested fit the following formula:

RO(CH.sub.2CH.sub.2O).sub.nH,

in which R is a linear or branched alkyl and n is an integer equal to or greater than 1 and equal to or less than 10.

TABLE-US-00007 TABLE 7 Raw material Test Test Test Test Test Test Test Test Test Test Test Test Test Test Test name Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Voranol Polyether triol based 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 3322 on gylcol 3600MW Random Alcupol F Polyether triol based 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 3231 on gylcol 4500 MW 70% EO Voranol Polyether triol based 3138 on gylcol 3000MW PO Control PE 40 2 BYK 307 Polyalkylenpolydimethyl- 2 siloxane for wetting and dispersing Genapol Nonionic EO/PO 2 PF 20 Blockpolymer 20% EO Genapol Nonionic EO/PO 2 PF 40 Blockpolymer 40% EO Genapol C12/C14 fatty alcohol 2 EA030 ethoxylate with 3 EO Genapol C12/C14 fatty alcohol 2 EA080 ethoxylate with 7 EO Propetal Nonionic EO/PO 2 160 Blockpolymer 16-20% EO Tomadol 2 1-3 Tomadol 2 23-6.5 Tomadol 2 900 Tomadol 2 91-6 Rewopol Aqueous solution of 2 SB DO sodium diisooctyl- 75PG sulfosuccinate. MH1000 Alkoxy Polyether 2 100MW Tomadol 2 400 Mixing procedure All componets are weighed into a PE 350 ml Beaker and mixed with a 4 cm diameter disk for 30 s. Then the dispersed mixture is put into a glass tube and stored at 23° C. 50% humidity Stability test time 1 h 1 h yes no yes yes yes no no no no no no yes no no no 2 h 2 h yes no yes yes yes no no no no no no yes no no no 4 h 4 h yes no yes yes yes no no no no no no yes no no no 1 day 1 day yes no yes yes yes yes yes yes yes yes yes yes yes yes yes 2 days 2 days yes no yes yes yes yes yes yes yes yes yes yes yes yes yes 1 week 2 week yes no yes yes yes yes yes yes yes yes yes yes yes yes yes 1 month 1 month yes no yes yes yes yes yes yes yes yes yes yes yes yes yes 2 month 2 month yes no yes yes yes yes yes yes yes yes yes yes yes yes yes 3 month 3 month yes no yes yes yes yes yes yes yes yes yes yes yes yes yes

[0112] While the invention has been described with reference to the above Examples, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.