Encapsulated flexible polyurethane foam and method for making polyol to form foam

Abstract

A cellular material. The cellular material can be the reaction product of a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and an isocyanate.

1 . A cellular material comprising the reaction product of: 
 a vegetable-based polyol made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol; and    an isocyanate.    
   
   
       2 . The cellular material of  claim 1  wherein the vegetable oil is further exposed to a blowing agent.  
   
   
       3 . The cellular material of  claim 2  wherein the blowing agent is oxygen.  
   
   
       4 . The cellular material of  claim 1  wherein the method of producing the vegetable-based polyol further includes the step of heating the vegetable oil while exposing the vegetable oil to UV light.  
   
   
       5 . The cellular material of  claim 1  wherein the method of producing the vegetable-based polyol is carried out at room temperature.  
   
   
       6 . The cellular material of  claim 1  wherein the cellular material has a rating of less than or equal to 2.7 according to the SAE J1351 odor test.  
   
   
       7 . The cellular material of  claim 1  wherein the UV light has a wavelength in the range of 300 nanometers to 400 nanometers.  
   
   
       8 . The cellular material of  claim 1  wherein the UV light has a wavelength of 315 nanometers.  
   
   
       9 . The cellular material of  claim 1  wherein the method of producing the vegetable-based polyol further includes stripping the vegetable polyol of one or more volatile by-product compounds after exposing the vegetable oil to UV light.  
   
   
       10 . The cellular material of  claim 1  further comprising an antioxidant.  
   
   
       11 . The cellular material of  claim 10  wherein the antioxidant is a light or heat stabilizer.  
   
   
       12 . The cellular material of  claim 1  wherein the vegetable oil is a soy oil.  
   
   
       13 . A cellular material comprised of: 
 a vegetable-based foam; and    a number of aldehyde or ketone compounds, wherein the number is in the range of 1 to 10.    
   
   
       14 . The cellular material of  claim 13 , wherein the number is in the range of 1 to 5.  
   
   
       15 . The cellular material of  claim 13 , wherein the vegetable-based foam is a reaction product of a vegetable-based polyol and an isocyanate, wherein the vegetable-based polyol is made from a vegetable oil exposed to ultraviolet (UV) light, a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol.  
   
   
       16 . The cellular material of  claim 13 , wherein the vegetable-based foam is a soy-based foam.  
   
   
       17 . A vegetable-based polyol comprised of: 
 a first number of oil products, the first number is in the range of 1 to 3;    a second number of volatile by-product compounds, the second number is in the range of 1 to 10; and    a third number of non-volatile by-product compounds, the third number is in the range of 1 to 5.    
   
   
       18 . The vegetable-based polyol of  claim 17 , wherein each oil product contains a mixture of difunctional hydroxylated vegetable oil and monofunctional hydroxylated vegetable oil.  
   
   
       19 . The vegetable-based polyol of  claim 17 , wherein the non-volatile by-product compounds include one or more free fatty acids.  
   
   
       20 . The vegetable-based polyol of  claim 17 , wherein the second number is in the range of 1 to 5.  
   
   
       21 . The vegetable-based polyol of  claim 17 , wherein the vegetable-based polyol is made from a vegetable oil exposed to ultraviolet (UV) light, wherein a free radical oxidation reaction is catalyzed by the UV light and the vegetable oil is converted into the vegetable-based polyol.  
   
   
       22 . An apparatus for use in encapsulating automotive interior components at least partially comprised of cellular material, the apparatus comprising: 
 an odor barrier layer for encapsulating the cellular material to confine odors emanating from the cellular material.    
   
   
       23 . The apparatus of  claim 22  wherein the odor barrier layer is a gas impermeable material.  
   
   
       24 . The apparatus of  claim 22  wherein the odor barrier layer is comprising of a first and second contacting layers, the first layer is a gas impermeable material, the second layer is a heat sealable thermoplastic material.  
   
   
       25 . The apparatus of  claim 24  wherein the gas impermeable material is polyester or nylon.  
   
   
       26 . The apparatus of  claim 24  wherein the sealable thermoplastic material is a polyurethane.  
   
   
       27 . The apparatus of  claim 22  wherein the automotive interior component is a headrest, armrest, or seat.