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a reaction known more t h a n a c e n t u r y ago. Subse- FIG. 2. A reaction product of castor oil with tolylene
quent reaction of the urethane polymers with w a t e r diisocyanate.
in the presence of an alkaline catalyst, usually terti-
a r y amines, causes erosslinking accompanied b y evo-
lution of carbon dioxide which expands the plastic is desirable to build up the molecular weight of the
material into a foam. F i g u r e 1 shows some typical prepolymer, too much erosslinking leads to excessive
viscosity.
Most information in the literature on castor oil
(I) RNCO + R'OH -----Y ~ C O O R ' polyurethane foams is somewhat scattered, limited in
(18ochre) (~co~oi) (uret~e) scope, and generally confined to special applications.
Since a favorable price differential exists for castor
(2) ~co + R'NNCOOR" , 9 ,)~HCON(R' )COOR" oil over most polyesters, information concerning the
(ure~hane) (sllophanlc ester) properties of various castor urethane foams should
be useful to m a n u f a c t u r e r s and consumers of ex-
(3) RNCO + R'COOH .~ ~HCOOOCR' > Y~HCOR' + co2~r panded plastic foams. I t was the purpose of this
(fatty acid) (m:txeaanhydride) (amide) ! investigation to evaluate the utility of castor oil and
to determine the effect, on properties of the foams
(~) ~co + ~oH ~ ~ + co2T obtained, of v a r y i n g the proportions of castor oil
(~e) over the range of 50 to 80%. The effect o~ modi-
t
fication of the double bonds in castor oil on foam
(5) ~co + R'gg2 - ) m~co~' properties was also investigated. Evaluations were
(eubstltuted ,area) obtained on foams p r e p a r e d f r o m h y d r o g e n a t e d castor
oil, elaidinized castor oil (containing trans double
bonds), and a formulation in which a portion of the
HCCge~(C~)sCHa SCCa~(C~)SCH
3 castor oil h a d been replaced with an epoxidized castor
(rlcinolele ester)
0 9OCIr~R
(a urethane)
oil. I n the interest of simplicity these investigations
were confined to readily available commercial mate-
FIG. 1, Typical isocyanate reactions related to preparation
of urethane foams. rials. Thus a commercial grade of d r y castor oil,
an 80/20 T D I (80% 2,4- and 20% 2,6-tolylene diiso-
cyanate), and a commercial p r e p a r a t i o n of buffered
reactions involved. B y v a r y i n g the ingredients, foam- 2-diethylaminoethanol catalyst were employed.
ing conditions, and additives, foams can be obtained Generally f r o m two to five tests were made on
which are flexible or semirigid in n a t u r e (as low in specimens f r o m about five separate batches of each
density as 1 to 2 lbs./cu, ft.) and possess m a n y other f o a m formulation studied. Properties tested were:
desirable properties. foaming time, density, shrinkage, tensile-elongation,
Most commercial applications have utilized poly- compression-deflection, compression set, accelerated
esters to produce urethane polymers (2). Castor oil, aging, energy absorption, and water absorption.
essentially a t r i h y d r o x y compound, i.e., an ester of
glycerol with ricinoleic acid, has been found useful Experimental
in urethane applications. An ester of ricinoleic acid Prepolymer Preparation. Castor oil urethane foams
will react with isocyanate as shown in equation 6 of are p r e p a r e d by the p r e p o l y m e r or two-stage method
F i g u r e 1. The reaction product of one mole of castor r a t h e r t h a n a one-step method as used with most
oil and three moles of tolylene diisoeyanate m a y be polyesters. The use of elevated t e m p e r a t u r e s for the
visualized as in F i g u r e 2. This shows t h a t it is neces- p r e p a r a t i o n of a castor oil p r e p o l y m e r is necessary to
s a r y to have an excess of isocyanate groups over hy- obtain a workable viscosity range of about 10,000
droxyl groups so t h a t the p r e p o l y m e r will contain to 30,000 centipoises at room temperature. This is
residual unreacted isocyanate necessary for the foam- because of the presence in castor oil of secondary
ing stage. Also, if the n u m b e r of isocyanate groups h y d r o x y l groups which are slow to react with the
is less t h a n twice the n u m b e r of h y d r o x y l groups, isocyanate. The general procedure used to p r e p a r e
crosslinking will occur. Although some crosslinking the p r e p o l y m e r (in batches of 400 to 800 g.) was as
1 Presented at the 49th Annual Meeting of the American Oil Chem- follows:
ists' Society, Memphis, Tenn., April 21-23, 1958.
One of the laboratories of the Southern Utilization Research and The required amount of 80/20 tolylene diisocyanate
Development Division, Agricultural l~esearch Service, U. S. Department
of Agriculture. was added at room t e m p e r a t u r e to castor oil contained
16
JAN., 1959 YEADON ET AL.: PREPARATIONS AND PROPERTIES 17
in a 1-quart fruit jar fitted through the top with a oil contained approximately 75% of its double bonds
stirrer, thermometer, reflux condenser, and dry nitro- in the trans configuration (7), and the partially epoxi-
gen inlet tube. After the initial exothermic reaction dized oil was used with about five parts of normal oil
reached its maximum of about 80~ the jar was to make a comparable prepolymer. In the preparation
lowered into a hot oil bath, allowed to reach the of these prepolymers the requisite amount of diisocy-
desired temperature, and then heated for the time anate was added to the modified castor oil at room
required. In preliminary tests it was found that in temperature and mixed manually while increasing the
making the 60% castor oil prepolymer at 130~ a temperature until fluid enough to be mechanically
viscosity of 60,000-100,000 eentipoises was usually stirred, then the usual procedure for the preparation
reached after heating 1 hr. Since this viscosity was of prepolymers was followed.
greater than that desired, a lower reaction temper- Table I presents some properties for the various
ature of 110~ was generally used thereafter. How- oils used. The viscosity and NCO content of the pre-
ever, to prepare a 50% castor oil prepolymer, it was polymers are listed in Table II.
found that a heating period of about 16 hrs. at Foam Preparation. In order to minimize variations
ll0~ would be required to attain the desired vis- produced by the foaming step, a uniform formulation
cosity. F u r t h e r tests showed that even at 130~ and foaming procedure was adopted. This procedure
the temperature chosen for preparing the 50% castor
oil prepolymer, about 4 hrs. of heating were necessary
TABLE
to reach the desired viscosity. The changes in vis-
P r o p e r t i e s of Castor Oil a n d Modifications
cosity of the 50% castor oil prepolymers on heating
at ll0~ and 130~ are shown i n Figure 3. The Normal Hydro- Elaidi~ Partially
changes in isocyanate content, as determined by the Tests genated ized epoxi-
(dry) dized a
method of Tazuma and Latourette (5), are also shown
:YIolecular w e i g h t ( m e a n ) b 926 945
in this figure. . . . . . . . . . . . . . .
(theor3
Viscosity, cps. at 25~ b ................. 68O 2000
I0 ~ 5,000 O
was to mix 100 g. of prepolymer with 0.5 g. of a
dispersing agent, 3'4 add 4.4 g. of a commercial 2-
diethylaminoethanol catalyst 5 and additional water
necessary to reach a minimum of 100% of the
REACTIONTIME,Hrs9 amount theoretically required to react with the ex-
:FIG] 3. Effee50-f time and temloerature of :preparation on
residual NCO content and viscosity of prepolvmers made with
50% of castor oil. TABLE II
I s o c y a n a t e C o n t e n t a n d Viscosity of P r e p o l y m e r s
TABLE III
Properties of ~oams
Type and characteristics Tensile strength and elongation
50 ..............................
(minutes)
20-25 Semirigid 1.7
(:;' l <:;) (%)
27
(p.s,i.)
13.5
(p.s.i.)
......
(~) (p.s.i.)10.3
(p.s.i.)
60 .............................. 30-40 Semirigid 2.8 11 ] 20 42 27.9 ...... 54 23.7
70 .............................. 30-45 Soft 3.5 4 8 121 20.6 18.4 136 19.5 15.8
80 .............................. 35-45 Soft 6.4 1 } 0.6 103 6.3 6.1 109 6.6 6.4
60 (]~) ....................... 30-35 Semirigid 3.0 6 / 19 37 28.1 ...... 45 28.8
60 ( E l ) ...................... 30-35 Semirigid 2.6 4 10 43 24.9 ...... 51 23.6
5 8 ( E p ) ..................... 20-25 Semirigid 2.6 8 I 22 42 22.0 ...... 42 25.5
Compression-deflection modulus Compression set, energy and water absorption
Castor oil ( % ) Original Aged Compression set Energy Water
_ _ - - - 25% - 1 ~ 50% Original Aged
absorption absorption
lO% I 25% 50%
(p.s.i.) I (p.s.i.) (p.s.i.) I (p..,.i.) i (p.s.i.) (%) (~) (%)~ (%)
5 0 .............................. 4.9 5.5 7.6 5,6 6.1 8.3 5O 19 515
6 0 ............................. 5.3 6.5 10 4 4.8 6.4 11,3 47 44 23 323
7 0 ............................. 0.55 0.71 1.19 0.43 ] 0.55 0,94 30 22 50 230
8o............................. 0.20 I 0.30 0.52 o.~o I o.23 I o.41 16 I0 47 170
~o (~) ..................... 4.9 i 7.7 13.7 a.4 / 4.9 I s.7 48 43 41 198
6 0 ( E l ) ..................... 5.6 ] 6.9 10.9 4.0 5,0 [ 8.6 45 42 30 234
5 8 ( E p ) .................... i 5.3 I 7.1 11.3 4.3 / 5.O I 7.7 49 48 28 286
aPercentage of value for control foam rubber having the following properties: density, 7.2 lbs./eu, f t . ; 5 0 % compression modnhs, 1.0 p.s.i.;
and ultimate tensile strength, 1 6 . 6 p . s . i , a t 2 1 8 % elongation.
50% to 80%. The data also show that foams made 5. Rates of compression and recovery were the same
with elaidinized or partially epoxidized castor oil have and relatively slow, 0.1 in. per rain. The foam
slightly lower densities than those made with normal made by using 80% of castor oil was resilient, and
or hydrogenated castor oil and that the foams made reminiscent of soft foam rubber; it is noted from
by using modified oils all showed improved shrinkage Figure 5 that the recovery curve resembles the com-
characteristics. pression curve. On the other hand, the recovery curve
Results of tests of tensile strength and elongation of the foam made with 70% of castor oil is very dif-
(Table III) show that foams made by using 60% ferent from its compression curve. Such a foam is
castor oil have the highest tensile strength. Neither slow to recover its initial shape and is useful to ab-
modification of the castor oil, as by hydrogenation or sorb shock without abrupt recoil, as in automotive
e]aidinization, nor aging greatly affected the tensile crash pads.
strength or elongation. Results of tests of compression set and energy and
Results of compression-deflection tests (Table III) water absorption are shown in Table III. As ex-
again point to the greater strength of the foams made pected, the softer foams resulting from the use of
by using 60% of castor oil. As anticipated, the foams larger proportions of castor oil exhibited less com-
made by using 70 and 80% of castor oil were weaker pression set than did the semirigid foams. The val-
but more flexible. A g i n g had only slight effect on u e s in this table indicate the percentage of the
compression resistance. F o a m s made with larger pro- original height which the foam test during the test;
portions of castor oil showed a slight decrease in thus a value of 50% indicates that the foam did not
compression resistance. F o a m s made with smaller recover at all after compression. A g i n g did not sig-
proportions of castor oil were greatly distorted on nificantly affect the compression set of the semirigid
aging so that compression-deflection was hard to meas- foams but markedly decreased the values obtained
ure accurately, but the compression resistance of these for the soft foams. Hydrogenation, claidinization, or
foams appeared actually to increase on aging. Typi- replacement of part of the castor oil with partially
cal compression-recovery curves are shown in Figure epoxidized castor oil did not significantly affect the
compression set. On the other hand, such modifica-
70~ CASTOR OIL FOAM 8 0 % CASTOR O i l FOAM
tion did markedly affect both the energy absorption
IE 16 and the water absorption. Hydrogenation of the cas-
tor oil greatly increased the energy absorption and
14 greatly decreased the water absorption. The corre-
sponding values for the foams made with elaidinized
x
/ 1.2
tO
castor oil and with partially epoxidized castor oil were
intermediate between those made with natural castor
oil and those made with the hydrogenated oil.
~e~ o.e Summary
The preparations and properties of urethane foams
~o.E 06 made from tolylene diisocyanate and 50, 60, 70, and
m
80% castor oil were investigated. F o a m s of 50 and
04 60% castor content were prepared by the prepoly-
mer technique; those of 70 and 80% castor content
o.~ -(
0.2 were prepared by mixing a 60% castor oil prepolymer
with additional castor oil just before foaming. F o a m
' 6'o 0 density increased from 1.7 to 6.4 lbs./cu, ft., and
DEFEECTION, ~ OF THICKNESS shrinkage decreased from 21 to about 1% as the pro-
FIG. 5. Compresslon-recovery curves of foams. portion of castor oil was increased. Tensile strength
20 THE JOURNAL OF T H E AMERICAN OIL CI-IEMISTS' SOCIETY VOL. 36
ranged from 6.3 to 27.9 p.s.i., ultimate elongation ized oil, and the Baker Castor Oil Company for a
from 27 to 121%, and 50% compression modulus from generous supply of normal, hydrogenated, and epoxi-
0.5 to 10.4 p.s.i. Neither modification of the unsatura- dized castor oils.
tion of castor oil, as by hydrogenation, elaidinization, REFERENCES
or partial epoxidation, nor aging at elevated tempera- 1. Bjorksten, g., Tovey, l=I., a n d Dollard, YI. L. Jr., Modern Plastics,
81, No. 8, 1 4 3 - 4 4 , 146, 228-30, 233 ( 1 9 5 4 ) .
ture and humidity greatly affected the density, tensile 2. t~irschbeck, R. D., :Plastics Technol., 1, 9 5 - 9 9 ( 1 9 5 5 ) .
3. Kenline, W. E., a n d Hirschbeck, R. D., .Plastics Teehnol., 2, 1 6 8 -
strength, or elongation, but water resistance and 94 1 7 8 - 1 7 9 (1956).
shrinkage of the foams were improved by such modi- 4. " U r e t h a n e 3Plastics," a staff report, I n d . E n g . Chem., 48, 1 3 8 3 -
1391 ( 1 9 5 6 ) .
fication. 5. Tazuma, J. J., a n d Latourette, H. K., Am. Chem. Soc., Div.
Paint, Plastics, a n d P r i n t i n g I n k Chem. Papers, 16, No. 3, 2 2 - 3 1
Acknowledgment (1956).
6. Bailey, M. E., K h a w a m , A., a n d Toone, G. C., Am. Chem. Soc.,
The authors gratefully acknowledge the assistance ]:)iv. Paint, Plastics, a n d P r i n t i n g I n k Chem. Papers, 17, No. 2, 5 0 - 5 6
(1957).
of T. H. Hopper for designing a compression attach- 7. MeCtltchon, M. A., O'Connor, R. T., DuPr6, E. Y., Goldblatt, L.
merit for the Instron Tensile Tester, A. 1~. Markezich A., a n d Biekford, W. G., in press.
8. Society of Plastics I n d u s t r y Inc., New York, "Tentative. Methods
for his aid in obtaining some of the physical data, of Test for Rigid Cellular Materials" ( J a n u a r y 28, 1957) ; a n d "Tenta-
tive ~/fethods of Test for Flexible Urethane F o a m " (May 24, 1957).
Mrs. V. 0. Cirino and J. A. Harris for analyses o f
the oils used, Miss M. A. McCutchon for the elaidin- [Received June 16, 1958]