Liquid base products, liquid-formulated products, liquid final products, renewable and biodegradable elastic polymers, processes for manufacturing liquid base products, processes for manufacturing liquid-formulated products, processes for manufacturing liquid final products, processes for manufacturing renewable and biodegradable elastic polymers.

Abstract

Invention details;

Description

Descriptive Report of the Invention Patent for "BASE LIQUID PRODUCT, FORMULATED LIQUID PRODUCT, FINAL LIQUID PRODUCT, RENEWABLE AND BIODEGRADABLE FLEXIBLE POLYMER, BASE LIQUID PRODUCT MANUFACTURING PROCESS, FORMULATED LIQUID PRODUCT MANUFACTURING PROCESS, FINAL LIQUID PRODUCT MANUFACTURING PROCESS, RENEWABLE AND BIODEGRADABLE FLEXIBLE POLYMER MANUFACTURING PROCESS".

[0001] The present invention relates to a flexible, biodegradable renewable polymer product for the manufacture of mattresses, pillows, furniture, and various other applications, and to a process for producing such a product. More particularly, the present invention relates to a flexible, biodegradable renewable polymer product and a process for manufacturing such a product, which serves as a sustainable alternative to products made with fossil-based flexible polyurethane (flexible PU). The product of the present invention is fully recyclable, non-toxic, and biodegradable.

[0002] The present invention relates to a basic liquid product, which is formed from the combination or reaction of one of the ingredients vegetable oil and / or modified vegetable oil and / or polyether polyol, with nitrilotriethanol, preferably, and / or its possible substitutes.

[0003] The present invention relates to a formulated liquid product, which is formed from the combination or reaction of one of the ingredients vegetable oil and / or modified vegetable oil and / or polyether polyol, with nitrilotriethanol, preferably, and / or its possible substitutes, further mixed with organic surfactants, catalysts, reagents, expanding agents and / or pure vegetable latex.

[0004] The present invention relates to a final liquid product, which is formed from the combination or reaction of one of the ingredients vegetable oil and / or modified vegetable oil and / or polyether polyol, with nitrilotriethanol, preferably and / or its possible substitutes, further mixed with organic surfactants, catalysts, reagents, expanding agents and / or pure vegetable latex and isocyanates.

[0005] The present invention relates to a final flexible, renewable and biodegradable product, which is formed from the combination or reaction of one of the ingredients vegetable oil and / or modified vegetable oil and / or polyether polyol, with nitrilotriethanol, preferably, and / or its possible substitutes, further mixed with organic surfactants, catalysts, reagents, expanding agents and / or pure vegetable latex and isocyanates, the final flexible product being polymerized solid. Description of the State of the Art

[0006] Global warming and climate change are currently a source of great concern and commitment for humanity to avoid a global climate catastrophe.

[0007] Not only public opinion, but also numerous scientific studies demonstrate that humanity's actions are increasingly interfering with the planet's ecosystems, and for this reason, the search for sustainable solutions is urgent.

[0008] One of the main production chains that harms nature is the oil industry, based on hydrocarbons, which are responsible for a large part of the gases that are harmful to the environment.

[0009] In this looming catastrophic scenario, it is necessary to immediately adopt new clean technologies capable of capturing carbon and replacing the use of oil by modern civilization.

[0010] Furthermore, it is important to highlight that petroleum serves as the basis for the production of polyurethane, or polyurethane foams, commonly referred to simply as PU, or fossil PU. One type of PU is Flexible polyurethane and due to its characteristics, its use is quite varied, being used in vehicle seats, mattresses, pillows, packaging, in the footwear industry, among others.

[0011] Flexible PU, or flexible polyurethane derived from petroleum, is non-biodegradable and therefore very harmful to the environment when discarded. However, given the significant use of this product and its increasing use, there is no viable and practical solution available in the state of the art for the safe and non-polluting disposal of this important industrial input.

[0012] In this report, the term "biodegradable product" should be understood as a product, part, article, accessory, utensil, device, packaging, artifact, among others, that has characteristics that allow it to degrade in nature in a reasonable time.

[0013] Fossil PU is non-biodegradable and difficult to collect, dispose of, and recycle. Typically, PU is recycled mechanically, with shredding and compaction, but even then, it doesn't return to its original properties, or it's disposed of by incineration, which is very harmful to the environment, or it's ultimately sent to landfills.

[0014] Furthermore, improperly disposed of PU ends up being found in large volumes in the world's oceans. Small, medium, or large-volume pieces of PU end up improperly in bodies of water or are carried into them by rain, where they are discharged into rivers and ultimately into the oceans.

[0015] These aquatic environments end up suffering from the constant reception of PU, and as they collide with each other and with other plastics floating in the oceans, the PU is fragmented into millions of pieces (microplastics), generating volumes astronomical over the years.

[0016] This microplastic generated by PU has the ability to absorb and concentrate toxic chemical compounds, such as pesticides, pesticides and heavy metals, such as mercury and lead, present mainly in rivers, lakes and oceans, becoming a potential contaminant especially if consumed by aquatic beings, which makes its presence in the marine environment dangerous, as fish, turtles, whales, dolphins and other marine animals mistake these microplastics for marine organisms and end up feeding on them, causing poisoning and putting the entire food chain at risk.

[0017] However, there are no known state-of-the-art solutions that could replace PU products in terms of commercial viability, application, practicality, or appropriate disposal. No products are known that can replace the physical characteristics of PU while also enabling environmentally sound disposal through natural biodegradation. Objectives of the Invention

[0018] In view of the problems described in the state of the art, the present invention aims to provide a biodegradable, non-toxic and recyclable product for the vehicle seat, mattress, pillow, packaging, footwear industry, among others, being a sustainable alternative to fossil flexible PU.

[0019] Another objective of the present invention is to provide a product with mechanical resistance characteristics similar to fossil flexible PU and also low density, being designed to fully replace fossil flexible PU in all its applications, including the application called integral skin.

[0020] In this regard, another objective of the present invention is to make use from clean and renewable sources as the basis for the composition of the Biodegradable Flexible Renewable Polymer, replacing petroleum as the base for PU (polyurethane).

[0021] Furthermore, another objective of the present invention is to enable the use of natural components, originating from renewable sources, which do not compete directly with the food chain, such as, for example, the so-called "frying oil", collected from restaurants, snack bars, condominiums, among others, resulting in the reuse of products that would otherwise be discarded and thus avoiding the contamination of water sources by discarded cooking oil.

[0022] Additionally, the product of the present invention aims to not cause harm to animals when ingested, differing completely from fossil PU, which when ingested does not decompose in the animal's digestive system, causing intoxication and death of the specimen.

[0023] Another objective of this invention is to reduce carbon emissions into the atmosphere, using components from renewable sources to replace products and their applications that use petroleum sources as a basis for their composition.

[0024] Another objective of this invention is to provide products in liquid or pasty state for the production of flexible biodegradable renewable polymer, in order to simplify and increase the efficiency of production chains. Brief Description of the Invention

[0025] The present invention relates to a liquid base product, which comprises a first base product component reacted with a second base product component, wherein: the first base product component is selected from at least one of: vegetable oil, modified vegetable oil or a combination of these components; and the second base product 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 of these components. The liquid base product comprises between 97% and 99.9% by weight of the first base product component and between 0.1% and 3% by weight of the second base product component, considering the total weight of the liquid base product. The hydroxyl number of the liquid base product is in the range between 45 and 180.

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

[0027] The present invention relates to a formulated liquid product comprising the base liquid product mixed with a blowing agent and at least one of organic surfactants, catalysts, and / or reagents. The blowing agent may be water. The organic surfactant may be selected from at least one of: silicone silosane and / or water-soluble silicone silosane. The catalyst may be selected from at least one of: tin octoate, dibutyltin dilaurate, cobalt octoate, bismuth octoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, or dimethylcyclohexylamine, wherein the catalyst is metallic or amine-based.The reagent may be selected from at least one of: nitrilotriethanol, preferably, 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 of these components.

[0028] The present invention relates to a final liquid product comprising the formulated liquid product reacted with an isocyanate. The isocyanate may be MDI, TDI, NDI, HDI, IPDI, HMDI, TPMTI, and / or PDI, or a blend of the aforementioned isocyanates, in which the isocyanate comprises an NCO, nitrogen-carbon-oxygen, ranging from 10% to 50%. The final liquid product may comprise between 31% and 93% formulated liquid product and between 7% and 69% isocyanate, considering the total weight of the final liquid product. The final liquid product may also comprise a physical blowing agent. The physical blowing agent may be selected from at least one of: hydrofluoroolefins, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, hydrogenated chlorofluorocarbon or a combination of these components.

[0029] The present invention relates to a renewable and biodegradable flexible polymer, which comprises the final liquid product polymerized in a solid state.

[0030] The present invention relates to a process for manufacturing a liquid base product, comprising the steps of: heating a first base product component to a temperature between 50°C and 70°C, wherein the first base product component is selected from at least one of: vegetable oil and / or modified vegetable oil; adding a second base product component, wherein the second base product component is selected from at least one of: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol, pentaerythritol, dimethylolpropane, sorbitol;heating the combination of the first base product component with the second base product component to a temperature between 90°C and 115°C if the melting point of the second base product component is below 115°C, or to a temperature above 115°C if the melting point of the second base product component is above 115°C; stirring the combination of the first base product component with the second base product component for a period between 20 and 40 minutes at the temperature of the previous step. The process of manufacturing a liquid base product may further comprise the steps of: cooling the product obtained after the step of stirring the combination to room temperature; adding a third base product component, wherein the third base product component is a polyether polyol; and stirring the combination comprising the third base product component; for a period of between 20 and 40 minutes at room temperature.

[0031] The present invention relates to a process for manufacturing a formulated liquid product, which comprises generating a base liquid product, stirring the base liquid product with at least one of: organic surfactants, catalysts and / or reagents, and gradually inserting a blowing agent throughout the period of stirring the base product with the organic surfactants, catalysts and / or reagents.

[0032] The present invention relates to a process for manufacturing a liquid end product, which comprises: generating the formulated liquid product; and stirring the formulated liquid product with an isocyanate until a reaction of the components occurs.

[0033] The present invention relates to a process for manufacturing a biodegradable flexible renewable polymer, which comprises: generating a final liquid product; and shaping the final liquid product through a polymerization reaction to obtain a biodegradable flexible renewable polymer. Detailed Description of the Invention

[0034] First, it should be noted that the term "preferred" used herein is intended to characterize a particularly effective embodiment of the invention among the many possible embodiments. Said term "preferred" should not be understood as limiting the possible embodiments of the present invention, that is, it should not be understood as "imperative" or "mandatory" for carrying out the present invention.

[0035] In the context of the process of the present invention, the term "phase" should be understood in a similar way to the term "step", being used in the context of the present invention as a step that may comprise one or more steps or substeps.

[0036] The term "generate" should be understood in the context of the present invention as conceiving, producing or obtaining something. It should therefore be understood broadly and not limited to a narrow understanding of its meaning.

[0037] The term "renewable product" should be understood as a product whose sources are natural sources that regenerate, that is, renewable sources, replacing the use of fossil fuels.

[0038] The term "room temperature" should be understood as normal temperature, that is, approximately 20°C.

[0039] The present invention relates to a liquid base product comprising a first base product component combined and / or reacted with a second and / or a third base product component.

[0040] In one embodiment of the present invention, the liquid base product comprises a first base product component reacted with a second base product component.

[0041] In another embodiment of the present invention, the liquid base product comprises a first base product component reacted with a second base product component and mixed with a third base product component.

[0042] The first base product component is selected from at least one of: vegetable oil, modified vegetable oil, or a combination of these components.

[0043] In one embodiment, the second base product component is selected from at least one of: nitrilotriethanol, preferably, 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 of these components.

[0044] In the present invention, substitutes or counterparts or alternative components of nitrilotriethanol are considered, such as monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylolpropane, pentaerythritol, or sorbitol. Therefore, although nitrilotriethanol is mentioned as the preferred component, nitrilotriethanol substitutes can also be used, individually or in combination, to achieve the desired base, formulated, liquid end, and flexible end products.

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

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

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

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

[0049] In other embodiments of the base liquid product of the present invention, the different sets of components cited above for the second base product component may be combined to form a new embodiment of the base liquid product.

[0050] The third base product component is selected from at least one of: polyether polyols of various hydroxyl numbers. That is, a polyether polyol that comprises a hydroxyl number appropriate to the desired application to produce a liquid product base with the desired hydroxyl number, as will be specified below.

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

[0052] In one embodiment, the hydroxyl number of the third base product component, the polyether polyols, is in a range between 10 and 80, or preferably between 25 and 56. Note that, optionally, it is possible to combine polyether polyols with different hydroxyl numbers to achieve the desired hydroxyl number for the third base product component.

[0053] In one embodiment, the amount of the first base product component, i.e., vegetable oil and / or modified vegetable oil, is 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% by weight, considering the total weight of the base liquid product, or any range between the indicated values. In a preferred embodiment, the amount of the first base product component is between 97% and 99.9% by weight, considering the total weight of the base liquid product.

[0054] In one embodiment, the amount of the second base product component, i.e., nitrilotriethanol and / or its substitutes, is preferably 0.1%, 1%, 2% or 3%, or any range between the indicated values, such as, for example, between 0.1% and 3% by weight, considering the total weight of the base liquid product.

[0055] In one embodiment, the amount of polyether polyol is preferably 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%, and 30% by weight, or any range between the indicated values, considering the total weight of the base liquid product, such as, for example, between 0% and 30%.

[0056] The present invention also relates to a formulated liquid product comprising the base liquid product mixed with a chemical blowing agent and at least one of: organic surfactants, catalysts, and / or reagents.

[0057] In one embodiment, the amount of base liquid product comprised in the formulated liquid product is preferably 41.78% to 99.80% by weight, considering the total weight of the formulated liquid product. In an embodiment that comprises the blowing agent, the amount of blowing agent is preferably 0.01% to 23.24% by weight, considering the total weight of the formulated liquid product, this weight being a possible sum of physical and chemical blowing agents. The amount of at least one of: organic surfactants, catalysts and / or reagents (considering the sum of these elements if present individually or in combination), is preferably 0.01% to 47.78% by weight, considering the total weight of the formulated liquid product.

[0058] The catalyst is selected from at least one of: tin octoate, dibutyl tin dilaurate, cobalt octoate, bismuth octoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, dimethylcyclohexylamine or other examples, both of metallic and amine nature.

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

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

[0061] The present invention also relates to a final liquid product comprising the formulated liquid product reacted with an isocyanate. The isocyanate may be MDI, wherein the MDI comprises an NCO, nitrogen-carbon-oxygen, ranging from 10% to 50%. The final liquid product may comprise between 31% and 93%, preferably between 59% and 89%, and more preferably between 60% and 85% of the total weight of the formulated liquid product. The amount of isocyanate, in turn, is comprised between 7% and 69%, preferably between 11% and 41%, and most preferably between 15% and 40% of the total weight of the formulated liquid product.

[0062] 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 the indicated values.

[0063] The present invention also relates to a process for manufacturing a biodegradable flexible renewable polymer comprising generating a base product, wherein generating the base product comprises stirring a first base product component with a second base product component until a reaction of the components occurs, wherein the first and second components react to generate the base product, and / or the result of the reaction of the first and second components second component is mixed with a third component, wherein the first base product component is selected from at least one of: vegetable oil and / or modified vegetable oil, the second base product component is selected from at least one of: 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, and the third base product component is selected from at least one of: polyether polyols of various hydroxyl indices.The manufacturing process for a flexible, biodegradable renewable polymer also involves generating a formulated product, wherein generating the formulated product involves: stirring the base product with organic surfactants, catalysts, and / or reagents, and gradually adding a chemical blowing agent while stirring the base product with the organic surfactants, catalysts, and / or reagents. The manufacturing process for a flexible, biodegradable renewable polymer also involves generating a final liquid product, wherein the step of generating the final liquid product involves stirring the formulated liquid product with one or more different types of isocyanate.

[0064] The process of generating the base product comprises the preliminary steps of dosing and introducing the first base product component, i.e., the vegetable oils and / or modified vegetable oil, into a reactor and / or mixer. In one embodiment, the reactor may be a heater reactor.

[0065] The process of generating the base product comprises a step of heating the first base product component, wherein the first base product component may be heated to a stirring temperature of between 50°C and 70°C before being stirred with the second base product component.

[0066] In an example embodiment, if, for example, nitrilotriethanol is chosen to balance the hydroxyl index of the product, a heating reactor can be used, where the heater is activated and heats the components present inside the reactor until they reach an agitation temperature, with the agitation temperature in the present example being a temperature between 50°C and 70°C.

[0067] The process of generating the base product further comprises a step of stirring the first base product component with the second base product component, in which the stirring preferably occurs at a stirring temperature between 90°C and 115°C, for a stirring time between 20 minutes and 40 minutes.

[0068] A stirring temperature between 90°C and 115°C is particularly relevant for some possible second base product components, such as nitrilotriethanol. However, as described, an alternative component may be used to replace nitrilotriethanol. If the alternative component or substitute for nitrilotriethanol is pentaritritol, the stirring temperature should be between 250°C and 300°C.

[0069] In one embodiment, if the chosen alternative component has a melting point above the flash point of the oil, a step must be taken to inject an antioxidant component, such as nitrogen, into the reaction.

[0070] In one embodiment, after the product resulting from the stirring / reaction of the first base product component with the second base product component has cooled to room temperature, the third base product component can be introduced at room temperature.

[0071] If polyether polyol is added to the base liquid product to balance the stoichiometry and obtain the desired hydroxyl index, stirring can be carried out only in a mixer, at room temperature, with a stirring and mixing time between 20 and 40 minutes, or preferably, between 25 and 35 minutes.

[0072] At the end of the steps of introducing, dosing and heating the vegetable oils and / or modified vegetable oil, introducing and dosing the nitrilotriethanol or its possible alternative components already listed, heating, stirring and cooling the base product in the reactor, after optionally introducing and dosing the polyether polyol, and stirring the base product components inside the reactor or mixer at room temperature, the base liquid product is obtained.

[0073] Alternatively, a possible step to generate the base product consists of heating the first component and recirculating it over a column containing molecular sieve granules with porosities ranging from 3 to 13 angstroms. The heating temperature should be maintained between 100 and 140°C, and the first component should only be brought into contact with the molecular sieve after 30 minutes, once the temperature has stabilized at the desired value. Recirculation of the first component through the column containing the molecular sieve should be sufficient to achieve the desired hydroxyl number value.

[0074] The process of generating the formulated liquid product involves stirring the base liquid product with organic surfactants, catalysts, and / or reagents, and gradually adding a chemical blowing agent while stirring the base product with the organic surfactants, catalysts, and / or reagents. The stirring time for generating the formulated liquid product ranges from 2 minutes to 120 minutes.

[0075] In a preferred embodiment, the catalyst is selected from at least one of: tin octoate, dibutyl tin dilaurate, cobalt octoate, bismuth octoate, bismuth trineodecanoate, diazabicyclooctane, triethylenediamine, dimethylcyclohexylamine or other examples, both of metallic and amine nature; the organic surfactant is selected from at least one of: silicone silosane and / or water-soluble silicone silosane; the reagent is selected from at least one of: nitrilotriethanol, preferably, and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol and / or nitrilomonoethanol, dimethylolpropane, pentaerythritol or sorbitol.

[0076] The organic reagents and surfactants used in the process of generating the formulated liquid product are essentially responsible for facilitating and improving the efficiency of the reaction between the base product and the components of the formulated product. Catalysts accelerate the reaction and help achieve the desired characteristics of the final product. Organic reagents and surfactants are the components of the formulated product that will react massively, increasing the volume and resilience of the final solid product when reacted with isocyanate. Silicone is responsible for cross-linking the cell opening.

[0077] In a preferred embodiment, the chemical blowing agent is water. The water component is a chemical blowing agent and must be gradually added to the formulated product during agitation. Gradually adding water during the agitation of the base product with organic surfactants, catalysts, and / or reagents means introducing multiple doses or percentages of this component, continuously or not, into the mixture throughout the agitation period. In a embodiment of the present invention that comprises water as a blowing agent, the amount of water is between 0.01% and 2.35% by weight, considering the total weight of the formulated liquid product.

[0078] In alternative embodiments, blowing agents other than the preferred chemical blowing agent, such as physical blowing agents, may be used in liquid or gaseous form. Non-exhaustive examples of physical blowing agents include hydrofluoroolefins, methylal, n-pentane, methylene chloride, isopentane, cyclopentane, and / or hydrogenated chlorofluorocarbons.

[0079] The components mentioned above for the preferred embodiment of the processes of the present invention are the main possible components for the formulation of the base product and the formulated product. However, it should be noted that in alternative embodiments, other alternative components may perform the same chemical function as the components already mentioned in the present invention.

[0080] The process of producing the formulated liquid product optionally includes a step of adding a colorant that adds color to the formulated product and, consequently, to the final product. Preferably, the colorants used in the present invention are vegetable dyes or water-based dyes.

[0081] The process of generating the formulated liquid product optionally comprises a step of adding a flame retardant and / or smoke suppressant.

[0082] The process of generating a final liquid product involves stirring the liquid product formulated with an isocyanate or different types of isocyanates. In one embodiment, the process of generating the final liquid product may include a step of introducing a physical blowing agent, wherein the physical blowing agent is selected from at least one of: hydrofluorolefins, methylal, n-pentane, methylene chloride, isopentane, cyclopentane and / or hydrogenated chlorofluorocarbon.

[0083] In a preferred embodiment, the isocyanate is an MDI. MDI is an organic methylene diphenyl diisocyanate, comprising a nitrogen-carbon-oxygen NCO ranging from 10% to 33.56%. The effect of MDI on the product is a reagent effect. MDI is a reagent that, when combined with the formulated liquid product, produces an exothermic reaction, massively increasing the volume of the final mixture. In this case, the final liquid product can fill a mold and polymerize to form a flexible solid foam, which is the final flexible solid product.

[0084] Although MDI is mentioned, other isocyanates may be used in alternative embodiments of the present invention. Alternatively to using MDI as a reagent, and provided that it does not alter the characteristic properties of the final product such as toxicity and biodegradability, other types of isocyanates may be used as reagents, such as: 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, it is possible to use as a reagent in a similar manner to those already listed a mixture of different isocyanates and variations with structural modifications of the molecules mentioned.

[0085] In one embodiment of the process of generating a final liquid product, application equipment may be used. In one embodiment, the application equipment comprises two working tanks, with at least one inlet and one outlet. The application equipment is essentially a container configured to promote the The reaction of isocyanate with the formulated liquid product at a given temperature. The reaction is temperature-independent, but temperature can influence the final characteristics of the solid product. Furthermore, the reaction time can vary considerably, as it depends on numerous factors, such as mold size, application type, desired final characteristics, and others.

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

[0087] In this sense, the application equipment is also the equipment of the present invention responsible for applying the formulated liquid product and the isocyanate to the mold or desired application site. Examples of application equipment used in the present embodiment include carousel-type application equipment and low- and high-pressure injection molding machines.

[0088] When the objective is to manufacture vehicle seats, the application equipment could be, for example, an injection molding machine that heats, massively mixes, and injects the final liquid product into molds with specific shapes, where polymerization will occur. The application equipment could be, for example, large molds without specific shapes, for the final solid product to be cut into application-specific parts. This step can also be understood as a step in generating the final product in a flexible solid state by shaping the final combination through a polymerization reaction.

[0089] The quantity of formulated liquid product introduced into one of the working tanks is between 31% and 93%, preferably between 59% and 89%, and most preferably between 60% and 85% by weight, considering the total weight of the final liquid product in liquid state. The quantity of isocyanate introduced into the other working tank is between 7% and 69%, preferably between 11% and 41% and, more preferably, between 15% and 40% by weight, considering the total weight of the final liquid product in liquid state.

[0090] During the application phase, depending on the application type, an optional step is performed, which involves waiting for a solidification period after applying the final liquid product. The solidification period ranges from 1 minute to 10 minutes. Solidification, which is the polymerization from a liquid to a solid state, must respect this handling time variation, depending on the complexity of the part to be produced. After the solidification period, the final product will be polymerized, having passed from a liquid to a solid state. When necessary, the final product must undergo a calendering process (roller or press) to expel internal gases by rupturing the material's cells.

[0091] In one embodiment, the process for manufacturing the biodegradable flexible renewable polymer of the present invention comprises forming the liquid end product through a polymerization reaction to obtain a solid end product. In one embodiment, the step of generating the end product comprises dosing the liquid product formulated with an isocyanate or its possible substitutes into the injection molding machine, reacting the formulated liquid product and the isocyanate, and injecting or applying the combination of the formulated liquid product and isocyanate to perform a step of generating a solid end product, which is a biodegradable flexible renewable polymer.

[0092] The combined and reacted components in the liquid state of the final product are applied and shaped to generate the final product in the solid state. In other words, the final product, which is the biodegradable flexible renewable polymer of the present invention, comprises a solid state that is obtained from the liquid final product, which comprises the components described above.

[0093] In general, the manufacturing process of the flexible biodegradable renewable polymer is divided into three phases: first phase, where a stage is carried out to generate the base product; second phase, where a stage is carried out to generate the formulated product; and third phase, where a stage is carried out to generate the final product.More specifically, the main steps or phases of the process for obtaining the biodegradable flexible renewable polymer of the present invention comprise: generating a base product, in which generating the base product comprises combining / reacting at least one vegetable oil and / or vegetable oil modified with nitrilotriethanol or its possible substitutes, and / or polyether polyol; generating a formulated product, in which generating the formulated product comprises stirring / mixing the base product with organic surfactants, with catalysts, with reagents and / or chemical blowing agent; generating a liquid final product, in which generating the liquid final product comprises stirring / mixing the formulated product with isocyanate and / or with some physical blowing agent; and generating a final product in the solid state by means of dosing, heating of the massive mixture and injection, obtaining the conformation of the final mixture by the polymerization process.

[0094] The base product or base liquid product can be understood as a product resulting from the first phase of the process of the present invention. The base product can be used and / or marketed individually to subsequently generate the formulated product or for other purposes not previously identified in this document.

[0095] The formulated product or formulated liquid product can be understood as a product resulting from the second phase of the process of the present invention. The formulated product can be used and / or marketed individually to subsequently generate the product final, liquid or flexible, or other specific purposes not previously identified in this document.

[0096] The final product or final liquid product can be understood as a product resulting from the third phase.

[0097] The term "solid end product" will also be used as the biodegradable flexible renewable polymer.

[0098] The base product is a liquid product resulting from a reaction comprising at least two products used to produce the liquid base. This base product is formed by the reaction of vegetable oil and / or modified vegetable oil, and / or with nitrilotriethanol and / or with the polyether polyol. Alternatively 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, listed by way of example and not exhaustive.

[0099] To form the base product that may compose the flexible biodegradable renewable polymer described in this invention, it is necessary to achieve a hydroxyl index between 45 and 180. In a preferred embodiment, the hydroxyl index 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 the indicated values.

[0100] The hydroxyl number, mentioned in the paragraph above, is a determining factor in obtaining the characteristics of the final biodegradable flexible renewable polymer. All vegetable oils have different hydroxyl numbers, ranging from approximately 1.2 to 165. Regardless of the hydroxyl number of the vegetable oil and / or modified vegetable oil, nitrilotriethanol and / or polyether polyol, or their substitutes, must be added until the combination reaches a hydroxyl number within the parameters already mentioned, that is, more preferably between 45 and 180.

[0101] Both the polyether polyol and nitrilotriethanol balance and increase or decrease the hydroxyl index. Thus, nitrilotriethanol increases the hydroxyl index of the base component, while the polyether polyol decreases it. Specifically, treatment with nitrilotriethanol favors the biodegradability of the flexible, solid, biodegradable renewable polymer material / product subject to the present invention.

[0102] The formulated product is a liquid product resulting from the liquid consubstance of the base liquid product described above with the components: chemical expanding agent, organic surfactants, catalysts and reagents for the formation of the formulated liquid product, which, subsequently reacted with an isocyanate catalyst, will form the flexible biodegradable renewable polymer.

[0103] In one embodiment, the biodegradable flexible renewable 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 flexible renewable 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 values indicated.

[0106] From a reaction of the mixture of liquids, a final liquid product polymerizes through an exothermic reaction, forming a solid in the form of flexible foam for use, for example, in mattresses and pillows. The product degrades within 6 months, and its density is between 15 kg / m 3 and 200 kg / m 3 .

[0107] In one embodiment, the amount of formulated liquid product comprised 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%, 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%, such as between 31% and 93% by weight, or any other range between the values ​​indicated.

[0108] The ratio of isocyanate to polyol in the final product may vary depending on the index of interest. In short, the greater the amount of isocyanate in the final product, the greater the rigidity of the flexible biodegradable renewable polymer. Therefore, for a less rigid solid flexible biodegradable renewable polymer, the lower the proportion of isocyanate in the final product should be.

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

[0110] Any of the oils mentioned above, in reaction with nitrilotriethanol or one of the substitutes described and / or the polyether polyol, to form the base product, must reach the hydroxyl levels previously mentioned as necessary for the present invention.

[0111] Among the base product components, in addition to vegetable oil and / or modified vegetable oil, one component includes a polyether polyol. In the formulation, the polyether polyol is responsible for maintaining the molecular chain of the low-hydroxyl compound, resulting in a flexible and resilient final product.

[0112] Similarly, another component that may be included in the base product is nitrilotriethanol, an organic chemical compound in a viscous liquid state, soluble in water and miscible with most oxygenated organic solvents. It is used to react with vegetable oil to adjust the hydroxyl index to achieve the desired parameter.

[0113] The industrial process for producing the products or mixtures that form the biodegradable flexible renewable polymer of the present invention presents similarities with the process described in document No. BR102023000639-6, and such document can be used to clarify any doubts and to better understand the details of the process of the present invention. However, there are important differences between the processes, which correspond to different compositions, stage executions and stage parameters (such as temperatures and times), since the process described in document No. BR102023000639-6 is aimed at obtaining a rigid product and the process of the present invention is aimed at obtaining a flexible product.

[0114] The final biodegradable product obtained, in its solid state, has its physical-chemical composition determined by a reaction exothermic, consequence of the final product that corresponds to the chosen proportion of the formulated product, depending on the desired characteristic, and isocyanate and consequent polymerization.

[0115] The flexible solid end product comprises a density between 15 kg / m 3 and 200 kg / m 3 , making it possible to obtain the final product in different density and formulation ranges.

[0116] To understand the elastomeric characteristics of the final product, the liquid final product can generate a solid final product with a density between 300 kg / m 3 and 800 kg / m 3 .

[0117] The biodegradable end product of the present invention has the characteristic of physically decomposing in certain situations. This is because it is not desirable for the product to decompose during use. For example, it is not desirable for the end product applied to a mattress or pillow to decompose. Therefore, the biodegradable product of the present invention decomposes only when in a state of decomposition. The state of decomposition occurs when the biodegradable product is exposed to microorganisms and fat-degrading biological agents found in soil, landfills, or anaerobic reactors.

[0118] Consequently, the biodegradable product of the present invention offers a significant advantage over other prior art products, as it decomposes rapidly when disposed of in the environment, where it will be in a state of decomposition. In a preferred embodiment, in a state of decomposition, the biodegradable product of the present invention begins to decompose within 15 days.

[0119] The flexible biodegradable product was subjected to degradation tests in anaerobic and aerobic environments, as well as toxicity tests on fish and microalgae. In the anaerobic digestion test, The flexible biodegradable product was placed in a reactor, along with nutrients and inoculum (bacterial colony), and the biogas release was continuously monitored. The result was an increasing curve of biogas release (mainly methane and CO2), indicating the foam's non-toxicity in this environment. After 60 days of experimentation, the flexible foam degradation reached 44.21%.

[0120] To assess aerobic degradation and toxicity, microalgae of the genus Chlorella sp. were used in a controlled environment, chosen because they are a biological indicator susceptible to toxic agents. The result was positive for non-toxicity; the algae exposed to the environment with the flexible biodegradable product had the same life cycle as the control samples.

[0121] To complement the study, the flexible biodegradable product was used as a fish feed supplement for 54 days. The non-toxicity of the flexible biodegradable product was once again observed, as no fish deaths occurred and no pathology was detected during the inspection of the test group.

[0122] Regarding the results of the degradation study, a superior degradation of the flexible biodegradable product was observed in an aerobic environment, in which after 37 days it was 31.93% degraded.

[0123] Therefore, the biodegradable product of the present invention presents excellent biodegradability when compared to flexible foams originating from non-renewable fossil sources.

[0124] Additionally, it should be noted that for all values ​​and all ranges of values ​​of any characteristic defined above, there may be a variation of up to plus or minus 5%. This means that any of the values ​​or ranges may vary within any interval up to 5%, for example, 1%, 2%, 3%, 4%, 5% or any decimal value included above or below the values ​​or ranges. of defined values. In a situation of variation, there will naturally be compensation of the formulations so that the total value obtained is maintained.

[0125] Having described examples of embodiment, it should be understood that the scope of the present invention encompasses other possible variations, being limited solely by the content of the claims alone, including possible equivalents.

Claims

DEPCT6930 / 10 / 25681. A liquid base product, characterized by its composition of a primary base product component which is reacted with a second primary base product component, where: the primary base product component is selected from at least one of: vegetable oil, modified vegetable oil or a mixture of these components; and the second primary base product component is selected from at least one of: nitrilotriethanol, monoethylene glycol, diethylene glycol, triethylene glycol. 1,4-Butanediol, tetraethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-butanediol, nitrilodiethanol, nitrilomonoethanol, dimethylpropane, pentaerythritol, sorbitol, or a combination of these components, in which the liquid base product comprises between 97% and 99.9% by weight of the first base product component and between 0.1% and 3% by weight of the second base product component, relative to the total weight of the liquid base product.

1. The hydroxyl index of the liquid base product is in the range of 45 to 180.

2. The liquid base product under Reputation 1, characterized by the inclusion of a third base product component, where the third base product component is a polyether polyol, where the amount of polyether polyol is determined by the hydroxyl index required for the liquid base product.

3. The liquid base product under Reputation 2, characterized by the hydroxyl index of the third base product component being in the range of 10 to 80.

4. Any one of the liquid base products under Reputations 1 to 3, characterized by the hydroxyl index of the primary base product component being in the range of 1.2 to 180.

5. Any one of the liquid base products under Reputations 1 to 4,Characterized by the quantity of the second primary base product component and the third primary base product component relative to the total weight of the liquid primary base product, determined by the required hydroxyl index of the liquid primary base product based on the hydroxyl index of the first primary base product component.

6. Liquid primary base product under one of the claims 1 to 5, characterized by the second primary base product component being selected from at least one of the following: nitrilotriethanol, nitrilodiethanol, nitrilomonoethanol.

7. A liquid primary product under one of the claims 1–5, characterized by the selection of at least one secondary primary product component from: monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, or a combination of these components.

8. A liquid primary product under one of the claims 1–5, characterized by the selection of at least one secondary primary product component from: propylene glycol, dipropylene glycol,9. A liquid base product as defined in any of the claims 1–5, characterized by the selection of at least one secondary base product component from: dimethylpropane, pentaerythritol, sorbitol, or a combination of these components.

10. A product formulated as a liquid, characterized by the inclusion of a liquid base product, as defined in any of the claims 1–9, mixed with a leavening agent and at least one reducing agent.

11. A product formulated as a liquid under patent 10, characterized by the leavening agent being water.

12. A product formulated as a liquid under patent 10 or 11, characterized by the organic surfactant being selected from at least one of: silosan, silicone and / or water-soluble silosan.

13. A product formulated as a liquid under any of patents 10 through 12, characterized by the catalyst being selected from at least one of: tin octoate, dibutyl tin dilorate,Cobalt octoate, bismuth octoate, bismuth trineodecanoate, diaza bicyclooctane, triethylenediamine, dimethylcyclohexylamine, where the catalyst is either metallic or amine-based.

14. The product, formulated as a liquid under one of the claims 10 to 13, is characterized by the selection of at least one of the following reagents: preferred to be nitrilotriethanol, and / or monoethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol, or tripropylene glycol.

15. A liquid final product, characterized as a product composed of a liquid formulation of a product as defined in any of Reputations 6 through 10, which is reacted with isocyanates.

16. A liquid final product, according to Reputation 15, characterized as isocyanates MDI, TDI, NDI, HDI, IPDI, HMDI, TPMTI and / or PDI, or even a mixture of the isocyanates mentioned.Where isocyanates are incorporated as NCO, nitrogen-carbon-oxygen, in the range of 10% to 50%17. The final liquid product, according to claim 15 or 16, is characterized as containing between 31% and 93% of the product formulated as liquid and between 7% and 69% isocyanates by weight of the total weight of the final liquid product18. The final liquid product, according to one of claims 15 through 17, is characterized as containing an additional physical leavening agent1.

9. A liquid final product as defined in any of the claims 15 to 18, characterized by the physical leavening agent being selected from at least one of: hydrofluorolefins, methyl, n-pentane, methylene chloride, isopentane, cyclopentane, hydrogenated chlorofluorocarbons or a combination of these components.

20. A recyclable and biodegradable elastic polymer, characterized by the polymer being composed of a liquid final product as defined in any of the claims 15 to 19.

21. The process for producing liquid base products, characterized by the following components: heating the first base product component to a temperature between 50°C and 70°C, where at least one of the following components is selected: vegetable oil and / or modified vegetable oil; adding the second base product component, where at least one of the following components is selected: nitrilotriethane. 1,4-Butanediol, Monoethylene Glycol, Diethylene Glycol, Triethylene Glycol, Tetraethylene Glycol, Propylene Glycol, Dipropylene Glycol, Tripropylene Glycol, 1,4-Butanediol, Nitrilodiethanol, Nitrilomonoethanol, Dimethylpropane, Pentaerythritol, Sorbitol, or a mixture of these components; heating the mixture of the first and second primary product components to a temperature between 90°C and 115°C if the melting point of the second primary product component is lower than 115°C;or until the combined temperature is between 250°C and 300°C if the second base product component is pentaerythritol; stirring of the combined mixture of the first base product component with the second base product component for a period of 20 to 40 minutes at the temperature of the preceding step.

22. The process for the production of a liquid base product, according to claim 21, is characterized by the inclusion of the following steps: cooling of the resulting product after stirring the combined mixture to room temperature; addition of a third base product component, where the third base product component is polyether polyol; and stirring of the combined mixture with the third base product component for a period of 20 to 40 minutes at room temperature.

23. The process for the production of a product formulated as a liquid, is characterized by the inclusion of the creation of a liquid base product as defined in claim 18 or 19,24. The process for the production of a final liquid product is characterized by the inclusion of: the creation of a liquid product as defined in claim 20; and the stirring of the liquid product with at least one of the following components: organic surfactants, catalysts and / or reagents; and the gradual addition of leavening agents throughout the stirring of the liquid product with the organic surfactants, catalysts and / or reagents.

25. The process for the production of a biodegradable, renewable, flexible polymer is characterized by the inclusion of: the creation of a liquid product as defined in claim 21; and the shaping of the liquid product by polymerization reaction to obtain a biodegradable, renewable, flexible polymer;