Bio-based polyurethane foam materials including graphite materials

Patent metadata

Field	Value
Publication number	US-9868835-B1
Application number	US-201615234367-A
Country	US
Kind code	B1
Filing date	Aug 11, 2016
Priority date	Aug 11, 2016
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

A bio-based polyol-containing polymer foam material, which includes a bio-based polyol-containing polymer foam present in a bulk concentration of the bio-based polymer foam material of 99% by weight or greater; and a graphite material present in a bulk concentration of the bio-based polyol-containing polymer foam material of 1% by weight or less. The bio-based polyol-containing polymer foam material is especially suitable for automotive components having deadening and vibration management features.

First claim

What is claimed is:

1. A bio-based polyol-containing polymer foam material comprising:
a bio-based polyol-containing polymer foam present in a bulk concentration of the bio-based polymer foam material of 99% by weight or greater; and
a graphite nano-platelet (GNP) material present in a bulk concentration of the bio-based polyol-containing polymer foam material of 1% by weight or less and having a surface area of 120 to 150 m 2 /g.

2. The bio-based polyol-containing polymer foam material of claim 1 , wherein the GNP material has an average particle diameter of 4 to 6 microns.

3. The bio-based polyol-containing polymer foam material of claim 1 , wherein the GNP material is finely dispersed within the bio-based polyol-containing polymer foam.

4. The bio-based polyol-containing polymer foam material of claim 1 , wherein the GNP material present in a bulk concentration of the bio-based polyol-containing polymer foam material is of 0.5%.

5. The bio-based polyol-containing polymer foam material of claim 1 , wherein the GNP material present in a bulk concentration of the bio-based polyol-containing polymer foam material is of 0.25%.

6. The bio-based polyol-containing polymer foam material of claim 1 , wherein the bio-based polyol-containing polymer foam is a mixture of 50% by weight petroleum based polyol and 50% by weight bio-based polyol.

7. The bio-based polyol-containing polymer foam material of claim 1 , wherein the bio-based polyol-containing polymer foam is a flexible foam.

8. A bio-based polyurethane foam comprising the reaction product of:
a bio-based containing polyol;
an isocyanate-containing compound; and
a graphite nano-platelet (GNP) material present in a bulk concentration of 1% by weight or less and having a surface area of 120 to 150 m 2 /g,
the bio-based polyurethane foam having a density in the range of 20-95 kg/m 3 , a wet compression set in the range of 5-50%, a tear resistance 200-350 N/m, and/or a tensile modulus in the range of 50-120 kPa.

9. The bio-based polyurethane foam of claim 8 , wherein the GNP material has an average particle diameter of 4 to 6 microns.

10. The bio-based polyurethane foam of claim 8 , wherein the GNP material is finely dispersed within the bio-based polyurethane foam.

11. The bio-based polyurethane foam of claim 8 , wherein the GNP material is present in a bulk concentration of the bio-based polyurethane foam of 0.5%.

12. The bio-based polyurethane foam of claim 8 , wherein the GNP material is present in a bulk concentration of the bio-based polyurethane foam of 0.25%.

13. The bio-based polyurethane foam of claim 8 , wherein a ratio of a petroleum based polyol to a bio-based polyol in the bio-based polyurethane foam is in the range of 2:1 to 1:2.

14. The bio-based polyurethane foam of claim 8 , wherein the bio-based polyurethane foam is a flexible foam.

15. A method for forming a bio-based polyurethane foam comprising the steps of:
mixing a bio-based polyol with a petroleum-based polyol to obtain a bio-based polyol mixture;
adding a graphite nano-platelet (GNP) material having a surface area of 120 to 150 m 2 /g to the bio-based polyol mixture to obtain a bio-based polyol-graphite mixture; and
adding an isocyanate containing material to the bio-based polyol-graphite mixture to obtain a bio-based polyurethane foam mixture.

16. The method of claim 15 , wherein the GNP material is present in the bio-based polyol-graphite mixture in a weight percent of 1.0 or less.

17. The method of claim 15 , wherein the GNP material has an average particle diameter of 4 to 6 microns.

18. The method of claim 15 , wherein the GNP material adding step includes dispersing the graphite material into the bio-based polyol mixture to obtain the bio-based polyol-graphite mixture.

19. The method of claim 15 , further comprising curing the bio-based polyurethane foam mixture to obtain a bio-based polyurethane foam.

20. The method of claim 15 , wherein the bio-based polyurethane foam is the flexible bio-based polyurethane foam.

Assignees

• Ford Global Tech Llc

Inventors

• Kiziltas Alper
• Mielewski Deborah Frances
• Lee Ellen Cheng-Chi

Classifications

• C08J9/008 Primary

  Nanoparticles · CPC title

• C08G18/0838

  Manufacture of polymers in the presence of non-reactive compounds (preparation of compositions C08L75/00) · CPC title

• C08G2101/0008

  Chemistry & Metallurgy · mapped topic

• C08G18/14

  Manufacture of cellular products · CPC title

• C08K3/04

  Carbon · CPC title