HK1092825B - Polyurethane foams made with alkoxylated vegetable oil hydroxylate - Google Patents

Description

Polyurethane foams made from alkoxylated vegetable oil hydroxylates

Technical Field

The present invention relates generally to polyurethanes, and more particularly to polyurethane foams and elastomers in which at least a portion of a petroleum-derived polyol is replaced with an alkoxylated vegetable oil hydroxylate.

Background

Polyurethane foams and elastomers have been widely used in many industrial and consumer products. This popularity is attributed to the broad mechanical properties of polyurethanes and the ability to be relatively easy to manufacture. For example, automobiles include many polyurethane parts, such as seats, dashboards, and other cabin interior parts. Polyurethane foams are traditionally classified as either flexible foams (or semi-rigid foams) or rigid foams; flexible foams are generally softer, less dense, more flexible, and more capable of structural rebound after being loaded than rigid foams.

Methods for preparing polyurethane foams are well known to those skilled in the art. Polyurethanes are formed by reacting NCO groups with hydroxyl groups. The most common method of producing polyurethanes is by reaction of polyols with isocyanates, which form backbone urethane groups. Crosslinking agents, blowing agents, catalysts and other additives may also be included in the polyurethane formulation as desired.

Polyols used in polyurethane production are typically petrochemical in origin, generally derived from propylene oxide, ethylene oxide, and various starters such as ethylene glycol, propylene glycol, glycerol, sucrose, and sorbitol. Polyester polyols and polyether polyols are the most commonly used polyols in polyurethane production. For semi-rigid foams, polyester polyols or polyether polyols having a molecular weight of about 300 to 2000 are generally used, whereas for flexible foams, long-chain polyols having a molecular weight of about 1000 to 10000 are generally used. The polyester polyol and polyether polyol may be selected to engineer a particular polyurethane elastomer or foam to have the desired final toughness, durability, density, flexibility, compression set and modulus, and hardness properties. In general, high molecular weight polyols and low functionality polyols tend to produce softer foams than low molecular weight polyols and high functionality polyols.

Petroleum derived components such as polyester polyols and polyether polyols pose several disadvantages. The use of such polyester or polyether polyols requires the consumption of petroleum, which is a non-renewable energy source. Moreover, the production of polyols requires a significant amount of energy investment, since the petroleum used to produce the polyols must be drilled, refined, and then transported to refineries where the petroleum is refined, processed, and the final polyols are produced. As the mass consumer becomes more aware of the environmental impact of this manufacturing chain, the consumer demand for "greener" products will continue to grow. To help reduce the consumption of petroleum while meeting the ever-increasing demands of consumers, it is desirable to replace, in part or in whole, petroleum-derived polyester or polyether polyols used in the production of polyurethane elastomers and foams with more versatile, renewable and environmentally responsible components.

Some attempts have been made by workers in the field to achieve such alternatives. Plastics and foams have been developed which are manufactured using vegetable derived fatty acid triglycerides, including soy derivatives. As a renewable, versatile and environmentally friendly resource, soybean has been and will always be an ideal ingredient for plastic manufacturing.

For example, U.S. patent 5221433 to Daute et al describes the use of an alkoxylated soybean oil prepared by epoxidizing soybean oil followed by hydrogenation over a nickel catalyst. The hydroxy-functional oil is alkoxylated using a potassium hydroxide catalyst and a product for deinking. However, Daute et al do not mention the use of these oils in the preparation of polyurethane foams or elastomers.

In U.S. patent 5512134, Daute et al provide a method for removing printing ink from printing waste paper in the presence of deinking chemicals. Alkoxylates of oxidized oils are used as deinking chemicals in the process. Among the alkoxylates mentioned there are alkoxylates of oxidized oils such as fish oil, rapeseed oil and soybean oil, in which the alkylene oxide component represents 20 to 95% by weight, preferably 50 to 80% by weight. Daute et al do not mention the use of these alkoxylates in the preparation of polyurethanes.

U.S. patent 5516853 to Schneider et al discloses that alkoxylated soybean oil can be used in the production of unsaturated polyesters. The use of these substances in water-dilutable binders and water-thinnable paints is described in this patent. Schneider et al do not describe or suggest the use in polyurethanes.

Kurth in a number of U.S. patents including 6180686, 6465569, and 6624244 describes the use of unmodified (oxidized) soybean oil as a polyol in the production of polyurethane materials. This oil was blown with air to oxidize it, but no description was given of any other modification treatment prior to using this oxidized soybean oil as a substitute for petroleum-based polyols.

One approach to alkoxylation of vegetable oils, and polyurethanes formed from these alkoxylated oils, is described in U.S. published patent application 2004/0209971A 1 to Kurth et al. Kurth et al seem to have propoxylated transesterification-oxidized oils, or they have used propoxylated glycerol or other materials for their transesterification reactions. Kurth et al describe that the limits of alkoxylated compounds they have prepared are 5-10%. Furthermore, Kurth et al may incorporate and use THF or other furfural derivatives to make foams.

Accordingly, there remains a need in the art for continued development of polyurethane foams and elastomers prepared from environmentally friendly, renewable components.

Disclosure of Invention

Accordingly, the present invention provides polyurethane foams and elastomers made from alkoxylated vegetable oil hydroxylates. Alkoxylated vegetable oil hydroxylates are environmentally friendly "bio-based" polyols which also have the potential to improve hydrophobicity in polyurethanes. Alkoxylated vegetable oil hydroxylates may replace all or a portion of the petroleum-derived polyols in polyurethane-forming formulations. The foams of the present invention are useful in a wide variety of applications.

These and other advantages and benefits of the present invention will be apparent from the detailed description of the invention provided below.

Detailed description of the invention

The present invention will now be described for purposes of illustration and not limitation. Except in the examples, or where otherwise indicated, all numbers expressing quantities, percentages, OH numbers, functionalities and so forth in the specification are to be understood as being modified in all instances by the term "about". Unless otherwise indicated, equivalent weights and molecular weights given herein in daltons (Da) are number average equivalent weights and number average molecular weights, respectively.

The present invention provides a polyurethane foam or elastomer comprising the product of reacting at least one polyisocyanate with at least one alkoxylated vegetable oil hydroxylate containing from 15 to 90 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate, optionally, at least one non-vegetable oil based polyol, optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers.

The present invention also provides a method of making a polyurethane foam or elastomer involving reacting at least one polyisocyanate with at least one alkoxylated vegetable oil hydroxylate containing from 15 wt.% to 90 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate, optionally at least one non-vegetable oil-based polyol, optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers.

The present invention also provides a polyurethane foam or elastomer comprising the product of reacting at least one polyisocyanate with at least one alkoxylated vegetable oil hydroxylate comprising from 15 to 90 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate, and alkoxylating in the presence of a Double Metal Cyanide (DMC) catalyst, optionally at least one non-vegetable oil based polyol, optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers.

The present invention also provides a process for preparing a polyurethane foam or elastomer involving reacting at least one polyisocyanate with at least one alkoxylated vegetable oil hydroxylate containing from 15% to 90% by weight alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate, and alkoxylating in the presence of a Double Metal Cyanide (DMC) catalyst, optionally at least one non-vegetable oil based polyol, optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers.

The present invention also provides a continuous process for the preparation of an alkoxylated vegetable oil hydroxylate, said process involving a) forming a first partial mixture of a Double Metal Cyanide (DMC) catalyst and a hydroxylated vegetable oil in a continuous reactor effective to initiate the polyoxyalkylation reaction of the hydroxylated vegetable oil following the addition of alkylene oxide to the continuous reactor, b) continuously adding one or more alkylene oxides to the continuous reactor, c) continuously adding the hydroxylated vegetable oil to the continuous reactor, d) continuously adding fresh Double Metal Cyanide (DMC) catalyst and/or more Double Metal Cyanide (DMC) catalyst/more hydroxylated vegetable oil mixture to the reactor to maintain catalytic activity, e) polyoxyalkylating the hydroxylated vegetable oil to form an alkoxylated vegetable oil hydroxylate by continuously repeating steps a) through d), and f) continuously removing the alkoxylated vegetable oil hydroxylate from the continuous reactor.

Suitable polyisocyanates are known to those skilled in the art and include unmodified isocyanates, modified polyisocyanates, and isocyanate prepolymers. These organic polyisocyanates include aliphatic and alicyclic polyisocyanatesAliphatic, araliphatic, aromatic polyisocyanates, and a class of heterocyclic polyisocyanates such as those described by w.siefken in Justus liebig annalen der Chemie, 562, pages 75-136. Examples of such polyisocyanates include those represented by the formula Q (NCO)_nPolyisocyanates of the formula (I) in which n is a number from 2 to 5, preferably from 2 to 3, and Q is an aliphatic hydrocarbon radical having from 2 to 18, preferably from 6 to 10, carbon atoms; alicyclic hydrocarbon groups having 4 to 15, preferably 5 to 10, carbon atoms; araliphatic hydrocarbon radicals containing 8 to 15, preferably 8 to 13, carbon atoms; or an aromatic hydrocarbon group containing 6 to 15, preferably 6 to 13, carbon atoms.

Examples of suitable isocyanates include ethylene diisocyanate; 1, 4-tetramethylene diisocyanate; 1, 6-hexamethylene diisocyanate; 1, 12-dodecane diisocyanate; cyclobutane-1, 3-diisocyanate; cyclohexane-1, 3-and-1, 4-diisocyanate, and mixtures of these isomers; 1-isocyanato-3, 3, 5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate, for example, German Ausleegeschrift 1202785 and U.S. Pat. No. 3401190); 2, 4-and 2, 6-hexahydrotoluylene diisocyanate and mixtures of these isomers; dicyclohexylmethane-4, 4' -diisocyanate (hydrogenated MDI or HMDI); 1, 3-and 1, 4-phenylene diisocyanates; 2, 4-and 2, 6-toluene diisocyanate and mixtures of these isomers (TDI); diphenylmethane-2, 4 '-and/or-4, 4' -diisocyanate (MDI); 1, 5-naphthalene diisocyanate; triphenylmethane-4, 4', 4 "-triisocyanate; polyphenyl-polymethylene-polyisocyanates of the kind obtainable by condensation of aniline with formaldehyde and subsequent phosgenation are described, for example, in GB 878430 and GB 848671; norbornane diisocyanates such as described in U.S. patent 3492330; meta-and para-isocyanatophenylsulfonyl isocyanate described in U.S. Pat. No. 3454606; perchloroaryl polyisocyanates such as those described in U.S. patent 3227138; modified polyisocyanates containing carbodiimide groups as described in us patent 3152162; modified polyisocyanates containing urethane groups such as described in U.S. Pat. Nos. 3394164 and 3644457; modified polyisocyanates containing allophanate groups such as described in GB 994890, BE761616 and NL 7102524; modified polyisocyanates containing isocyanurate groups such as those described in U.S. Pat. No. 3002973, German Patentschriften 1022789, 1222067 and 1027394 and German Offenlegungsschriften1919034 and 2004048; modified polyisocyanates containing urea groups as described in German Patentschrift 1230778; biuret group-containing polyisocyanates such as those described in german patent publication 1101394, U.S. patents 3124605 and 3201372, and GB 889050; polyisocyanates obtained by telomerization as described, for example, in U.S. Pat. No. 3654106; polyisocyanates containing ester groups such as described in GB 965474 and GB 1072956, us 3567763 and german patent schrift 1231688; reaction products of the above isocyanates with acetals as described in German Patentschrift 1072385; and polyisocyanates containing polymerized fatty acid groups as described in U.S. patent 3455883. It is also possible to use the isocyanate-containing distillation residues accumulated in the industrial scale production of isocyanates, optionally in the form of one or more of the polyisocyanate solutions described above. Those skilled in the art will recognize that mixtures of these polyisocyanates described above may also be used.

In general, it is preferred to use readily available polyisocyanates such as 2, 4-and 2, 6-toluene diisocyanate and mixtures of these isomers (TDI); polyphenyl polymethylene polyisocyanate (crude MDI) obtained by condensing aniline with formaldehyde and then carrying out phosgenation reaction; and polyisocyanates containing carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups (modified polyisocyanates).

Isocyanate-terminated prepolymers may also be used in the foam and elastomer preparation process of the present invention. Prepolymers can be prepared by reacting an excess of organic polyisocyanate or mixtures thereof with a small amount of an active hydrogen-containing compound as determined by the well-known Zerewitinoff test, as described by Kohler in the Journal of the American Chemical Society, 49, 3181 (1927). These compounds and their preparation are well known to those skilled in the art. The use of any one particular active hydrogen compound is not critical; any such compound may be used in the practice of the present invention.

The alkoxylated vegetable oil hydroxylates of the present invention may replace, in part or in whole, the petroleum-derived polyols typically used in the production of polyurethanes. The preferred vegetable oil starting molecule for producing the alkoxylated vegetable oil hydroxylates of the present invention is soybean oil, although the inventors herein contemplate that virtually any other vegetable oil, such as sunflower oil, canola oil, linseed oil, cottonseed oil, tung oil, palm oil, poppy seed oil, corn oil and peanut oil, may be hydroxylated and used in accordance with the present invention.

Hydroxylation, by which the inventors herein mean introducing and/or increasing the number of hydroxyl groups (i.e., OH) in the molecule. In the present invention, the vegetable oil may be hydroxylated by any method known in the art including, but not limited to, air oxidation, use of peroxides, and by hydroformylation.

After this hydrogenation, the vegetable oil hydroxylates may be alkoxylated by any method known to those skilled in the art. Particularly preferred processes are base (e.g., KOH) catalyzed processes and Double Metal Cyanide (DMC) catalyzed processes.

Alkylene oxides that may be used in the alkoxylation process of the present invention include, but are not limited to, ethylene oxide, propylene oxide, 1, 2-and 2, 3-butylene oxide, isobutylene oxide, epichlorohydrin, cyclohexene oxide, styrene oxide, and higher alkylene oxides such as C₅-C₃₀An alpha-alkylene oxide. Ethylene oxide alone is generally not preferred, but mixtures of propylene oxide and ethylene oxide with high ethylene oxide content (i.e., up to 85 mole%) can be effectively used. Propylene oxide or mixtures of propylene oxide with ethylene oxide or another alkylene oxide are preferred for the claimed process. Other polymerizable monomers such as polycarboxylic anhydrides (phthalic anhydrides) may also be usedTrimellitic anhydride, pyromellitic anhydride, methylnadic anhydride, nadic anhydride, chlorendic anhydride, and maleic anhydride) lactone and other monomers as disclosed in U.S. patents 3404109, 5145883, and 3538043. The alkoxylated vegetable oil hydroxylates of the present invention may optionally be capped with ethylene oxide (cap), as is known in the art and disclosed, for example, in U.S. patents 4355188, 4721818 and 5563221.

The alkoxylated vegetable oil hydroxylates preferably have an alkoxylate content of from 15 to 90 wt.%, more preferably from 20 to 80 wt.%, based on the weight of the alkoxylated vegetable oil hydroxylate. The alkoxylate content of the alkoxylated vegetable oil hydroxylate of the present invention may be in the range of any combination of these values, inclusive of the recited values.

As noted above, the alkoxylation of the vegetable oil hydroxylate may be catalyzed by any alkoxylation catalyst known in the art, but Double Metal Cyanide (DMC) catalysts are particularly preferred in the present invention because the resulting polyols have higher molecular weights which enhance the comfort of the resulting foam or elastomer. The alkoxylation process of the present invention may use any Double Metal Cyanide (DMC) catalyst. Suitable Double Metal Cyanide (DMC) catalysts are known to those skilled in the art. Double metal cyanide complex (DMC) catalysts are non-stoichiometric complexes of low molecular weight organic complexing agents and optionally other complexing agents with double metal cyanide salts such as zinc hexacyanocobaltate.

Exemplary Double Metal Cyanide (DMC) complex catalysts for use in the alkoxylation of vegetable oil hydroxylates of the present invention include those suitable for use in the preparation of low unsaturation polyoxyalkylene polyether polyols, such as those disclosed in U.S. patents 3427256, 3427334, 3427335, 3829505, 4472560, 4477589 and 5158922. More preferred Double Metal Cyanide (DMC) catalysts in the process of the present invention are those capable of preparing "ultra-low" unsaturation polyether polyols. Such catalysts are disclosed in U.S. Pat. Nos. 5470813, 5482908, and 5545601, the entire contents of which are incorporated herein by reference. Particularly preferred in the process of the present invention is the zinc hexacyanocobaltate catalyst prepared by the process described in U.S. patent 5482908.

The concentration of the DMC catalyst is chosen to ensure good control of the polyoxyalkylation reaction under the given reaction conditions. The concentration of the catalyst is preferably in the range of 0.0005 to 1% by weight, more preferably in the range of 0.001 to 0.1% by weight, most preferably in the range of 0.001 to 0.01% by weight, based on the amount of polyol to be produced. The DMC catalyst may be present in the alkoxylation process of the present invention in an amount ranging between any combination of these values, inclusive of the recited values.

As will be appreciated by those skilled in the art, an organic complexing ligand may be present with the DMC catalyst. In the process of the present invention, any organic complexing ligand may be part of the DMC catalyst, such as those described in U.S. Pat. Nos. 3404109, 3829505, 3941849, 5158922 and 5470813 and EP 0700949, EP 0761708, EP 0743093, WO 97/40086 and JP 4145123. These organic complexing ligands include water-soluble organic compounds having heteroatoms such as oxygen, nitrogen, phosphorus or sulfur, which may form complexes with the DMC compound. Preferred organic complexing ligands are alcohols, aldehydes, ketones, ethers, esters, amides, ureas, nitriles, sulfides and mixtures thereof. More preferred organic complexing ligands include water-soluble aliphatic alcohols such as ethanol, isopropanol, n-butanol, isobutanol, sec-butanol and tert-butanol. Most preferred is tert-butanol.

The DMC catalyst in the process of the present invention may optionally contain at least one functionalized polymer. As used herein, a "functionalized polymer" is a polymer or salt thereof that contains one or more functional groups including oxygen, nitrogen, sulfur, phosphorus, or halogen. Examples of functionalized polymers preferred in the method of the present invention include, but are not limited to, polyethers, polyesters, polycarbonates, polyalkylene glycol sorbitolsAnhydride esters, polyalkylene glycol glycidyl ethers, polyacrylamides, acrylamide-acrylic acid copolymers, polyacrylic acids, acrylic acid-maleic acid copolymers, N-vinylpyrrolidone-acrylic acid copolymers, acrylic acid-styrene copolymers and salts thereof, maleic acid, styrene-maleic anhydride copolymers and salts thereof, block copolymers composed of branched ethoxylated alcohols and alkoxylated alcohols, such as NEODOL (sold by Shell Chemical Company), polyethers, polyacrylonitriles, polyalkyl acrylates, polyalkyl methacrylates, polyvinyl methyl ethers, polyvinyl ethyl ethers, polyvinyl acetates, polyvinyl alcohols, poly-N-vinylpyrrolidone, polyvinyl methyl ketones, poly (4-vinylphenol),Oxazoline polymers, polyalkyleneimines, hydroxyethylcellulose, polyacetals, glycidyl ethers, glycosides, carboxylic esters of polyols, bile acids and their salts, their esters or their amides, cyclodextrins, phosphorus compounds, unsaturated carboxylic esters and ionic surface-or interface-active compounds. Polyether polyols are most preferably used as functionalized polymers in the alkoxylation process of the present invention.

When used, the functionalized polymer is present in the DMC catalyst in an amount of from 2 to 80 wt.%, preferably from 5 to 70 wt.%, and more preferably from 10 to 60 wt.%, based on the total weight of the DMC catalyst. The amount of functionalized polymer in the DCM catalyst can range from any combination of these values, inclusive of the recited values. Alternatively, catalyst polyol suspensions may be used, as described in U.S. patent 6699961.

The process of the present invention for alkoxylating vegetable oil hydroxylates may be batch, semi-batch or continuous. In a batch or semi-batch process for the production of polyols, the high molecular weight starter compound and the catalyst are added all at once to the reactor. A number of workers have patented continuous processes for the production of polyols.

A continuous process for preparing polyoxyalkylene polyethers using Double Metal Cyanide (DMC) catalysts as the polyoxyalkylation catalyst and employing continuous addition of alkylene oxide to a continuous oxyalkylation reactor with continuous addition of starter and catalyst is disclosed in U.S. Pat. No. 5689012 to Pazos et al, the contents of which are incorporated herein by reference. The polyether product is said to be particularly suitable for use in polymer forming systems, particularly polyurethanes. In the process of Pazos et al, polyol synthesis begins with the addition of a catalyst/initiator to a continuous reactor, initiates an alkoxylation reaction, and continues with the addition of catalyst, initiator, and alkylene oxide while continuing with the removal of polyol product. The process described by Pazos et al adds "fresh" catalyst or pre-activates the catalyst.

The term "continuous" as used herein may be defined as a mode of adding the relevant catalyst or reactant such that an effective concentration of the catalyst or reactant is maintained substantially continuously during that mode. For example, the addition of catalyst may be truly continuous, or may be performed in relatively closely spaced increments. Likewise, continuous starter addition may be truly continuous, or may be performed in an incremental manner. The addition of the catalyst or reactants in this manner reduces the concentration of the added material to a very low level (5-10ppm) at some time prior to the next incremental addition, which is not to be distinguished from the polyol production process of the present invention. However, it is preferred that the catalyst concentration be maintained at substantially the same level throughout most of the continuous reaction and that a low molecular weight starter be present throughout most of the reaction. Incremental addition of catalyst and/or reactants does not significantly affect product properties and is still "continuous" as defined herein.

The nominal functionality of the alkoxylated vegetable oil hydroxylates of the present invention is preferably in the range of from 1-5 to 6, more preferably in the range of from 2-4, and the molecular weight is in the range of from 300 to 10000Da, more preferably in the range of from 500 to 7000 Da. The functionality and molecular weight of the alkoxylated vegetable oil hydroxylates of the present invention may range between any combination of these values, inclusive of the recited values.

The polyurethane-forming formulations of the present invention may optionally include one or more non-vegetable oil-based (i.e., petroleum-derived) polyols, such as polyether polyols, polyester polyols, polyacetal polyols, polycarbonate polyols, polyester ether polyols, polyester carbonate polyols, polythioether polyols, polyamide polyols, polyester amide polyols, polysiloxane polyols, polybutadiene polyols, and polyacetone polyols. The optional non-vegetable oil-based polyol may preferably be prepared in the presence of a Double Metal Cyanide (DMC) catalyst.

Suitable additives that may optionally be included in the polyurethane-forming formulations of the present invention include, for example, foam stabilizers, catalysts, cell regulators, reaction inhibitors, flame retardants, plasticizers, pigments, fillers, and the like.

Suitable foam stabilizers which may be used in the process of the present invention include, for example, polyether siloxanes, preferably those which are insoluble in water. Such compounds generally have a structure in which a copolymer of ethylene oxide and propylene oxide is attached to the residue of polydimethylsiloxane. Such foam stabilizers are described, for example, in U.S. patents 2834748, 2917480 and 3629308.

Catalysts suitable for use in the foam or elastomer forming process of the present invention include those known in the art. These catalysts include, for example, tertiary amines such as triethylamine, tributylamine, N-methylmorpholine, N-ethylmorpholine, N, N, N ', N' -tetramethylethylenediamine, pentamethyldiethylenetriamine and higher homologues (for example, as described in DE-A2624527 and 2624528), 1, 4-diazabicyclo (2.2.2) octane, N-methyl-N '-dimethylaminoethylpiperazine, bis- (dimethylaminoalkyl) piperazine, N, N-dimethylbenzylamine, N, N-dimethylcyclohexylamine, N, N-diethylbenzylamine, bis (N, N-diethylaminoethyl) adipate, N, N, N' N '-tetramethyl-1, 3-butanediamine, N, N-dimethyl-beta-phenylethylamine, N, N' -dimethyl-beta-phenylethylamine, N-ethylmorpholine, N-ethyldiethylenetriamine and higher homologues thereof, 1, 2-dimethylimidazole, 2-methylimidazole, monocyclic and bicyclic amines, and bis (dialkylamino) alkyl ethers such as 2, 2-bis (dimethylaminoethyl) ether.

Other suitable catalysts that may be used in the production of the polyurethane foams and elastomers of the present invention include, for example, organometallic compounds, particularly organotin compounds. Suitable organotin compounds include organotin compounds containing sulfur. Such catalysts include, for example, di-n-butyltin mercaptide. Other types of suitable organotin catalysts include: preferred are tin (II) carboxylates, such as tin (II) acetate, tin (II) octanoate, tin (II) ethylhexanoate and/or tin (II) laurate; tin (IV) compounds, such as dibutyltin oxide, dibutyltin dichloride, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate and/or dioctyltin diacetate.

Further examples of suitable additives which may optionally be included in the flexible polyurethane foams of the present invention may be found, for example, in Kunststoff-Handbuch, Vol.VII, edited by Vieweg & Hochtlen, Carl Hanser Verlag, Munich 1993, third edition, p.104-127. Details regarding the use and mode of action of these additives are also set forth in this document.

Examples

The invention is further illustrated but is not intended to be limited by the following examples in which all amounts given in parts and percentages are to be understood as being by weight unless otherwise indicated.

Propoxylated oxidized soybean oil-polyol A

The hydroxylated soybean oil was alkoxylated using a two gallon pressure reactor equipped with an internal heat exchanger, three feed streams, and computer program control. The reactor was evacuated and heated to 130 ℃. A1: 1 mixture of oxidized (hydroxylated) soybean oil and toluene (60 grams) was charged to the reactor, along with a double metal cyanide catalyst as described in U.S. Pat. No. 5482908 (200 ppm based on the weight of the final polyol). Oxidized soybean oil was produced by urea Soy Systems in a controlled process in which air was blown through the oil at elevated temperatures. This step introduces hydroxyl groups into the fatty acid groups. The oxidized soybean oil had a hydroxyl number of 267.

The catalyst was activated with about 10% propylene oxide based on the initial charge of toluene and hydroxylated soybean oil (i.e., a total of 75 grams of propylene oxide was used to activate the catalyst). After activation, a 1: 1 mixture of hydroxylated soybean oil and toluene (1140 g) was added via one feed stream over a period of 6 hours, and propylene oxide (1140 g) was added via a second feed stream at a temperature of 130 ℃ over a period of 8 hours.

The reactor was stripped at 130 ℃ to remove toluene and excess propylene oxide, and the contents were cooled to 80 ℃ and labeled polyol A.

And (3) analysis: OH number 56.

Propoxylated oxidized soybean oil-polyol B

Some modifications were made to the general procedure and equipment described above for making polyol A, and to make polyol B. First 700MW of propoxylated glycerol (100 g) was charged to the reactor, followed by the catalyst (0.743 g). After evacuation and purging the system with nitrogen, propylene oxide (50 g) was added to activate the catalyst. A1: 1 mixture of hydroxylated soybean oil and toluene (1600 g) was added over 2.5 hours, while propylene oxide (1964 g) was added over 3.3 hours. After the addition was complete, the temperature was raised from 130 ℃ to 150 ℃ to complete the propylene oxide reaction. The system was then stripped to remove toluene. A product with a hydroxyl number of 78 is obtained, designated polyol B.

The above procedure was used to make other polyols B-1 and B-2 from hydroxylated soybean oil, except as shown below; is differentInstead, a small amount of 700MW propoxylated glycerol was used as a starter to activate the catalyst prior to the addition of soybean oil dissolved in toluene as a propylene oxide co-feed. All operations were carried out at 130 ℃ and finally stripping was carried out at 150 ℃ to remove toluene.

	Polyol B-1	Polyol B-2
			Initiator (propoxylated glycerol with OH number 240)	100 g	100 g
Toluene	400 g	400 g
			Propylene oxide for activation	50 g	50 g
1: 1 toluene and soybean oil, OH number 174	1400 g	-
			1: 1 toluene and soybean oil, OH 294	-	2220 g
Propylene oxide feed	1754 g	2921 g
			Time of feed	2 hours	2 hours
Target OH number	56	56

Propoxylated-ethoxylated oxidized soybean oil-polyol C

A solution was prepared from toluene (2000 g), hydroxylated soybean oil (hydroxyl number 179, functionality 3, available as GC-5N from Urethane Soy Systems, 2000 g) and concentrated phosphoric acid (1 g). The solution was added to a two gallon container (Pope Scientific Inc.) and the reactor was pressurized with 50psia nitrogen in preparation for charging to the two gallon reactor.

A two gallon stainless steel polyol reactor was charged with a 36 hydroxyl value polyether triol (500 g; 0.321OH equivalent) derived from glycerol containing 20 wt% ethylene oxide chain ends (tip) and 1.088 g of double metal cyanide catalyst (as described in U.S. Pat. No. 5482908). The mixture was heated to 130 ℃ under vacuum with stirring and nitrogen was slowly bubbled through enough to maintain the reactor pressure at 1.0 psia. After purging/stripping for 30 minutes, the nitrogen was stopped and the vacuum valve was closed, thus sealing the reactor interior under a vacuum of-0.3 psia. Propylene oxide (50 g) was pumped into the closed reactor over 5 minutes. After this addition, the pressure in the reactor was raised to 23.4 psia. The pressure began to drop very quickly and reached 3.5psia at 6 minutes after the propylene oxide addition, indicating activation of the DMC catalyst. The mixed feeds of propylene oxide (90 g) and ethylene oxide (10 g) were added at 9.5 g/min and 1 g/min, respectively, without causing a rise in reactor pressure-indicating that the catalyst was activated. The third feed stream containing the hydroxylated soybean oil in toluene solution described above was started at 11 grams/minute while continuing to add ethylene oxide and propylene oxide at the same rate. After 1 hour, the feed rate of hydroxylated soybean oil was increased to 16.7 g/min and the feed was continued at this rate until a total of 1880 g of solution (3.0 OH equivalents) was added. The addition of the oxide was continued at the same rate until a total of 1355 g of propylene oxide and 155 g of ethylene oxide were added. The ethylene oxide feed rate was increased to 6.3 grams/minute and the propylene oxide feed rate was maintained at 9.5 grams/minute, and another portion of ethylene oxide (600 grams) and propylene oxide (900 grams) were added to the reactor.

After the oxide addition was complete, the pressure in the reactor was about 30 psia. After the feed of both ethylene oxide and propylene oxide was stopped, the pressure dropped by about 3psia to 27psia over 3 minutes, which remained constant during 30 minutes of heating at 130 ℃. The mixture was then cooled to 80 ℃ and the vacuum valve was slowly opened to begin stripping toluene. When no volatilization of toluene into the vacuum tube cold trap was observed, the temperature was raised to 130 ℃ and purged with nitrogen at this temperature under high vacuum for an additional 30 minutes. The product discharged from the reactor was an orange liquid with a hydroxyl number of 45.7 and a kinetic viscosity of 1117 cSt.

Propoxylated-ethoxylated oxidized soybean oil-polyol D

A two gallon stainless steel polyol reactor was charged with polyol C (500 g) and double metal cyanide catalyst (1.088 g) (as described in U.S. patent 5482908). The mixture was heated to 130 ℃ under vacuum with stirring and nitrogen was slowly bubbled through enough to maintain the reactor pressure at 1.0 psia. After purging/stripping for 30 minutes, the nitrogen was stopped and the vacuum valve was closed, thus sealing the reactor interior under a vacuum of-0.3 psia. Propylene oxide (50 g) was pumped into the closed reactor over 5 minutes. After this addition, the pressure in the reactor was raised to 25.1 psia. The pressure began to drop very quickly and reached 5.0psia at 4 minutes after the addition of propylene oxide, indicating activation of the DMC catalyst. The mixed feeds of propylene oxide (90 g) and ethylene oxide (10 g) were added at 9.5 g/min and 1 g/min, respectively, without causing a rise in reactor pressure-indicating that the catalyst was activated. While continuing to add ethylene oxide and propylene oxide at the same rate, a third feed stream containing a toluene solution of hydroxylated soybean oil (described above in making polyol C) was started at 5 grams/minute and increased to 20 grams/minute in a linear fashion over 40 minutes. The addition of hydroxylated soybean oil was continued at this rate until a total of 1880 grams of solution (3.0 OH equivalents) were added. The addition of the oxide was continued at the same rate until a total of 1355 g of propylene oxide and 155 g of ethylene oxide were added. The ethylene oxide feed rate was then increased to 6.3 g/min and the propylene oxide feed rate was maintained at 9.5 g/min, and another portion of ethylene oxide (600 g) and propylene oxide (900 g) was added to the reactor.

After the oxide addition was complete, the pressure in the reactor was about 28 psia. After the feed of both ethylene oxide and propylene oxide was stopped, the pressure dropped by about 4psia to about 24psia in 5 minutes, which remained constant during 30 minutes of heating at 130 ℃. The mixture was then cooled to 80 ℃ and the vacuum valve was slowly opened to begin stripping toluene. When no volatilization of toluene into the vacuum tube cold trap was observed, the temperature was raised to 130 ℃ and purged with nitrogen at this temperature under full vacuum for an additional 30 minutes. The product withdrawn from the reactor was an orange liquid with a hydroxyl number of 42.6 and a kinetic viscosity of 1353 cSt.

The following components were used to prepare the foams:

polyol A propoxylated Soybean oil hydroxylate having a hydroxyl number of about 56 mg KOH/g

The preparation method is as above;

polyol B propoxylated Soybean oil hydroxylate having a hydroxyl number of about 78 mg KOH/g

The preparation method is as above;

polyol D propoxylated soybean oil hydroxylate having a hydroxyl number of about 42.6 mg KOH/g,

prepared according to the method;

a triol having a polyol E hydroxyl number of about 56 mg KOH/g;

MeCl₂dichloromethane;

surfactant A Silicone surfactant available from GE Silicones as NIAX L620

An agent;

surfactant B silicon available from Goldschmidt AG as TEGOSTAB B-8715LF

An alkylene oxide surfactant;

surfactant C Silicone surfactant available from Air Products as DABCO 5943

An agent;

85/15 mixture of DEOA diethanolamine and water;

catalyst A (2-ethylhexyl) phthalate/tin alkyl hexanoate (ratio 50/50)

Catalyst, available as DABCO T-10 from Air Products;

catalyst B an amine catalyst available as NIAX A-1 from GE Silicones;

catalyst C an amine catalyst available from Air Products as DABCO 33-LV;

catalyst D amine catalyst available from GE Silicones as NIAX A-4;

catalyst E can be catalyzed by a delayed action amine available as NIAX A-300 from GE Silicones

An agent;

isocyanate A toluene diisocyanate available as MONDUR TD-80 from Bayer

Material science; and

diphenylmethane diisocyanate (PMDI) polymerized with isocyanate B and having an NCO group content of about

32.4, a functionality of about 2.3 and a viscosity of about 25 mPas at 25 ℃.

The components were mixed in the amounts (parts) listed in Table I below and reacted at an isocyanate index (100A/B) of 110. The physical properties of the resulting free-blown foams were determined and are summarized in table I. It is apparent from reference to Table I that the foam-forming formulations of the present invention having alkoxylated soybean oil hydroxylates produced useful foam materials.

TABLE I

Component (php)	Comparative example 1	Example 2	Comparative example 3	Example 4
					Polyol E	100	50	100	50
Polyol A	0	50	-	-
					Polyol B	-	-	0	50
MeCl2	11.3	11.3	11.3	11.3
					Water (W)	4.5	4.5	4.5	4.5
Surfactant A	0.9	1.1	0.9	1.1
					Catalyst A	0.75	0.9	0.75	0.9
Catalyst B	0.1	0.1	-	-
					Isocyanate A	57.4	57.4	54.7	59.3
Physical Properties
					Density (pounds per cubic foot)	0.95	0.94	0.91	0.96
Air flow (cubic feet/minute)	3.45	4.22	4.79	4.55
					IFD 25% (pounds/50 square inch)	21.0	21.0	17.3	18
IFD 65% (pounds/50 square inch)	38.30	35.30	28.5	30.8
					IFD 25% recovery (pounds per 50 square inches)	15.0	15.0	12.0	12.8
Percent recovery	71.4	71.4	69.6	71.1
					Comfort factor	1.8	1.7	1.7	1.7
Tensile Strength (psi)	11.68	10.12	12.32	12.68
					Elongation (%)	128.9	97.8	193.4	104.6
Tear Strength (pli)	2.21	1.31	1.9	1.3
					Compression set rate 90% (%)	62.2	14.5	47.9	16.7

The components were mixed in the amounts (parts) listed in Table II below and reacted at an isocyanate index (100A/B) of 110. The physical properties of the resulting free-blown foams were determined and are summarized in table II.

TABLE II

Component (php)	Example 5	Example 6	Example 7
				Polyol E	50	50	50
Polyol B	50	50	50
				Water (W)	4.50	4.50	4.50
MeCl2	11.30	11.30	11.3
				Catalyst A	0.10	0.10	0.10
Surfactant A	1.3	1.20	1.10
				Isocyanate A	59.3	59.3	59.3
				Density (pounds per cubic foot)	0.91	0.91	0.91
Air flow (cubic feet/minute)	3.4	4.2	4.9
				Observation results	Opening of the container	Opening of the container	Good taste

The components were mixed in the amounts (parts) listed in Table III below and reacted at the isocyanate index (100A/B) in a closed mold. The physical properties of the resulting free-rise foams from the molding were determined and are summarized in Table III.

TABLE III

Component (php)	Example 8	Example 9	Example 10	Example 11
					Polyol D	100	100	100	100
Water (W)	3.29	3.29	3.29	3.29
					DEOA	0.412	0.412	0.412	0.412
Surfactant B	1.38	1.38	1.38	1.38
					Surfactant C	0.06	0.12	0.12	0.12
Catalyst B	0.17	0.17	0.17	0.17
					Catalyst C	0.75	-	-	-
Catalyst D	0.5	0.5	0.5	0.5
					Catalyst E	-	0.75	0.75	0.75
Isocyanate B	60.37	64.46	51.57	58.02
					Index of refraction	100	100	80	90
					Part density (pounds per cubic foot)	2.74	2.82	2.70	2.87
Observation results			Hole collapse

The polyurethane foams and elastomers of the present invention may find use in a number of applications, for example where environmental concerns are valued, a percentage of renewable resource content is required, and/or increased hydrophobicity is advantageous. The inventors contemplate that these conditions may include, but are not limited to, automotive interior parts such as instrument panels, seat cushions, and headrests; a polyurethane structural foam material; coating the floor; and a sports track.

The foregoing description of the embodiments of the invention has been presented for purposes of illustration and not of limitation. It will be apparent to those skilled in the art that various changes or modifications may be made in the embodiments described herein without departing from the spirit and scope of the invention. The scope of the invention is defined by the appended claims.

Claims (50)

1. A polyurethane foam or elastomer comprising

At least one polyisocyanate and

at least one alkoxylated vegetable oil hydroxylate containing from 15 to 90 wt.%, based on the weight of the alkoxylated vegetable oil hydroxylate,

optionally at least one non-vegetable oil based polyol,

optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers, wherein the vegetable oil hydroxylate is prepared by air oxidation.

2. The polyurethane foam or elastomer of claim 1, wherein the at least one polyisocyanate is selected from the group consisting of ethylene diisocyanate, 1, 4-butylene diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 12-dodecane diisocyanate, cyclobutane-1, 3-diisocyanate, cyclohexane-1, 3-and-1, 4-diisocyanate, 1-isocyanato-3, 3, 5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate), 2, 4-and 2, 6-hexahydrotoluene diisocyanate, dicyclohexylmethane-4, 4' -diisocyanate (hydrogenated MDI or HMDI), 1, 3-and 1, 4-phenylene diisocyanate, mixtures thereof, and mixtures thereof, 2, 4-and 2, 6-Tolylene Diisocyanate (TDI), diphenylmethane-2, 4 ' -and/or 4, 4 ' -diisocyanate (MDI), 1, 5-naphthylene diisocyanate, triphenylmethane-4, 4 ', 4 "-triisocyanate, polyphenyl-polymethylene-polyisocyanates (crude MDI), norbornane diisocyanate, m-and p-isocyanatophenylsulfonyl isocyanate, perchloroaryl polyisocyanate, carbodiimide-modified polyisocyanate, urethane-modified polyisocyanate, allophanate-modified polyisocyanate, isocyanurate-modified polyisocyanate, urea-modified polyisocyanate, biuret-containing polyisocyanate, isocyanate-terminated prepolymer, and mixtures thereof.

3. The polyurethane foam or elastomer of claim 1, wherein the at least one polyisocyanate is Toluene Diisocyanate (TDI).

4. The polyurethane foam or elastomer of claim 1, wherein the vegetable oil is selected from the group consisting of sunflower oil, canola oil, linseed oil, cottonseed oil, tung oil, palm oil, poppy seed oil, corn oil, peanut oil, and soybean oil.

5. The polyurethane foam or elastomer of claim 1, wherein the vegetable oil is soybean oil.

6. The polyurethane foam or elastomer of claim 1 wherein the alkoxylated vegetable oil hydroxylate contains from 20 to 80 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate.

7. The polyurethane foam or elastomer of claim 1, wherein the vegetable oil hydroxylate is alkoxylated with an alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, isobutylene oxide, epichlorohydrin, cyclohexene oxide, styrene oxide, C₅-C₃₀Alpha-alkylene oxides and mixtures thereof.

8. The polyurethane foam or elastomer of claim 1, wherein the alkoxylated vegetable oil hydroxylate is capped with ethylene oxide.

9. The polyurethane foam or elastomer of claim 1, wherein the non-vegetable oil based polyol is selected from the group consisting of polyethers, polyesters, polyacetals, polyesterethers, polythioethers, polyamides, polyesteramides, polysiloxanes, polybutadienes, and polypropions.

10. The polyurethane foam or elastomer of claim 1, wherein the non-vegetable oil based polyol is a polyether polyol.

11. The polyurethane foam or elastomer of claim 10, wherein the polyether polyol is prepared in the presence of a Double Metal Cyanide (DMC) catalyst.

12. One of an automotive interior part, a polyurethane structural foam, a floor coating, and a sports track comprising the polyurethane foam or elastomer of claim 1.

13. A method of preparing a polyurethane foam or elastomer comprising reacting:

at least one polyisocyanate; and

at least one alkoxylated vegetable oil hydroxylate containing from 15 to 90 wt.%, based on the weight of the alkoxylated vegetable oil hydroxylate,

optionally at least one non-vegetable oil based polyol,

optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers;

wherein the vegetable oil hydroxylate is prepared by air oxidation.

14. The process of claim 13, wherein the at least one polyisocyanate is selected from the group consisting of ethylene diisocyanate, 1, 4-butylene diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 12-dodecane diisocyanate, cyclobutane-1, 3-diisocyanate, cyclohexane-1, 3-and-1, 4-diisocyanate, 1-isocyanato-3, 3, 5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate), 2, 4-and 2, 6-hexahydrotoluylene diisocyanate, dicyclohexylmethane-4, 4' -diisocyanate (hydrogenated MDI or HMDI), 1, 3-and 1, 4-phenylene diisocyanate, 2, 4-and 2, 6-Toluene Diisocyanate (TDI), diphenylmethane-2, 4 ' -and/or-4, 4 ' -diisocyanate (MDI), 1, 5-naphthalene diisocyanate, triphenylmethane-4, 4 ' -triisocyanate, polyphenyl-polymethylene-polyisocyanate (crude MDI), norbornane diisocyanate, m-and p-isocyanatophenylsulfonyl isocyanate, perchloroaryl polyisocyanate, carbodiimide-modified polyisocyanate, urethane-modified polyisocyanate, allophanate-modified polyisocyanate, isocyanurate-modified polyisocyanate, urea-modified polyisocyanate, biuret-containing polyisocyanate, isocyanate-terminated prepolymer and mixtures thereof.

15. The method of claim 13, wherein the at least one polyisocyanate is Toluene Diisocyanate (TDI).

16. The method of claim 13, wherein the vegetable oil is selected from the group consisting of sunflower oil, canola oil, linseed oil, cottonseed oil, tung oil, palm oil, poppy seed oil, corn oil, peanut oil, and soybean oil.

17. The method of claim 13, wherein the vegetable oil is soybean oil.

18. The method of claim 13, wherein the vegetable oil hydroxylate is alkoxylated with an alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, isobutylene oxide, epichlorohydrin, cyclohexene oxide, styrene oxide, C₅-C₃₀Alpha-alkylene oxides and mixtures thereof.

19. The method of claim 13, wherein the alkoxylated vegetable oil hydroxylate is capped with ethylene oxide.

20. The method of claim 13, wherein the alkoxylated vegetable oil hydroxylate comprises from 20 wt.% to 80 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate.

21. The method of claim 13, wherein the non-vegetable oil based polyol is selected from the group consisting of polyethers, polyesters, polyacetals, polyesterethers, polythioethers, polyamides, polyesteramides, polysiloxanes, polybutadienes, and polypropiones.

22. The method of claim 13, wherein the non-vegetable oil based polyol is a polyether polyol.

23. The method of claim 13, wherein the non-vegetable oil-based polyol is prepared in the presence of a Double Metal Cyanide (DMC) catalyst.

24. The method of claim 23, wherein the Double Metal Cyanide (DMC) catalyst is zinc hexacyanocobaltate.

25. One of an automotive interior part, a polyurethane structural foam, a floor coating, and a sports track comprising the polyurethane foam or elastomer produced by the method of claim 13.

26. A polyurethane foam or elastomer comprising

At least one polyisocyanate and

at least one alkoxylated vegetable oil hydroxylate containing from 15 to 90 wt.%, based on the weight of the alkoxylated vegetable oil hydroxylate, and being alkoxylated in the presence of a Double Metal Cyanide (DMC) catalyst,

optionally at least one non-vegetable oil based polyol,

optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers;

wherein the vegetable oil hydroxylate is prepared by air oxidation.

27. The polyurethane foam or elastomer of claim 26, wherein the at least one polyisocyanate is selected from the group consisting of ethylene diisocyanate, 1, 4-butylene diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 12-dodecane diisocyanate, cyclobutane-1, 3-diisocyanate, cyclohexane-1, 3-and-1, 4-diisocyanate, 1-isocyanato-3, 3, 5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate), 2, 4-and 2, 6-hexahydrotoluene diisocyanate, dicyclohexylmethane-4, 4' -diisocyanate (hydrogenated MDI or HMDI), 1, 3-and 1, 4-phenylene diisocyanate, mixtures thereof, and mixtures thereof, 2, 4-and 2, 6-Tolylene Diisocyanate (TDI), diphenylmethane-2, 4 ' -and/or 4, 4 ' -diisocyanate (MDI), 1, 5-naphthylene diisocyanate, triphenylmethane-4, 4 ', 4 "-triisocyanate, polyphenyl-polymethylene-polyisocyanates (crude MDI), norbornane diisocyanate, m-and p-isocyanatophenylsulfonyl isocyanate, perchloroaryl polyisocyanate, carbodiimide-modified polyisocyanate, urethane-modified polyisocyanate, allophanate-modified polyisocyanate, isocyanurate-modified polyisocyanate, urea-modified polyisocyanate, biuret-containing polyisocyanate, isocyanate-terminated prepolymer, and mixtures thereof.

28. The polyurethane foam or elastomer of claim 26, wherein the at least one polyisocyanate is Toluene Diisocyanate (TDI).

29. The polyurethane foam or elastomer of claim 26, wherein the vegetable oil is selected from the group consisting of sunflower oil, canola oil, linseed oil, cottonseed oil, tung oil, palm oil, poppy seed oil, corn oil, peanut oil, and soybean oil.

30. The polyurethane foam or elastomer of claim 26, wherein the vegetable oil is soybean oil.

31. The polyurethane foam or elastomer of claim 26, wherein the alkoxylated vegetable oil hydroxylate contains 20 to 80 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate.

32. The polyurethane foam or elastomer of claim 26, wherein the vegetable oil hydroxylate is alkoxylated with an alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, isobutylene oxide, epichlorohydrin, cyclohexene oxide, styrene oxide, C₅-C₃₀Alpha-alkylene oxides and mixtures thereof.

33. The polyurethane foam or elastomer of claim 26, wherein the alkoxylated vegetable oil hydroxylate is capped with ethylene oxide.

34. The polyurethane foam or elastomer of claim 26, wherein the non-vegetable oil-based polyol is selected from the group consisting of polyethers, polyesters, polyacetals, polyesterethers, polythioethers, polyamides, polyesteramides, polysiloxanes, polybutadienes, and polypropionones.

35. The polyurethane foam or elastomer of claim 26, wherein the non-vegetable oil based polyol is a polyether polyol.

36. The polyurethane foam or elastomer of claim 35, wherein the polyether polyol is prepared in the presence of a Double Metal Cyanide (DMC) catalyst.

37. One of an automotive interior part, a polyurethane structural foam, a floor coating, and a sports track comprising the polyurethane foam or elastomer of claim 26.

38. A method of preparing a polyurethane foam or elastomer comprising reacting:

at least one polyisocyanate; and

at least one alkoxylated vegetable oil hydroxylate containing from 15 to 90 wt.%, based on the weight of the alkoxylated vegetable oil hydroxylate, and being alkoxylated in the presence of a Double Metal Cyanide (DMC) catalyst,

optionally at least one non-vegetable oil based polyol,

optionally in the presence of at least one of blowing agents, surfactants, pigments, flame retardants, catalysts and fillers;

wherein the vegetable oil hydroxylate is prepared by air oxidation.

39. The process of claim 38, wherein the at least one polyisocyanate is selected from the group consisting of ethylene diisocyanate, 1, 4-butylene diisocyanate, 1, 6-hexamethylene diisocyanate, 1, 12-dodecane diisocyanate, cyclobutane-1, 3-diisocyanate, cyclohexane-1, 3-and-1, 4-diisocyanate, 1-isocyanato-3, 3, 5-trimethyl-5-isocyanatomethylcyclohexane (isophorone diisocyanate), 2, 4-and 2, 6-hexahydrotoluylene diisocyanate, dicyclohexylmethane-4, 4' -diisocyanate (hydrogenated MDI or HMDI), 1, 3-and 1, 4-phenylene diisocyanate, 2, 4-and 2, 6-Toluene Diisocyanate (TDI), diphenylmethane-2, 4 ' -and/or-4, 4 ' -diisocyanate (MDI), 1, 5-naphthalene diisocyanate, triphenylmethane-4, 4 ' -triisocyanate, polyphenyl-polymethylene-polyisocyanate (crude MDI), norbornane diisocyanate, m-and p-isocyanatophenylsulfonyl isocyanate, perchloroaryl polyisocyanate, carbodiimide-modified polyisocyanate, urethane-modified polyisocyanate, allophanate-modified polyisocyanate, isocyanurate-modified polyisocyanate, urea-modified polyisocyanate, biuret-containing polyisocyanate, isocyanate-terminated prepolymer and mixtures thereof.

40. The method of claim 38, wherein the at least one polyisocyanate is Toluene Diisocyanate (TDI).

41. The method of claim 38, wherein the vegetable oil is selected from the group consisting of sunflower oil, canola oil, linseed oil, cottonseed oil, tung oil, palm oil, poppy seed oil, corn oil, peanut oil, and soybean oil.

42. The method of claim 38, wherein the vegetable oil is soybean oil.

43. The method of claim 38, wherein said vegetable oil hydroxylate is alkoxylated with an alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, 1, 2-butylene oxide, 2, 3-butylene oxide, isobutylene oxide, epichlorohydrin, cyclohexene oxide, styrene oxide, C₅-C₃₀Alpha-alkylene oxides and mixtures thereof.

44. The method of claim 38, wherein the alkoxylated vegetable oil hydroxylate is capped with ethylene oxide.

45. The method of claim 38, wherein the alkoxylated vegetable oil hydroxylate comprises from 20 wt.% to 80 wt.% alkoxylate, based on the weight of the alkoxylated vegetable oil hydroxylate.

46. The method of claim 38, wherein the non-vegetable oil based polyol is selected from the group consisting of polyethers, polyesters, polyacetals, polyesterethers, polythioethers, polyamides, polyesteramides, polysiloxanes, polybutadienes, and polypropiones.

47. The method of claim 38, wherein the non-vegetable oil based polyol is a polyether polyol.

48. The method of claim 38, wherein the non-vegetable oil-based polyol is prepared in the presence of a Double Metal Cyanide (DMC) catalyst.

49. The method of claim 48, wherein said Double Metal Cyanide (DMC) catalyst is zinc hexacyanocobaltate.

50. One of an automotive interior part, a polyurethane structural foam, a floor coating, and a sports track comprising the polyurethane foam or elastomer produced by the method of claim 38.