THEREOF

Description

FIELD OF THE INVENTION

[0001] The invention relates to a method of manufacture of a thermoset polymer foam that is at least from 50 to 100 percent by weight of renewable raw material resources. Foam is obtained from a two-component system that cures at room temperature after mixing in the presence of a strong base catalyst by carbon-Michael addition polymerization, forming mechanically rigid and highly cross-linked polymer. Both components of the carbon-Michael addition are developed from bio-based feedstock.

BACKGROUND OF THE INVENTION

[0002] The main challenge of the polyurethane foam material industry is associated with the production and handling of isocyanates. It is unlikely that urethane chemistry will be displaced as it exhibits very high effectiveness and highly advantageous economies of scale. However, for instances where polyurethane foam chemistry is undesired, it is very beneficial to have a useful alternative.

[0003] EP1162222A2 discloses a low index polyurethane foam that is at least partially biodegradable, comprising the reaction product of from about 10 to about 35 percent by weight of an isocyanate; from about 90 to about 65 percent by weight of active hydrogencontaining component selected from the group consisting of from about 80 to about 100 percent by weight of a component derived from a natural, renewable component and from about 0 to about 20 percent by weight of a component derived from a petrochemical source to total 100 percent by weight of active hydrogen containing component; from about 0.5 to about 1 percent by weight of a catalyst from about 0.3 to about 3 percent by weight of a surfactant; and from about 0.5 to about 20 percent by weight of a blowing agent. The disclosure includes a component derived from a natural, renewable component, however, still uses from about 10 to about 35 percent by weight of an isocyanate. [0004] PCT/US2019/018710 proposes methods of making isocyanate-free foam using isocyanate-free polyurethane chemistry. The disclosed formulation has the first part with at least one multifunctional acrylate. The disclosed formulations have a second part with at least one non-isocyanate polyurethane oligomer derived from a reaction of at least one multifunctional cyclocarbonate and at least one first multifunctional amine, and a second multifunctional amine. The formulation may also have a blowing agent and at least one surfactant. Although the method uses isocyanate-free polyurethane chemistry, it still requires feedstock that is not bio-based.

SUMMARY OF THE INVENTION

[0005] The objective of the invention is to provide an alternative, sustainable method of production of polymer foam that would exploit only bio-based feedstock.

[0006] The goal is achieved by the invented method, which comprises the following steps: a) providing a plant oil; b) epoxidation of a double bond of the plant oil of step (a); c) obtaining of an epoxidized plant oil polyol, that includes heating up the epoxidized plant oil at about 80 °C to 250 °C, preferably about 180 °C, for about 5 h to 10 h; d) obtaining of Michael donor of Formula (II) and Michael acceptor of Formula (III): wherein R ¹⁰ is selected from the group comprising hydrogen, alkyl, alkenyl, oxirane group, hydroxyl -OH, ester -C(=O)-O-, -C=C-, -C=C-, carboxyl group -C(=O)-OH, -C- O-C-, -C=C, acetoacetate -O-C(=O)-C-C(=O)-C, P-ketoester group -O-C(=O)-C- C(=O)-C-, nitrogen-containing group; wherein R ⁹ is selected from the group comprising hydrogen or organic radicals such as alkyl (linear, branched, or cyclic), alkenyl, oxirane group, hydroxyl -OH, ester -C(=O)- O-, -C=C-, -C=C-, carboxyl group C(=O)-OH, -C-O-C-, -C=C, acrylic -O-C(=O)-C=C, methacrylic -O-C(=O)-C(=C)-C, thio analogs thereof, nitrogen-containing groups, or combinations thereof, including derivatives and substituted versions thereof; e) mixing of the Michael donor with the Michael acceptor obtained in step (d) in the presence of a catalyst, adding a surfactant and a blowing agent, resulting in a reaction mixture; f) heating up the reaction mixture for foam forming up to a temperature from 0 °C to 80 °C, preferably from 25 °C to 55 °C; g) mixing of the reaction mixture for 1 s to 300 s, preferably for 3 s to 120 s, more preferably for 5 s to 60 s; in the result of steps e), f), and g) the blowing agent is expanded, forming the polymeric foam material.

[0007] The examples of plant oil include, but are not limited to coconut oil; canola oil; castor oil; coconut oil; colza oil; copaiba oil; corn oil; cottonseed oil; false flax oil; hemp oil; jatropha oil; jojoba oil; milk bush oil; mustard oil; nahor oil; nut oils, such as almond oil, brazil nut oil, cashew oil, hazelnut oil, macadamia oil, pecan oil, pine nut oil, pistachio oil, walnut oil; linseed oil; olive oil; palm oil; pongamia oil; radish oil; ramtil oil; rapeseed oil; rice bran oil; safflower oil; salicornia oil; sesame oil; soybean oil; sunflower oil; tall oil and mixtures and derivatives thereof;

[0008] The plant oils used in the invention contain a mixture of one or more unsaturated fatty acids including, but not limited to arachidonic acid; cervonic acid; dihomo-y-linolenic acid; docosatetraenoic acid; eicosapentaenoic acid; elaidic acid; erucic acid; gondoic acid; linoleic acid; linolelaidic acid; mead acid; nervonic acid; oleic acid; palmitoleic acid; paullinic acid; stearidonic acid; vaccenic acid; a-linolenic acid; y- linolenic acid; ricinoleic acid.

[0009] The plant oil may contain monoglycerides, diglycerides and triglycerides. Monoglycerides are esters derived from glycerol and one fatty acid. Diglycerides are esters derived from glycerol and two fatty acids. Triglycerides are esters derived from glycerol and three fatty acids. Triglycerides and diglycerides may contain both saturated and unsaturated fatty acid groups. All reactions and transformations also apply to the functional groups contained in molecules of diglycerides and triglycerides.

[0010] The epoxidation is carried out by obtaining a mixture of the plant oil comprising a double bond and peroxyacid that transform a part or all of the oil's double bonds to oxirane groups, that can be added to the reaction mixture directly or created in-situ by reacting a hydroperoxide with a corresponding acid such as formic acid, acetic acid, trifluoroacetic acid, benzoic acid, benzyloxy formic acid, benzyloxy acetic acid, and heating 40 °C to 60 °C, then adding hydrogen peroxide while monitoring a temperature of the mixture so that it does not exceed 50 °C to 70 °C, preferably 60 °C, after the addition of hydrogen peroxide, the temperature is kept at 50 °C to 70 °C, preferably 60 °C for 4 h to 8 h, preferably 6 h in an inert environment provided by argon or nitrogen gas, the obtained mixture is washed with a distilled water having a temperature in a range of 40 °C to 80 °C, preferably about 60 °C, resulting in an epoxidized plant oil of Formula (I): wherein

R ⁴ and R ⁵ are each selected from hydrogen, alkyl, alkenyl, oxirane group, hydroxyl -OH, ester -C(=O)-O-, -C=C-, -C=C-, carboxyl group -C(=O)-OH, -C-O-C-, -C=C, nitrogencontaining group;

[0011] When the plant oil of step (a) is selected from a group, comprising coconut oil; canola oil; castor oil; coconut oil; colza oil; copaiba oil; corn oil; cottonseed oil; false flax oil; hemp oil; jatropha oil; jojoba oil; milk bush oil; mustard oil; nahor oil; nut oils, such as almond oil, brazil nut oil, cashew oil, hazelnut oil, macadamia oil, pecan oil, pine nut oil, pistachio oil, walnut oil; linseed oil; olive oil; palm oil; pongamia oil; radish oil; ramtil oil; rapeseed oil; rice bran oil; safflower oil; salicornia oil; sesame oil; soybean oil; sunflower oil; and mixtures and derivatives thereof, the epoxidized plant oil polyol is obtained by opening the oxirane ring of the epoxidized plant oil of step (b).

[0012] When the plant oil of step (a) is selected from a group, comprising tall oil and mixtures and derivatives thereof, the epoxidized plant oil polyol is obtained by oxirane ring-opening of the epoxidized plant oil of step (b), and subsequent carboxyl group esterification with alcohols. The oxirane ring-opening can take place both in the presence and absence of a ring-opening catalyst, wherein the ring-opening catalyst is selected from boronic acids; hydrobromic acid; hydrochloric acid; perchloric acid; perchloric acid metal salts, such as lithium perchlorate; phosphoric acid; phosphorous acid; sulfonic acids, such as para-toluene sulfonic acid, methanesulfonic acid, and trifluoromethane sulfonic acid; sulfuric acid; tetrafluoroboric acid; tetrafluoroboric acid metal salts, such as copper tetrafluoroborate and iron tetrafluoroborate; triflic acid and ion exchange resins in the protic form. The concentration of the ring-opening catalyst is in a range of 0.01 wt% to about 1 wt%, preferably from 0.05 wt% to 0.5 wt%. The alcohol is selected from oxirane ring-opening alcohols, comprising 2-ethyl-l -hexanol; 2-methyl-2-butanol; ethanol; isobutanol; isopropanol; methanol; n-butanol; n-propanol; propanol; 1,2- cyclohexanediol; 1,3 -butanediol; 1,3 -propanediol; 1,4-butanediol; 1,5-pentanediol; 1,6- hexanediol; 1,12-dodecan ediol; 2, 3 -butanediol; 2-methyl-l,3-propandiol; 3-methyl- 1,5- pentanediol; diethanolamine; ethylene glycol; hexanediol; pentanediol; propylene glycol; triethylene glycol; tripropylene glycol; erythritol; glycerol; pentaerythritol; triethanolamine; trimethylolethane; trimethylolpropane and mixtures thereof.

[0013] The Michael donor is obtained by subjecting the epoxidized plant oil polyol of step (c) to transesterification (see step (dl) in Fig. 1). The transesterification is performed using an acetoacetylating reagent at a temperature in a range of 100 °C to 140 °C, preferably about 120 °C, for 3 h to 8 h, preferably 4 h.

[0014] When the plant oil of step (a) is selected from a group, comprising coconut oil; canola oil; castor oil; coconut oil; colza oil; copaiba oil; corn oil; cottonseed oil; false flax oil; hemp oil; jatropha oil; jojoba oil; milk bush oil; mustard oil; nahor oil; nut oils, such as almond oil, brazil nut oil, cashew oil, hazelnut oil, macadamia oil, pecan oil, pine nut oil, pistachio oil, walnut oil; linseed oil; olive oil; palm oil; pongamia oil; radish oil; ramtil oil; rapeseed oil; rice bran oil; safflower oil; salicornia oil; sesame oil; soybean oil; sunflower oil; and mixtures and derivatives thereof, the Michael acceptor is obtained by opening an oxirane ring of the epoxidized plant oil of step (b) by acrylating the epoxidized plant oil of step (b) by acrylic group containing acid or an anhydride at a temperature in range from 60 °C to 130 °C, preferably from 100 °C to 110 °C for 1 h to 24 h, then washing with a distilled water having a temperature in a range of 40 °C to 80 °C, and drying (see step (d2) in Fig. 1). The opening of the oxirane ring can take place both in the presence and absence of the free radical inhibitors. Examples of suitable free radical inhibitors include but are not limited to substances based on phenolic groups such as hydroquinones; hydroquinone; catechols; phenothiazines; phenonthi azine and mixtures thereof. Examples of suitable acid for acrylation include but are not limited to acrylic acid; methacrylic acid and mixtures thereof. Examples of suitable anhydride for acrylation include but are not limited to acrylic anhydride; methacrylic anhydride and mixtures thereof.

[0015] When the plant oil of step (a) is selected from a group, comprising tall oil and mixtures and derivatives thereof, the Michael acceptor is obtained by acrylation of the epoxidized plant oil polyol of step (c) with acryloyl chloride or methacryloyl chloride in triethanolamine and ethyl acetate solution at a temperature in a range from -5 °C to 5 °C and then stirring the resulting mixture at a temperature in a range from 10 °C to 30 °C for 12 h to 24 h (see step (d3) in Fig. 1). Acrylation can take place both in the presence and absence of free radical inhibitors. Examples of suitable free radical inhibitors include but are not limited to substances based on phenolic groups such as hydroquinones; hydroquinone; catechols; phenothiazines; phenon thiazine and mixtures thereof.

[0016] A ratio of the Michael acceptor functional groups to the Michael donor functional groups in step (d) is in a range of 1: 1 to 3:1, preferably 1.5:1 to 2.5:1, more preferably 1.9:1 to 2.1:1.

[0017] The concentration of the catalyst is in a range of 0.05 wt% to 10 wt% based upon the total weight of the Michael donor and the Michael acceptor. [0018] The catalyst is selected from the group comprising aliphatic amines; alkanolamines; aromatic amines; amidine; imine; imidazoles; metal salts; nitrogen; 1 -(dmethylamino)-2-propanol; 1 , 1 ,3,3-tetramethylguanidine; 1 ,2-dimethylimidazole;

1.4-diazabicyclo[2.2.2]octane; l,5,7-triazabicyclo[4.4.0]dec-5-ene;

1.5-diazabicyclo[4.3.0]non-5-ene; l,8-bis(tetramethylguanidino)naphthalene; l,8-diazabicyclo[5.4.0]undec-7-ene;

1 - [bis [3-(dimethy lamino)propyl] amino] -2-propanol ;

1 - [N,N-bis(2-hydroxyethyl)amino] -2-propanol; 1 -azabicyclo [3.3.0]octane ;

1 -ethylpiperidine; 2-((dimethylamino)ethyl)methylaminopropanol; 2-

(diethylamino)ethanol; 2-(diisopropylamino)ethanol; 2-(dimethylamino)ethyl methacrylate; 2-[2-(dimethylamino)ethoxy]ethanol; 2-ethyl-4-methyl-lH-imiazole; 2- tert-butyl- 1,1, 3 ,3 -tetramethylguanidine ; 4-butanediamine ; 7 -methyl- 1,5,7- triazabicyclo[4,4,0]dec-5-ene; bis(3-aminopropyl)amine; bis(N,N-dimethyl-3- aminopropyl)amine; N-(2-aminopropyl)imidazole; N-(2-hydroxypropyl)-2-methylprop- 2-enamide ; N-(2-hydroxypropyl)imidazole ; N-(3-aminopropyl)-2-pyrrolidinone ; N,N,N',N'-tetramethylhexanediamine; N,N,N',N'-tetraacetylethylenediamine;

N,N,N',N' -tetramethyl- 1 ,3-propanediamine; N,N,N',N' -tetramethyl- 1 , 4-butanediamine; N,N,N',N' -tetramethyl- 1 ,6-hexanediamine; N,N,N',N'-tetramethyl-2-butene- 1 ,4- diamine; N,N,N',N' -tetramethyldiaminomethane; N,N,N'-trimethyl-N'-hydroxyethyl bis(aminoethyl) ether; N,N-bis(3-dimethylaminopropyl)N-isopropanolamine; N,N- dimefhylpiperazine ; N,N-dimethylaminopropylamine ; N,N-dimethylaminopropyl-N'- methylethanolamine; N,N-dimethylefhanolamine; N,N-dimethyl-N'- ethylethylenediamine; N,N-dimorpholinodiethylether; N'-butyl-N',N'- dicyclohexylguanidine; N-ethylmorpholine; N-methylimidazole; N-methylmorpholine; potassium hydroxide; potassium phenoxide; potassium phosphate; sodium hydroxide; sodium phenoxide; tertraethyl ammonium hydroxide; tetramethylamino bis (propylamine); tetramethylammonium hydroxide; tetramethylguanidine; triazabcyclodecene; triethanolamine; trimethylamine; triethylenediamine; trimethylamine; tris(dimethylamino propyl)amine; tris (dimethylaminopropyl) amine; tris-isopropanolamine; N,N,N',N'-tetramethyl-l , 4-butanediamine; N,N,N',N'- tetramethylguanidine; N,N-dimethylaminopropyldipropanolamine; N,N- dimethylbenzylamine; N,N-dimethylethanolamine; N,N-dimorpholinodiethyl ether and mixtures thereof, preferably nitrogen.

[0019] The concentration of the surfactant is in a range of 0.1 wt% to 10 wt% based upon the total weight of the Michael donor and the Michael acceptor.

[0020] Suitable surfactants that can be used in the invention include but are not limited to alkoxylated poly siloxanes ;ethoxylated fatty acids; salts of fatty acids; ethoxylated fatty alcohols; salts of sulfonated fatty alcohols; fatty acid esters of sorbitan; and fatty acid ester sorbitan ethoxylates; silicone glycol copolymer and mixtures thereof.

[0021] The concentration of the blowing agent is in a range of 0.5 wt% to 50 wt% based upon the total weight of the Michael donor and the Michael acceptor.

[0022] The blowing agents that can be used in the invention include compounds that have a boiling temperature in a range from -50 °C to +100 °C. A preferred boiling temperature for blowing agents is in a range from 0 °C to 50 °C, and a more preferred boiling temperature is in a range from 10 °C to 40 °C. The blowing agents expand during the exothermic polymerization reaction. The blowing agents that can be used in the invention include, but are not limited to hydrocarbons (cyclopentane; isopentane; n-pentane); hydrofluorocarbons; hydrochlorofluorocarbons; hydrofluorocarbons; chlorofluorocarbons; fluorocarbons; chlorocarbons; esters; aliphatic alcohols; carbon dioxide; air; argon; nitrogen and mixtures thereof. In some embodiments, the suitable blowing agent can be a physical blowing agent. Examples of blowing agents include, but are not limited to 1,1 -difluoroethane; 1,1,1,2,3,4,4,5,5,5-decafluoropentane; 1 , 1 , 1 , 3 , 3 -pentafluorobutane ; 1 , 1 , 1 , 3 , 3 -pentafluoropropane ;

1 , 1 ,2,2,3-pentafluoropropane; 1 , 1 ,2,2-tetrafluoroethane; 1 , 1 ,4,4,4-hexafluoro-2-butene; 1 , 1 -dichloro- 1 -fluoroethane; 1 ,2-dichloro- 1 , 1 ,2,2-tetrafluoroethane;

1.2-dichloropropane; 1 ,2-dichloro tetrafluoroethane; 1 -chloro- 1 , 1 -difluoroethane;

2.2-dichloro- 1,1,1 -trifluoroethane; cis- 1,1,1 ,4,4,4-hexafluoro-2-butene; cyclopentane; formaldehyde dimethylacetal; isobutane; isopentane; methylbutane; methylformate; n- butane; n-pentane; pentane; perfluoromethane; propane; trichloromonofluoromethane; trichloromonofluoromethane; trichloro trifluoroethane; argon; carbon dioxide; nitrogen; and mixtures thereof.

[0023] One or more additives can be used in foam-forming compositions. Examples of additives that can be used in the invention include, but are not limited to, antioxidants; antistatic agents; biocides; colorants; cure promoters; dyes; fillers; flame retardants; foam cell nucleators; foaming agents; functionalized fillers; odor inhibitors; odoriferous substances; perfumes; pigment dispersing agents; plasticizers; preservatives; reactive fillers; UV stabilizers and mixtures thereof. The one or more additives is/are in a range of 0.10 wt% to 20.0 wt% based upon the total weight of the Michael donor and the Michael acceptor.

[0024] The peroxyacid for epoxidation is selected from the group comprising peroxyformic acid; peroxyacetic acid; trifluoroperoxyacetic acid; benzyloxyperoxy formic acid and mixtures thereof.

[0025] The acetoacetylating reagent is selected from the group comprising tert-butyl acetoacetate; methyl acetoacetate; ethyl acetoacetate; or isopropyl acetoacetate and mixtures thereof.

[0026] The carbon-Michael donor may react difunctionally with the carbon-Michael acceptor; therefore, this ratio should be no more than 3 moles of Michael acceptor functional groups per mole of carbon Michael donor functional groups. The ratio of Michael acceptor functional groups to Michael donor functional groups can be in a range from 1 : 1 to 3 : 1. The ratio Michael acceptor functional groups : Michael donor functional groups can be 1.1: 1, 1.2:1, 1.3: 1, 1.4:1, 1.5: 1, 1.6:1, 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1, 2.2:1, 2.3:1, 2.4:1, 2.5:1, 1.6:1, 2.7:1, 2.8:1, 2.9:1, 3:1. A more preferred ratio is from 1.5:1 to 2.5:1, and a more preferred ratio is from 1.9:1 to 2.1 : 1.

[0027] The catalyst can have a concentration of 0.05 wt% to 10 wt%based upon the total weight of the Michael donor and the Michael acceptor. The reaction mixture may contain 0.06 wt%, 0.07 wt%, 0.08 wt%, 0.09 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.75 wt%, 0.9 wt%, 1 wt%, 1.1 wt%, 1.25 wt%, 1.5 wt%, 1.75 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt% catalyst, or any range between these values. [0028] The surfactant can have a concentration of 0.1 wt%to 10 wt% based upon total weight of the Michael donor and the Michael acceptor. The reaction mixture for foam may contain 0.10 wt%, 0.15 wt%, 0.2 wt%, 0.25 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1.0 wt%, 1.1 wt%, 1.2 wt%, 1.3 wt%, 1.4 wt%, 1.5 wt%, 1.75 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 4.5 wt%, 5 wt%, 5.5 wt%, 6 wt%, 6.5 wt%, 7 wt%, 7.5 wt%, 8 wt%, 8.5 wt%, 9 wt%, 9.5 wt%, 10 wt% surfactant, or any range between these values.

[0029] The blowing agent can have a concentration of 0.5 wt% to 50 wt% based upon the total weight of the Michael donor and the Michael acceptor. The reaction mixture for foam may contain 0.5 wt%, 0.55 wt%, 0.6 wt%, 0.65 wt%, 0.7 wt%, 0.75 wt%, 0.8 wt%, 0.85 wt%, 0.9 wt%, 0.95 wt%, 1 wt%, 1.1 wt%, 1.2 wt%, 1.3 wt%, 1.4 wt%, 1.5 wt%, 1.75 wt%, 2 wt%, 2.25 wt%, 2.5 wt%, 2.75 wt%, 3 wt%, 3.25 wt%, 3.5 wt%, 3.75 wt%, 4 wt%, 4.25 wt%, 4.5 wt%, 4.75 wt%, 5 wt%, 5.5 wt%, 6 wt%, 6.5 wt%, 7 wt%, 7.5 wt%, 8 wt%, 8.5 wt%, 9 wt%, 9.5 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 16 wt%, 18 wt%, 20 wt%, 22 wt%, 24 wt%, 26 wt%, 28 wt%, 30 wt%, 32 wt%, 34 wt%, 36 wt%, 38 wt%, 40 wt%, 42 wt%, 44 wt%, 46 wt%, 48 wt%, 50 wt% blowing agent or any range between these values.

[0030] One or more additives can be used in foam forming compositions and mixtures thereof. The reaction mixture for foam may contain 0.1 wt%, 0.15 wt%, 0.2 wt%, 0.25 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1.0 wt%, 1.1 wt%, 1.2 wt%, 1.3 wt%, 1.4 wt%, 1.5 wt%, 1.75 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 4.5 wt%, 5 wt%, 5.5 wt%, 6 wt%, 6.5 wt%, 7 wt%, 7.5 wt%, 8 wt%, 8.5 wt%, 9 wt%, 9.5 wt%, 10 wt%, 11 wt%, 12 wt%, 13 wt%, 14 wt%, 15 wt%, 16 wt%, 18 wt%, 20 wt% additives, or any range between these values.

[0031] The reaction mixture for foam forming may be heated to a temperature from 0 °C to 80 °C. The reaction mixture for foam forming may be heated to a more preferred temperature of 25 °C to 55 °C. The reaction mixture for foam forming may be heated to

25 °C, 26 °C, 27 °C, 28 °C, 29 °C, 30 °C, 31 °C, 32 °C, 33 °C, 34 °C, 35 °C, 36 °C, 37

°C, 38 °C, 39 °C, 40 °C, 41 °C, 42 °C, 43 °C, 44 °C, 45 °C, 46 °C, 47 °C, 48 °C, 49 °C, 50 °C, 51 °C, 52 °C, 53 °C, 54 °C, 55 °C or any range between these values. Preheated to the above temperatures before adding to and creating the reaction mixture may also be any individual component or a mixture of components in any possible variation.

[0032] Examples of mixture that can be preheated to the above temperatures before adding to and creating the reaction mixture include but are not limited to a mixture of Michael acceptor and catalyst, a mixture of Michael acceptor and catalyst and surfactant, a mixture of Michael acceptor and catalyst and surfactant and blowing agent, a mixture of Michael acceptor and catalyst and blowing agent, a mixture of Michael acceptor and catalyst, a mixture of Michael donor and catalyst and surfactant, a mixture of Michael donor and catalyst and surfactant and blowing agent, a mixture of Michael donor and catalyst and blowing agent, a mixture of catalyst and surfactant and blowing agent and others.

[0033] After adding components or during the addition of components to the reaction mixture, the reaction mixture is mixed and stirred using any suitable mixing and stirring equipment, including static mixing and stirring equipment, impingement mixing and stirring equipment, or other suitable mixing equipment.

[0034] The mixing time for a mixture containing a Michael donor and Michael acceptor may be from 1 s to 300 s. The more preferred mixing time for a mixture containing Michael donor and Michael acceptor may be 3 s to 120 s, and still more preferred mixing time for a mixture containing Michael donor and Michael acceptor may be 5 s to 60 s. The mixing time for a mixture containing a Michael donor and Michael acceptor may be 5 s, 6 s, 7 s, 8 s, 9 s, 10 s, 11 s, 12 s, 13 s, 14 s, 15 s, 16 s, 17 s, 18 s, 19 s, 20 s, 21 s, 22 s, 23 s, 24 s, 25 s, 26 s, 27 s, 28 s, 29 s, 30 s, 32 s, 34 s, 36 s, 38 s, 40 s, 42 s, 44 s, 46 s, 48 s, 50 s, 52 s, 54 s, 56 s, 58 s, 60 s or any range between these values.

[0035] Premixed may also be any individual component or a mixture of components in any possible variation.

[0036] The bio-based foam of the invention is a reaction product of the reaction of the mixture described above. [0037] These blowing agents expand during the exothermic reaction of Michael donor and Michael acceptor to generate the blowing gas, which forms a foam structure. These formed foams are the bio-based foams of the invention.

[0038] Another aspect of the invention is the bio-based foams obtained by the method of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 shows a principal scheme of manufacturing technology of a polymer. DETAILED DESCRIPTION OF THE INVENTION

[0040] The invention is described but not limited by the following examples:

[0041] Example 1

[0042] Example 2

[0043] Example 3