Liquid base products, liquid compounded products, liquid final products, renewable and biodegradable flexible polymers, methods for manufacturing liquid base products, methods for manufacturing liquid compounded products, methods for manufacturing liquid final products, methods for manufacturing renewable and biodegradable flexible polymers

Abstract

The present invention relates to a liquid base product containing vegetable oil and / or modified vegetable oil, nitrilotriethanol and / or polyether polyol. Furthermore, the present invention relates to a liquid formulation product containing the base product and an organic surfactant, a catalyst, a reactant and / or a chemical blowing agent. Furthermore, the present invention relates to a liquid final product containing the liquid formulation product and / or a physical blowing agent and at least one isocyanate. The present invention further relates to a biodegradable, renewable flexible polymer formed from the liquid final product, and in addition, to a method for producing a biodegradable, renewable flexible polymer.

Description

Technical Field

[0001] The present invention relates to biodegradable and renewable flexible polymer products used in mattresses, pillows, furniture, and various other applications, and methods for obtaining such products. More specifically, the present invention relates to biodegradable and renewable flexible polymer products that function as sustainable alternatives to flexible polyurethane (flexible PU) products derived from fossil resources, are fully recyclable, non-toxic, and biodegradable, and methods for manufacturing the same.

[0002] The present invention relates to liquid base products formed by combining or reacting any component of vegetable oil and / or modified vegetable oil and / or polyether polyol, preferably with nitrilotriethanol and / or its alternatives.

[0003] The present invention relates to liquid formulated products formed by combining or reacting any component of vegetable oil and / or modified vegetable oil and / or polyether polyol, preferably with nitrilotriethanol and / or its alternatives, and further mixing with organic surfactants, catalysts, reactants, blowing agents, and / or pure plant latex.

[0004] The present invention relates to liquid final products formed by combining or reacting any component of vegetable oil and / or modified vegetable oil and / or polyether polyol, preferably with nitrilotriethanol and / or its alternatives, and further mixing with organic surfactants, catalysts, reactants, blowing agents, and / or pure plant latex and isocyanate.

[0005] The present invention relates to a renewable and biodegradable flexible end product obtained by combining or reacting a component of a vegetable oil and / or modified vegetable oil and / or polyether polyol, preferably with nitrilotriethanol and / or a substitute thereof, and further mixing it with an organic surfactant, catalyst, reagent, foaming agent and / or pure vegetable latex and isocyanate, and polymerizing it as a flexible polymer solid. [Background technology]

[0006] (Overview of cutting-edge technology) In recent years, global warming and climate change have become serious concerns for humanity, and efforts are needed to avoid a global climate catastrophe.

[0007] Not only public opinion, but also numerous scientific studies indicate that human behavior is increasingly interfering with the Earth's ecosystems, making the search for sustainable solutions an urgent necessity.

[0008] One of the major production chains that harms the environment is the hydrocarbon-based petroleum industry, which is responsible for generating the majority of environmentally harmful gases.

[0009] Given these catastrophic future predictions, it is essential to immediately adopt new clean technologies capable of capturing carbon and to replace the use of petroleum in modern civilization.

[0010] Furthermore, it should be specifically noted that petroleum is the basis for the production of polyurethane or polyurethane foam (PU, also known as fossil fuel-derived PU). Flexible polyurethane, a type of PU, has a very wide range of applications due to its properties and is used in automotive seats, mattresses, pillows, packaging materials, and the footwear industry, among others.

[0011] Petroleum-derived flexible PU is not biodegradable and, when discarded, poses significant environmental harm. However, despite the widespread and increasing use of this product, current technology lacks a practical and feasible solution for the safe and pollution-free disposal of this vital industrial raw material.

[0012] In this specification, “biodegradable products” should be understood to mean products, parts, articles, accessories, tools, equipment, packaging materials, artifacts, etc., that have the property of being able to decompose in nature within a reasonable period of time.

[0013] Fossil fuel-derived plastic (PU) is not only non-biodegradable, but also difficult to recover, dispose of, and recycle. PU recycling is usually done mechanically through crushing and compression, but even then, it cannot be restored to the same properties as new material, and is often incinerated. This incineration causes significant environmental damage, and the material may end up in landfills.

[0014] Furthermore, improperly disposed PU is flowing into oceans worldwide in massive quantities. From small fragments to large chunks, PU is carried into bodies of water by rain and other means, eventually reaching the ocean.

[0015] These bodies of water are exposed to a continuous influx of plastic (PU), which is broken down into millions of tiny fragments (microplastics) over the years by colliding with each other or with other plastics floating on the surface, resulting in enormous quantities.

[0016] These PU-derived microplastics have the ability to adsorb and concentrate toxic chemicals such as pesticides, insecticides, and heavy metals like mercury and lead, which are mainly found in rivers, lakes, and oceans, and become a source of pollution, especially when ingested by aquatic organisms. In marine environments, marine animals such as fish, sea turtles, whales, and dolphins may mistake these microplastics for marine organisms and ingest them, causing poisoning and endangering the entire food chain.

[0017] However, in terms of commercial application, use, practicality, and proper disposal methods, no solutions currently exist in existing technology that can replace PU products. No products are known that can replace the physical properties of PU while being properly disposed of in the environment through natural biodegradation. [Overview of the project]

[0018] Object of the invention Based on the problems of the prior art described above, the present invention aims to provide a biodegradable, non-toxic, and recyclable product that can be used in automotive seats, mattresses, pillows, packaging materials, footwear, and the like, and serves as a sustainable alternative to flexible fossil resource-derived PU.

[0019] Another object of the present invention is to provide a product that has mechanical strength properties equivalent to fossil resource-derived flexible PU, is low in density, and can completely replace fossil resource-derived flexible PU in all applications, including so-called integral skin.

[0020] From this perspective, another object of the present invention is to provide a biodegradable, flexible, and renewable polymer composition based on clean and renewable resources, instead of using petroleum as a raw material for PU (polyurethane).

[0021] Another objective of the present invention is to enable the use of natural ingredients derived from renewable resources that do not directly compete with the food chain. For example, "waste cooking oil" collected from restaurants, cafeterias, and apartment buildings can be reused as a raw material, achieving resource recycling and avoiding water source pollution caused by waste cooking oil.

[0022] Furthermore, the products of this invention are designed to be harmless even if ingested by animals. This is a fundamentally different characteristic from fossil fuel-derived PU, which, when ingested, does not break down in the digestive tract of animals and can cause poisoning or death.

[0023] Another object of the present invention is to reduce carbon emissions into the atmosphere by using components derived from renewable resources to replace petroleum-derived products and their uses.

[0024] Another object of the present invention is to provide a liquid or slurry product for producing a biodegradable flexible renewable polymer, thereby simplifying and enhancing the production process.

[0025] (Summary of the Invention) The present invention relates to a liquid base material product obtained by reacting a first base material component and a second base material component. Here, the first base material component is selected from at least any one of the following: vegetable oil, modified vegetable oil, or a combination of these components. The second base material component is selected from at least any one of the following: nitrilotriethanol, monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination of these components. The liquid base material product contains 97% to 99.9% by mass of the first base material component and 0.1% to 3% by mass of the second base material component based on the total mass, and its hydroxyl value is in the range of 45 to 180.

[0026] The liquid base product may further contain a third base component, which is a polyether polyol, and the amount of polyether polyol is determined by the desired hydroxyl value of the final product. The hydroxyl value of the third base component may be in the range of 10 to 80. The hydroxyl value of the first base component may be in the range of 1.2 to 180. The amounts of the second and third base components relative to the total mass of the liquid base product are determined by the desired hydroxyl value of the liquid base product, based on the hydroxyl value of the first base component. The second base component is selected from at least one of the following: nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol, 1,4-butanediol, or a combination thereof. The second base component is selected from at least one of the following: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, or a combination of these components. The second base component is selected from at least one of the following: propylene glycol, dipropylene glycol, tripropylene glycol, or a combination of these components. The second base component is selected from at least one of the following: dimethylolpropane, pentaerythritol, sorbitol, or a combination of these components.

[0027] The present invention relates to a liquid formulation product obtained by mixing a blowing agent, at least an organic surfactant, a catalyst and / or a reactant with a liquid base material product. The blowing agent may be water. The organic surfactant may be selected from at least any one of the following: siloxane silicone and / or water-soluble silsesquioxane silicone. The catalyst may be selected from at least any one of the following: tin octoate, dibutyltin dilaurate, cobalt octoate, bismuth octoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, dimethylcyclohexylamine, and may be metal-based or amine-based. The reactant is preferably selected from nitrilotriethanol and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof.

[0028] The present invention relates to a liquid final product obtained by reacting the liquid formulation product with an isocyanate. The isocyanate may be MDI, TDI, NDI, HDI, IPDI, HMDI, TPMTI and / or PDI, or a mixture thereof, and the NCO (nitrogen-carbon-oxygen) content ranges from 10% to 50%. The liquid final product may contain 31% to 93% of the liquid formulation product and 7% to 69% of the isocyanate based on the total mass. Further, the liquid final product may further contain a physical blowing agent. The physical blowing agent may be selected from at least any one of the following: hydrofluoroolefin, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, hydrogenated chlorofluorocarbon, or a combination thereof.

[0029] The present invention relates to a renewable and biodegradable flexible polymer obtained by polymerizing the liquid final product in a solid state.

[0030] The present invention relates to a method for manufacturing a liquid base product, the method comprising the following steps: a step of heating a first base component to a temperature of 50°C to 70°C, wherein the first base component is selected from at least one of the following: vegetable oil and / or modified vegetable oil; a step of adding a second base component, wherein the second base component is selected from at least one of the following: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol A step of heating the combination of the first and second base components to 90°C to 115°C if the melting point of the second base component is less than 115°C, and heating the combination to a temperature above 115°C if the melting point of the second base component is greater than 115°C; and stirring the combination of the first and second base components for 20 to 40 minutes under the aforementioned temperature conditions. The method for producing a liquid base product may further include a step of cooling the product obtained after stirring to room temperature, a step of adding a third base component (where the third base component is a polyether polyol), and a step of stirring the combination containing the third base component at room temperature for 20 to 40 minutes.

[0031] The present invention also relates to a method for producing a liquid compound product, comprising generating a liquid base product, stirring the liquid base product with at least an organic surfactant, a catalyst and / or a reactant, and adding a foaming agent stepwise during the stirring period.

[0032] The present invention further relates to a method for producing a liquid final product, comprising generating a liquid compound product and stirring the liquid compound product with an isocyanate to induce a reaction between its components.

[0033] The present invention further relates to a method for producing a biodegradable, flexible, and renewable polymer, comprising generating a liquid final product and molding the liquid final product by a polymerization reaction to obtain a biodegradable, flexible, and renewable polymer. [Modes for carrying out the invention]

[0034] (Detailed description of the invention) First, it should be noted that the term “preferred” as used herein is intended to characterize particularly efficient embodiments among the multiple possible embodiments of the present invention. The term “preferred” should not be understood as “essential” or “mandatory” for carrying out the present invention.

[0035] The term "phase" in the process of the present invention should be understood to have a similar meaning to "step," and in the context of the present invention, it refers to a stage that may include one or more steps or sub-steps.

[0036] In this invention, the term "to produce" means to devise, manufacture, or obtain something, and should be interpreted broadly, not limited to its narrow sense.

[0037] The term "renewable product" refers to a product whose raw materials are derived from renewable natural resources, that is, a product that utilizes renewable resources as an alternative to the use of fossil fuels.

[0038] The term "room temperature" refers to a normal temperature, i.e., around 20°C.

[0039] The present invention relates to a liquid substrate product obtained by combining and / or reacting a first substrate component with a second and / or third substrate component.

[0040] In one embodiment of the present invention, a liquid substrate product is obtained by reacting a first substrate component with a second substrate component.

[0041] In another embodiment of the present invention, a liquid base product is obtained by reacting a first base component with a second base component and then mixing it with a third base component.

[0042] The first base component is selected from at least one of the following: vegetable oil, modified vegetable oil, or a combination thereof.

[0043] In one embodiment, the second base component is preferably selected from nitrilotriethanol and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof.

[0044] In the present invention, alternatives or substitutes for nitrilotriethanol include monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, and sorbitol. Therefore, even when nitrilotriethanol is described as a preferred component, its substitute components can be used alone or in combination to obtain desired base products, compounded products, liquid final products, and flexible final products.

[0045] In one embodiment, the second base component is selected from at least one of the following: nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol, 1,4-butanediol, or a combination thereof.

[0046] In one embodiment, the second base component is selected from at least one of the following: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, or a combination thereof.

[0047] In one embodiment, the second base component is selected from at least one of the following: propylene glycol, dipropylene glycol, tripropylene glycol, or a combination thereof.

[0048] In one embodiment, the second base component is selected from at least one of the following: dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof.

[0049] In other embodiments of the present invention, the different groups of components listed as the second base material components may be combined to form a new embodiment of the liquid base material product.

[0050] The third base component is selected from at least one polyether polyol having various hydroxyl values. That is, the polyether polyol as the third base component has a hydroxyl value suitable for the desired application, thereby enabling the production of a liquid base product having the desired hydroxyl value, as will be described later.

[0051] In one embodiment, the hydroxyl value of the first base component is in the range of 1.2 to 180, and the hydroxyl value of the liquid base product is in the range of 45 to 180. The amount of the second and / or third base component is determined based on the hydroxyl value of the first base component, according to the desired hydroxyl value of the liquid base product.

[0052] In one embodiment, the hydroxyl value of the third base component, i.e., the polyether polyol, is in the range of 10 to 80, more preferably 25 to 56. It is also possible to obtain a desired hydroxyl value for the third base component by combining multiple polyether polyols having different hydroxyl values.

[0053] In one embodiment, the content of the first base component, i.e., vegetable oil and / or modified vegetable oil, may be 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77.5%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 99.9% or any of these ranges based on the total mass of the liquid base product. In a preferred embodiment, the first base component is 97-99.9% by mass.

[0054] In one embodiment, the content of the second base component, i.e., nitrilotriethanol and / or its substitute, may be in the range of 0.1%, 1%, 2%, or 3%, or 0.1–3%, based on the total mass.

[0055] In one embodiment, the polyether polyol content may be 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or 30% of the total mass, or in the range of 0 to 30%.

[0056] The present invention also relates to a liquid formulation product, which is composed of a mixture of a liquid base product, a chemical blowing agent, and at least one or more organic surfactants, catalysts, and / or reactants.

[0057] In one embodiment, the amount of liquid base product contained in the liquid formulation product is preferably 41.78 to 99.80% by mass of the total mass of the liquid formulation product. In embodiments containing a blowing agent, the amount of the blowing agent is preferably 0.01 to 23.24% by mass of the total mass of the liquid formulation product. This mass percentage may be the sum of the physical blowing agent and the chemical blowing agent. The amount of organic surfactant, catalyst and / or reactant (total when present individually or in combination) is preferably 0.01 to 47.78% by mass of the total mass of the liquid formulation product.

[0058] The catalyst is selected from at least one of the following: tin octanoate, dibutyltin dilaurate, cobalt octanoate, bismuth octanoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, dimethylcyclohexylamine, or other metal-based or amine-based catalysts.

[0059] The organic surfactant is selected from at least one of the following: siloxane silicone and / or water-soluble siloxane silicone.

[0060] The reactant is preferably selected from nitrilotriethanol and / or one or more of monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, and sorbitol.

[0061] The present invention further relates to a liquid final product obtained by reacting a liquid formulation with an isocyanate. The isocyanate may be MDI, which contains 10 to 50% by mass of nitrogen-carbon-oxygen (NCO). In the liquid final product, the amount of the liquid formulation may be 31 to 93% by mass, preferably 59 to 89% by mass, and more preferably 60 to 85% by mass, based on the total mass. The amount of isocyanate is 7 to 69% by mass, preferably 11 to 41% by mass, and more preferably 15 to 40% by mass, based on the total mass of the liquid final product.

[0062] In one embodiment, the amount of isocyanate is 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 3% of the total mass. 7%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, or 69%, or within these ranges.

[0063] The present invention further relates to a method for producing a biodegradable flexible renewable polymer, the method comprising the steps of producing a base product, the steps of stirring a first base component and a second base component until a reaction occurs between the components, the first and second base components react with each other to produce a base product, and / or mixing the reaction product of the first and second base components with a third component. The first base component is selected from at least one of the following: vegetable oil and / or modified vegetable oil. The second base component is selected from at least one of the following: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, and / or sorbitol. The third base component is selected from at least one of polyether polyols having various hydroxyl values. The method for producing a biodegradable flexible renewable polymer further includes a step of producing a compound product, the compound product production step of stirring a base product with an organic surfactant, a catalyst and / or a reagent, and adding a chemical blowing agent stepwise while stirring the base product with the organic surfactant, a catalyst and / or a reagent. Furthermore, the method for producing a biodegradable flexible renewable polymer further includes a step of producing a liquid final product, the liquid final product production step of stirring a liquid compound product with one or more different types of isocyanates.

[0064] The process for producing the base product includes a preliminary step of weighing and introducing a first base component (vegetable oil and / or modified vegetable oil) into a reaction vessel and / or mixer. In one embodiment, the reaction vessel may be a reaction vessel having a heating function.

[0065] The process for producing a base product includes a step of heating a first base component, which can be heated to a stirring temperature in the range of 50°C to 70°C before being stirred with a second base component.

[0066] As an example, if nitrilotriethanol is selected to adjust the hydroxyl value of the product, a reactor equipped with a heating function can be used. In this case, the heater is activated and the components present in the reactor are heated until they reach a stirring temperature. In this example, the stirring temperature is in the range of 50°C to 70°C.

[0067] The process for producing the base product further includes a step of stirring the first base component and the second base component, which is preferably carried out at a stirring temperature of 90°C to 115°C for 20 to 40 minutes.

[0068] A stirring temperature of 90°C to 115°C is particularly suitable for certain second base components, such as nitrilotriethanol. However, as mentioned above, alternative components to nitrilotriethanol can also be used. For example, if pentaerythritol is chosen as the alternative component, the stirring temperature must be 250°C to 300°C.

[0069] In one embodiment, if the melting point of the selected alternative component exceeds the flash point of the oil, it is necessary to inject an antioxidant component such as nitrogen during the reaction.

[0070] In one embodiment, the product produced after stirring / reacting the first base component and the second base component can be cooled to room temperature, and then the third base component can be added at room temperature.

[0071] When adding a polyether polyol to a liquid base product to adjust the stoichiometry and obtain a desired hydroxyl value, stirring can be performed only by a mixer at room temperature, and the stirring time is 20 to 40 minutes, preferably 25 to 35 minutes.

[0072] A liquid base product is obtained by adding, weighing, and heating vegetable oil and / or modified vegetable oil, adding and weighing nitrilotriethanol or its substitute, heating, stirring, and cooling, and then, if necessary, adding and weighing polyether polyol, and stirring the base components in a reactor or mixer at room temperature.

[0073] In another embodiment, the process of producing the base product may include heating a first component and circulating it through a column packed with molecular sieve particles having pores of 3 to 13 angstroms. The heating temperature is maintained at 100°C to 140°C, and only after 30 minutes have elapsed since this temperature stabilized is the process of contacting the first component with the molecular sieves initiated. The first component is circulated through the column sufficiently until the desired hydroxyl value is obtained.

[0074] The process for producing a liquid formulation product includes stirring a liquid base product with an organic surfactant, a catalyst, and / or a reactant, and adding a chemical blowing agent stepwise during the stirring time. The stirring time for the process of producing the liquid formulation product is in the range of 2 minutes to 120 minutes.

[0075] In preferred embodiments, the catalyst is selected from at least one of the following: tin octanoate, dibutyltin dilaurate, cobalt octanoate, bismuth octanoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, dimethylcyclohexylamine, and may be metallic or amine-based. The organic surfactant is selected from at least one of silosacin and / or water-soluble silosacin. The reactant is preferably selected from at least one of nitrilotriethanol and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, and sorbitol.

[0076] Organic reagents and surfactants used in the production process of liquid compound products play a role in promoting and improving the efficiency of reactions between the base product and the compound product components. Catalysts accelerate the reaction, ensuring that the final product has the desired properties. Organic reagents and surfactants are components that increase the volume and elasticity of the solid final product when reacted with isocyanates. Silicones are responsible for crosslinking of cell openings.

[0077] In a preferred embodiment, the chemical blowing agent is water. The water component is a chemical blowing agent and needs to be added in stages throughout the entire stirring time of the compound. Adding water in stages throughout the entire stirring time means adding this component to the mixture multiple times or continuously. In one embodiment, when water is included as a blowing agent, the amount is 0.01 to 2.35% by mass of the total mass of the liquid compound.

[0078] As an alternative embodiment, a physical blowing agent can be used in liquid or gaseous form instead of the preferred chemical blowing agent. In non-limiting examples, the physical blowing agent may be hydrofluoroolefin, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, and / or hydrogenated chlorofluorocarbon.

[0079] In the process of the present invention, the above-mentioned components of the preferred embodiment are the main possible components in the formulation of the base product and the compounded product. However, it should be noted that in alternative embodiments, other alternative components that perform the same chemical functions as the components already mentioned in the present invention may be used.

[0080] The liquid formulation process may optionally include a step of adding a coloring agent to give color to the formulation and the final product. Preferably, the coloring agent used in the present invention is a plant-derived coloring agent or an aqueous coloring agent.

[0081] The process for producing the liquid formulation product may optionally further include a step of adding a flame retardant and / or a smoke suppressant.

[0082] The liquid final product production process includes a step of stirring the liquid formulation product with isocyanates, or different types of isocyanates. In one embodiment, the liquid final product production process may include a step of introducing a physical blowing agent, which is selected from at least one of hydrofluoroolefins, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, and / or hydrogenerated chlorofluorocarbons.

[0083] In a preferred embodiment, the isocyanate is MDI, which is methylenediphenyl diisocyanate, an organic compound containing nitrogen-carbon-oxygen (NCO) in the range of 10% to 33.56%. The MDI acts as a reactant, reacting exothermically with the liquid formulation to significantly increase the volume of the final mixture. In this case, the liquid final product is filled into a mold and polymerized to form a flexible solid foam, i.e., the final flexible solid product.

[0084] While MDI is exemplified, other isocyanates may be used in alternative embodiments of the present invention. Other types of isocyanates can be used as reagents instead of MDI, provided that the properties of the final product (e.g., toxicity and biodegradability) are not impaired. Examples include 2,4-toluene diisocyanate or 2,6-toluene diisocyanate (TDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), 4,4'-dicyclohexylmethane diisocyanate (HMDI), naphthalene-1,5-diisocyanate (NDI), triphenylmethane-4,4,4-triisocyanate (TPMTI), and 1,4-phenylenediisocyanate (PDI). Furthermore, mixtures of the reagents already listed, as well as structurally modified forms of these molecules, may also be used.

[0085] In one embodiment, the application apparatus can be used in the process of producing the final liquid product. In one embodiment, this application apparatus comprises two working tanks having at least one inlet and one outlet. The application apparatus is a vessel for causing a reaction between isocyanate and the liquid formulation product at a predetermined temperature. The reaction is temperature independent, but temperature can affect the final properties of the solid product. Furthermore, the reaction time varies greatly depending on a number of factors, such as the size of the mold, the application method, and the desired final properties.

[0086] In one embodiment, the reaction temperature between the liquid formulation product and the isocyanate is 20°C to 45°C.

[0087] From this perspective, the application apparatus of the present invention also plays a role in supplying the liquid compound product and isocyanate to the desired mold or application location. Examples of embodiments include carousel-type application apparatuses and low-pressure and high-pressure injection molding machines.

[0088] When manufacturing vehicle seats, the applicable equipment may be, for example, an injection molding machine that heats, mixes in large quantities, and injects the liquid final product into a mold of a specific shape. Polymerization takes place within this mold. The applicable equipment may also be, for example, a large, irregularly shaped mold that is ultimately cut to suit a specific application. This process can also be understood as a process for producing a flexible solid final product, which forms the final mixture through a polymerization reaction from a liquid state to a solid state.

[0089] The amount of liquid compound product introduced into one working tank is 31 to 93% by mass, preferably 59 to 89% by mass, and more preferably 60 to 85% by mass, relative to the total mass of the final liquid product (in liquid state). The amount of isocyanate introduced into the other working tank is 7 to 69% by mass, preferably 11 to 41% by mass, and more preferably 15 to 40% by mass, relative to the total mass of the final liquid product (in liquid state).

[0090] During the application phase, depending on the type of application, an optional step may be taken to allow the liquid final product to solidify after application. The solidification time is typically 1 to 10 minutes. Polymerization (solidification) from liquid to solid must be handled considering this time variation, depending on the complexity of the manufactured part. After the solidification time has elapsed, the final product polymerizes from a liquid to a solid state. If necessary, the final product is calendered (rolled or pressed) to break down the cellular structure of the material and release internal gases.

[0091] In one embodiment, the method for producing the biodegradable flexible renewable polymer of the present invention includes the step of forming a liquid final product by a polymerization reaction to obtain a solid final product. In one embodiment, the final product production step includes the step of introducing a liquid formulation product and an isocyanate into an injector or an alternative device, reacting the liquid formulation product and the isocyanate, and injecting or applying the combination to obtain a solid final product, i.e., a biodegradable flexible renewable polymer.

[0092] The final product components, combined and reacted in a liquid state, are applied and molded to produce a solid final product. In other words, the biodegradable, renewable, and flexible polymer of the present invention is a solid product obtained from the aforementioned liquid final product.

[0093] Generally, the method for producing the biodegradable and renewable flexible polymer of the present invention is divided into three stages. That is, the first stage involves the production of a base product, the second stage involves the production of a compound product, and the third stage involves the production of the final product. More specifically, the main steps or stages of the process for obtaining the biodegradable and renewable flexible polymer of the present invention include: producing a base product, which includes combining / reacting at least one vegetable oil and / or modified vegetable oil with nitrilotriethanol or its substitute and / or polyether polyol; producing a compound product, which includes stirring / mixing the base product with an organic surfactant, catalyst, reagent and / or chemical blowing agent; producing a liquid final product, which includes stirring / mixing the compound product with an isocyanate and / or some physical blowing agent; and producing a solid final product by obtaining the shape of the final mixture through a polymerization process by weighing, heating, and pouring the bulk mixture.

[0094] A base product or liquid base product can be understood as a product obtained from the first step of the process of the present invention. The base product may be used and / or sold on its own for the subsequent production of a compound product or for other purposes not previously specified herein.

[0095] The compounded product or liquid compounded product may be understood as a product obtained from the second step of the process of the present invention. The compounded product may be used and / or sold on its own to produce a liquid or flexible final product or for other purposes not previously specified herein.

[0096] The final product or liquid final product can be understood as a product obtained from the third step of the process of the present invention.

[0097] The term "solid end product" is also used to refer to biodegradable, renewable, and flexible polymers.

[0098] The base product is a liquid product obtained from a reaction involving at least two components to produce a liquid base material. Such a base product is formed by reacting a vegetable oil and / or modified vegetable oil with nitrilotriethanol and / or polyether polyol. As an alternative to nitrilotriethanol, monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, or sorbitol may be used, and these are illustrative examples and do not limit the invention.

[0099] In order to form a base product that can contain a biodegradable and renewable flexible polymer as described in the present invention, the hydroxyl value must be between 45 and 180. In a preferred embodiment, the hydroxyl value is preferably 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175 or 180, or any range between these values.

[0100] The hydroxyl value mentioned in the previous paragraph is a determinant for obtaining the final properties of biodegradable and renewable flexible polymers. All vegetable oils have different hydroxyl values, ranging from approximately 1.2 to 165. Regardless of the hydroxyl value of the vegetable oil and / or modified vegetable oil, nitrilotriethanol and / or polyether polyols, or their substitutes, must be added until the aforementioned parameter, namely more preferably in the range of 45 to 180, is reached.

[0101] Both polyether polyols and nitrilotriethanol play a role in adjusting and increasing or decreasing the hydroxyl value. Therefore, nitrilotriethanol increases the hydroxyl value of the base component, while polyether polyols decrease it. In particular, treatment with nitrilotriethanol promotes the biodegradability of the solid, biodegradable, and regenerative flexible polymer material / product that is the subject of this invention.

[0102] The compounded product is a liquid product obtained by mixing the above-mentioned liquid base product with a chemical blowing agent, an organic surfactant, a catalyst, and a reactant in liquid form. This liquid compounded product is then reacted with an isocyanate catalyst to form a biodegradable and regenerative flexible polymer.

[0103] In one embodiment, the biodegradable and renewable flexible polymer comprises the following raw materials: vegetable oil and / or modified vegetable oil; and / or polyether polyol, nitrilotriethanol; water; organic surfactant and / or catalyst and / or reagent; and isocyanate.

[0104] In one embodiment, the biodegradable and renewable flexible polymer comprises the following raw materials: vegetable oil and / or modified vegetable oil; and / or polyether polyol, nitrilotriethanol; water; organic surfactant and / or catalyst and / or reagent; and / or pure vegetable latex; and isocyanate.

[0105] In one embodiment, the amount of isocyanate is preferably 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38% %, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, or 69%, or any range between these values.

[0106] Through a liquid mixing reaction, the final liquid product polymerizes via an exothermic reaction, forming a flexible, foamy solid, such as those used in mattresses and pillows. Product degradation occurs within 6 months, and the product density is 15 kg / m³. 3 From 200 kg / m 3 It is within the range.

[0107] In one embodiment, the amount of liquid formulation product contained in the final product is preferably 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, The percentages are 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, or 93%, and are in the range of 31% to 93% by mass ratio, or any range between the aforementioned values.

[0108] The ratio of isocyanate to polyol in the final product varies depending on the desired index. In summary, the higher the amount of isocyanate in the final product, the higher the rigidity of the biodegradable and renewable flexible polymer. Therefore, to obtain a biodegradable and renewable flexible polymer with low rigidity, the ratio of isocyanate in the final product needs to be low.

[0109] Among the components of the base product, at least one component comprises at least one type of vegetable oil and / or modified vegetable oil. The vegetable oils used in this embodiment are, but are not limited to, the following: frying oil, cooking oil, cottonseed oil, macauba oil, palm oil, soybean oil, corn oil, canola oil, sunflower oil, rapeseed oil, or castor oil. Alternatively, a mixture of multiple vegetable oils may be used as a component of the base product.

[0110] When any of the aforementioned oils react with nitrilotriethanol or one of its substitutes and / or a polyether polyol to form a base product, they must achieve the aforementioned hydroxyl value required in the present invention.

[0111] Among the components of the base product, there are ingredients containing polyether polyols in addition to vegetable oils and / or modified vegetable oils. In formulation, polyether polyols play a role in maintaining a low hydroxyl value of the molecular chains in the composition, resulting in a final product that possesses both flexibility and elasticity.

[0112] Similarly, another component that may be included in base products is nitrilotriethanol. This is an organic chemical compound, supplied in a viscous liquid state, soluble in water, and miscible with most oxygen-containing organic solvents. It is used to adjust the hydroxyl value and achieve the desired parameter by reacting it with vegetable oils.

[0113] The industrial process for producing a product or mixture comprising the biodegradable and renewable flexible polymer of the present invention has similarities to the process described in document number BR102023000639-6, which can be used to resolve any doubts and to better understand the details of the process of the present invention. However, there are significant differences between the two processes, corresponding to differences in composition, the method of performing the process, and process parameters (such as temperature and time). This is because the process described in document number BR102023000639-6 aims to obtain a rigid product, while the process of the present invention aims to obtain a flexible product.

[0114] The final biodegradable product obtained in solid state has a physicochemical composition determined by an exothermic reaction, which results from the ratio of the selected compound and isocyanate according to the desired properties, and the subsequent polymerization reaction.

[0115] The density of the flexible solid final product is 15 kg / m³ 3 From 200 kg / m 3 This range allows for obtaining final products with different densities and formulations.

[0116] To understand the elastomer properties of the final product, the liquid final product has a density of 300 kg / m³. 3 From 800 kg / m 3 It is possible to produce solid final products within this range.

[0117] The biodegradable end product of the present invention has the property of physically decomposing under specific conditions. This is because it is undesirable for the product to decompose during use. For example, it is undesirable for an end product applied to a mattress or pillow to decompose. Therefore, the biodegradable product of the present invention decomposes only when placed under decomposition conditions. Decomposition conditions refer to situations in which the biodegradable product is exposed to microorganisms or lipid-degrading biofactors present in soil, landfills, or anaerobic reactors.

[0118] Therefore, the biodegradable product of the present invention has a significant advantage over other prior art products in that it decomposes rapidly when discarded into the environment and subjected to decomposition conditions. In a preferred embodiment, under decomposition conditions, the biodegradable product of the present invention begins to decompose within 15 days.

[0119] The flexible biodegradable product underwent degradation tests under anaerobic and aerobic conditions, as well as toxicity tests against fish and microalgae. In the anaerobic digestion test, the flexible biodegradable product was placed in a reaction vessel along with nutrients and inoculants (bacterial colonies), and biogas generation was continuously monitored. The biogas (mainly methane and CO2) emission curve increased, demonstrating the non-toxicity of the foam under this environment. After 60 days of experimentation, the degradation rate of the flexible foam was 44.21%.

[0120] To evaluate aerobic degradation and toxicity, microalgae of the genus Chlorella (Chlorella sp.), selected as bioindicators sensitive to toxic substances, were used in controlled culture media. The results confirmed the non-toxicity of the biodegradable flexible product, and algae exposed to environments containing this product exhibited the same life cycle as the control sample.

[0121] As a supplement to the study, the biodegradable flexible product was used as a fish feed supplement for 54 days. The non-toxicity of the biodegradable flexible product was confirmed again, there were no deaths among the test group fish, and no lesions were detected in pathological examinations.

[0122] Regarding the results of the decomposition test, the biodegradable flexible product showed higher decomposition in an aerobic environment, achieving a decomposition rate of 31.93% after 37 days.

[0123] Therefore, the biodegradable product of the present invention has superior biodegradability compared to flexible foams derived from non-renewable fossil resources.

[0124] Furthermore, it should be noted that the numerical values ​​and ranges of any of the aforementioned characteristics may vary by up to ±5%. This means that any numerical value or range may fluctuate within ±5% of the defined value or range, for example, 1%, 2%, 3%, 4%, 5%, or any positive or negative decimal value of those values. If such fluctuations occur, corrections will naturally be made during the formulation process to maintain the overall yield.

[0125] While embodiments of the present invention have been described, the scope of the invention should be limited only by the content of the claims and their equivalents, and should also include other possible modifications.

Claims

1. A liquid-based product characterized by containing a product obtained by reacting a first base component with a second base component, The first base component is selected from at least one of vegetable oil, modified vegetable oil, or a combination thereof. The second base component is selected from at least one of nitrilotriethanol, monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof. The liquid substrate product contains 97 to 99.9% by mass of the first substrate component and 0.1 to 3% by mass of the second substrate component, based on the total mass of the liquid substrate product. A liquid base product wherein the hydroxyl value of the liquid base product is in the range of 45 to 180.

2. A liquid substrate product according to claim 1, further comprising a third substrate component, wherein the third substrate component is a polyether polyol, and the amount of the polyether polyol is determined by a desired hydroxyl value relative to the liquid substrate product.

3. A liquid base product according to claim 2, characterized in that the hydroxyl value of the third base component is in the range of 10 to 80.

4. A liquid base product according to any one of claims 1 to 3, characterized in that the hydroxyl value of the first base component is in the range of 1.2 to 180.

5. A liquid substrate product according to any one of claims 1 to 4, characterized in that the amounts of the second substrate component and the third substrate component relative to the total mass of the liquid substrate product are determined by a desired hydroxyl value of the liquid substrate product based on the hydroxyl value of the first substrate component.

6. A liquid base product according to any one of claims 1 to 5, characterized in that the second base component is selected from at least one of nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol, 1,4-butanediol, or a combination thereof.

7. A liquid substrate product according to any one of claims 1 to 5, characterized in that the second substrate component is selected from at least one of monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, or a combination thereof.

8. A liquid substrate product according to any one of claims 1 to 5, characterized in that the second substrate component is selected from at least one of propylene glycol, dipropylene glycol, tripropylene glycol, or a combination thereof.

9. A liquid base product according to any one of claims 1 to 5, characterized in that the second base component is selected from at least one of dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof.

10. A liquid compound product characterized by comprising a liquid base product according to any one of claims 1 to 9, a foaming agent, and at least one of an organic surfactant, a catalyst, and / or a reactant.

11. A liquid compounding product according to claim 10, characterized in that the foaming agent is water.

12. A liquid formulation product according to claim 10 or 11, characterized in that the organic surfactant is selected from at least one of siloxane silicone and / or water-soluble siloxane silicone.

13. A liquid formulation product according to any one of claims 10 to 12, characterized in that the catalyst is selected from at least one of tin octanoate, dibutyltin dilaurate, cobalt octanoate, bismuth octanoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, and dimethylcyclohexylamine, and the catalyst is metallic or amine-based.

14. A liquid formulation product according to any one of claims 10 to 13, characterized in that the reactant is preferably selected from at least one of nitrilotriethanol and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof.

15. A liquid final product characterized by comprising a liquid formulation product obtained by reacting an isocyanate with any one of claims 6 to 10.

16. A liquid final product according to claim 15, wherein the isocyanate is MDI, TDI, NDI, HDI, IPDI, HMDI, TPMTI and / or PDI, or a mixture thereof, and the isocyanate has 10 to 50% NCO (nitrogen-carbon-oxygen).

17. A liquid final product according to claim 15 or 16, characterized in that it contains 31 to 93% by mass of the liquid compounding product and 7 to 69% by mass of the isocyanate, based on the total mass of the liquid final product.

18. A liquid final product according to any one of claims 15 to 17, further comprising a physical foaming agent.

19. A liquid final product according to any one of claims 15 to 18, characterized in that the physical blowing agent is selected from at least one of hydrofluoroolefin, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, hydrochlorofluorocarbon, or a combination thereof.

20. A renewable, biodegradable, flexible polymer characterized by comprising a liquid final product according to any one of claims 15 to 19 that is polymerized in a solid state.

21. A method for manufacturing a liquid base product, - A step of heating a first base material component to 50-70°C, wherein the first base material component is selected from at least one of vegetable oils and / or modified vegetable oils; - A step of adding a second base component, wherein the second base component is selected from at least one of nitrilotriethanol, monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, sorbitol, or a combination thereof; - A step of heating the combination of the first base component and the second base component, wherein if the melting point of the second base component is less than 115°C, the temperature is 90 to 115°C, and if the second base component is pentaerythritol, the temperature is 250 to 300°C; and - A step of stirring the combination of the first base material component and the second base material component for 20 to 40 minutes at the temperature of the preceding step, A method for producing a liquid base product, characterized by including the following:

22. A method for producing a liquid base product according to claim 21, further, - A step of cooling the product obtained after stirring the above combination to room temperature; - A step of adding a third base material component, wherein the third base material component is a polyether polyol; and - A step of stirring the combination containing the third base component at room temperature for 20 to 40 minutes. A manufacturing method characterized by including the following.

23. A method for manufacturing a liquid compound product, A method for producing a liquid base product according to claim 18 or 19, wherein the production of the compound product comprises shaking the liquid base product with at least one of an organic surfactant, a catalyst and / or a reagent, and adding a foaming agent stepwise throughout the entire period of stirring the base product with the organic surfactant, catalyst and / or reagent.

24. A method for manufacturing a liquid final product, A step of producing the liquid compound product according to claim 20; and The process involves stirring the liquid formulation until a reaction occurs with the isocyanate. A manufacturing method characterized by including the following.

25. A method for producing a biodegradable and regenerative flexible polymer, A step of producing the liquid final product according to claim 21; and The process involves molding the aforementioned liquid final product by a polymerization reaction to obtain the biodegradable and regenerative flexible polymer. A manufacturing method characterized by including the following.

Images