Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4829—Polyethers containing at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/2805—Compounds having only one group containing active hydrogen
  • C08G18/2815—Monohydroxy compounds
  • C08G18/283—Compounds containing ether groups, e.g. oxyalkylated monohydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4833—Polyethers containing oxyethylene units
  • C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
  • C08G18/4841—Polyethers containing oxyethylene units and other oxyalkylene units containing oxyethylene end groups
• • C08G2101/0008—
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0008—Foam properties flexible
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0041—Foam properties having specified density
  • C08G2110/005—< 50kg/m3
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0083—Foam properties prepared using water as the sole blowing agent

Definitions

• This disclosure relates to stable hydrophobic hydrophylic-polyol dispersions, a method of preparing such mixtures, their uses in manufacturing polyurethane foams, and articles made therefrom.
• Polyurethane foam made from polyols with different hydrophobicity or polarity or polyoxyethylene and polyoxypropylene content, molecular weight, and structure are used in a wide variety of applications ranging from cushioning (such as mattresses, pillows and seat cushions) to packaging, thermal and acoustical insulation, medical applications, and carpet padding in automobiles.
• the differing hydrophobicity, molecular weight, and structure of the polyols lead to pre-mix system phase separation and foam processing problems such as pinholes, splits, banding, defects and foam collapse when producing the flexible polyurethane foam.
• the phase separation problem and processing difficulties are resolved when a fatty alcohol ethoxylate is used enabling insitu or in a stable, homogeneous one phase blend of the polyol mixtures or blended components.
• U.S. Pat. No. 4,125,505 discloses that polyalkylene oxides having a certain arrangement as one of the polyol components can be improved in their compatibility with an inherently incompatible chain extender, like a low molecular weight polyol, by means of particulated polymers formed from unsaturated monomers such as, for example, styrene-acrylonitrile copolymers.
• the disadvantages for the polyurethane producer are that the dispersed particles of polymer can sediment out of mixtures, if not used directly, or have an unintended influence on the mechanical properties of the polyurethanes produced therefrom.
• U.S. Pat. No. 5,344,584 discloses admixing a mixture of two isocyanate-reactive compounds that are normally not miscible with each other with a surface-active compound which, as carboxylic ester or carboxamide, has acidic groups.
• the polycarboxylic ester preferably derives from a hydroxycarboxylic acid or from a ring-opened lactone. Adding the surface-active compound to the inherently incompatible polyol components does improve compatibility, but not always to the desired extent.
• these polycarboxylic esters are also not universally applicable because of the possible reactivity of their acidic groups.
• U.S. Pat. No. 7,223,890 B2 describes an isocyanate-reactive mixture which in addition to water and a DMC-catalyzed alkoxylated polyol contains a compound which has ethylene oxide units and improves the water compatibility of the mixture. Examples mentioned of these compounds include block copolymers of ethylene oxide and propylene oxide. None in the disclosure points to any compatibility improvement of mutually incompatible polyols.
• US 2006/0189704 discloses the compatibility improvement, i.e., prevention of phase separation, of compositions containing at least a polyol, water and an alkoxylate with three or more hydroxyl groups of compounds with reactive hydrogen, for example glycerol, as compatibility-improving agents.
• compatibility-improving agents prevents the separation of water and polyol in storage.
• US 2008/009209 describes a curable composition containing a polyacid, one or more polyols and also one or more reactive water-repellant agents.
• Polyalkoxylates of alkyl- and alkenylamines are among the recited examples of water-repellant compounds.
• These known water-repellant, curable compositions are used for coating glass fibers or mineral wool, while a specific range is recommended for the ratio of carboxyl groups to OH groups in the mixture. Compatibilization of polyol mixtures forms no part of the subject matter of this published US application.
• U.S. Pat. No. 5,668,187 B2 discloses the production of rigid polyurethane foam wherein the blowing agent comprises an aqueous emulsion containing a copolymer of various unsaturated monomers in emulsified form being directly added, as further reaction component, in the reaction of polyol with polyisocyanate.
• Polyurethanes are produced by reaction of OH reactive polyols with at least an isocyanate or polyisocyanates. While the selection of polyisocyanates available on a large industrial scale is limited, there are a multiplicity of polyols or OH active components which can be used. These range from polyether polyols to polyester polyols and hydroxyl-functional polybutadienes to low molecular weight polyols used as chain extenders or chain crosslinkers for example.
• a polyurethane is produced by reacting not just one specific polyol with polyisocyanates, but a mixture of various polyols, which can be of low or comparatively high molecular weight.
• the mixture of polyols used is not stable, but tends to phase separation over time at least. This separation is caused for example by different molecular weights, differing monomeric composition, differing polarity and/or a differing structural arrangement such as, for example, a random or block wise arrangement or a linear or branched structure of the polyols.
• Polyurethane foam production involves the accurate pumping, mixing and dispensing of several components or streams into a mold or onto a moving conveyor belt.
• the number of streams can be from two to >50.
• the typical formulation is composed of two streams consisting of an isocyanate stream and a resin stream.
• the resin or polyol stream is a mixture of polyether or polyester polyol, crosslinkers (e.g. diethanolamine, glycerol) surfactant, catalyst, water or/and auxiliary blowing agent and other additives.
• the isocyanate stream comprises toluene diisocyanate, various forms of diphenylmethane diisocyanate, or mixes of the two, or other isocyanate types.
• separation tendency is amplified in the presence of certain substances such as water for example. Separation can also be caused or amplified by the use of additives and/or auxiliary agents, or by the presence of more than two polyols during production or as a ready to use mix.
• This invention solves the above problems by providing stable polyol compositions at all states and these compositions are stable for at least 24 hours, in some cases for more than 6 months among many other objects and benefits.
• Another object of this invention is to provide 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.
• a further object is to provide a method preparing the stable-polyol mixture of the invention.
• a further object of this invention is to provide a formulation and a method for making stable polyurethane foams from the invention.
• this disclosure provides a polyol mixture comprising:
• this disclosure provides a polyol mixture comprising:
• this invention discloses a polyol mixture comprising:
• this invention provides a method for making the above polyol mixture, such method comprises the following steps:
• this invention provides a method for making the above polyol mixture, such method comprises the following steps:
• 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
• 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; and
• HLB hydrophilic-lipophilic balance
• this invention provides a method for making the above polyol mixture, such method includes the following steps:
• 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 less than or equal to 17.9; and
• HLB hydrophilic-lipophilic balance
• Another aspect of the invention relates to a polyurethane foam formulation
• a polyurethane foam formulation comprising the polyol mixture disclosed above, along with 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.
• this invention discloses a polyurethane foam made with the previously disclosed foam formulation.
• this invention provides a method for preparing a polyurethane foam comprising the following steps:
• 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.
• the at least one ethoxylated alcohol of the present invention has the following formula A:
• 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.
• HLB hydrophilic-lipophilic balance
• 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.
• n may be any integer equal to or greater than 1.
• HLB hydrophilic-lipophilic balance
• 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.
• An HLB value of 0 corresponds to a completely hydrophobic molecule, and a value of 20 corresponds to a completely hydrophilic molecule.
• the HLB value of C 13 H 27 (CH 2 CH 2 O) 40 H is calculated as the following:
• Mh is the molecular mass of the hydrophilic part (CH 2 CH 2 O) 40 H and M is the molecular mass of the entire molecule.
• 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.
• 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:
• 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
• 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.
• 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
• 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.
• 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.
• 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.
• 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.
• Typical manufacturing conditions involve contacting polyol, and ethoxylated alcohol solution of formula A in a blending tank with a capacity of 20 m 3 and mixing with a 30 watt mechanical stirrer at about 1800 revolutions per minute (rpm).
• 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.
• 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.
• NCO Index isocyanate index
• NCO index [NCO/(OH+NH)] ⁇ 100
• 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.
• 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).
• polyurethane foams of any type may be prepared according to the invention.
• the polyurethane formulation disclosed herein can contain any of the catalysts, and combination of catalysts, known or used for the production of polyurethane foams.
• 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.
• 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.
• 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.
• Polyurethane foam production may be aided by the inclusion of a blowing agent to produce voids in the polyurethane matrix during polymerization.
• a blowing agent 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.
• 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.
• suitable blowing agents include compounds, for example water, that react with isocyanate compounds to produce a gas.
• 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).
• HDI hexamethylene diisocyanate
• PDI phenylene diisocyanate
• TDI toluene diisocyanate
• MDI 4,4′-diphenylmethane diisocyanate
• 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.
• 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.
• ingredients may be included in the formulations for making foams according to the invention.
• 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.
• 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.
• the present invention is directed to a composition
• a composition comprising a) at least one isocyanate reactive polyol, and b) at least one ethoxylated alcohol of the following formula: RO(CH 2 CH 2 O) n H, 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.
• HLB hydrophilic-lipophilic balance
• 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.
• 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.
• 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.
• the present invention is also directed to a polyol mixture
• 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 2 CH 2 O) n H, 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.
• HLB hydrophilic-lipophilic balance
• 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
• 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.
• HLB hydrophilic-lipophilic balance
• At least one polyol is derived from natural resources and a second polyol containing polyoxylene or a polymeric polyol.
• 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 2 CH 2 O) n H, 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.
• HLB hydrophilic-lipophilic balance
• 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
• 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.
• HLB hydrophilic-lipophilic balance
• the polyoxyethylene based polyol and polyoxyethylene based polyol is further combined with a natural resource based polyol.
• the present invention is also directed to a polyurethane foam composition
• 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 2 CH 2 O) n H, 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.
• HLB hydrophilic-lipophilic balance
• 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.
• HLB hydrophilic-lipophilic balance
• 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.
• 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.
• 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.
• 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.
• 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.
• 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:
• 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.
• a polyol mixture without any ethoxylated alcohol became unstable in less than 2 hours.
• Other compounds such as CARBOWAXTM Polyethylene Glycol (PEG) 200 from Dow Chemical with a formula of HO—(CH 2 CH 2 O) 4 H did not stabilize polyol mixtures when combined thereinto.

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