Tannin-based environmentally friendly rigid foam composition and foam production method

Abstract

The invention relates to the development and production method of tannin-based rigid foams produced from environmentally friendly, biorenewable raw materials. The invention particularly encompasses tannin-based composite systems formulated to provide an alternative to polyurethane rigid foams.

Description

[0001] TANNIN-BASED ENVIRONMENTALLY FRIENDLY RIGID FOAM COMPOSITION AND FOAM PRODUCTION METHOD

[0002] Technical Field

[0003] The invention relates to the development and production method of tannin-based rigid foams produced from environmentally friendly, biorenewable raw materials. The invention particularly encompasses tannin-based composite systems formulated to provide an alternative to polyurethane rigid foams.

[0004] State of Art

[0005] Polyurethane foams are often produced using petrochemically derived polyols and isocyanates. This increases the reliance on non-renewable resources and enlarges the carbon footprint. Isocyanates are harmful to human health. They can cause skin irritation, respiratory diseases and allergic reactions, especially in workers during production. Polyurethane foams can undergo thermal degradation at high temperatures. This poses a fire safety risk.

[0006] In the patent application numbered TR2019 / 14209, the production method of viscoelastic polyurethane sponge produced using materials suitable for human and environmental conditions is described. However, although biopolyol is used in the foam composition, isocyanate is used.

[0007] In the patent application numbered TR2018 / 11705, polyurethane foam reinforced with recycled powder from sawdust form is described. However, even if natural content is used as reinforcement, the foam is obtained from polyols and isocyanates.

[0008] As a result, due to the above-mentioned disadvantages and the inadequacy of the existing solutions, it has become necessary to make a development in the relevant technical field.

[0009] Purpose of the Invention

[0010] The invention is inspired by the current situation and aims to solve the above-mentioned negativities.The main purpose of this invention is to eliminate the environmental and health problems caused by polyurethane rigid foams by providing an environmentally friendly, biorenewable and non-toxic alternative. The tannin-based rigid foam formulation aims to offer low carbon footprint and high performance properties by using sustainable raw materials.

[0011] The invention provide a tannin-based rigid foam formulation to eliminate the environmental and toxic effects seen in polyurethane rigid foams. Since tannins are a naturally renewable and biodegradable raw material, they constitute an environmentally friendly alternative to polyurethane systems. While polyurethane rigid foams require extra additives for fire retardancy, tannin-based foams are inherently fire retardant.

[0012] In order to achieve the purposes described above, the invention is an environmentally friendly rigid foam composition comprising; Comonomer, Catalyst, Crosslinker, Blowing agent; and Tannin as resin.

[0013] An embodiment of the invention comprise 45-60% Tannin, 10-15% Comonomer, 10-20% Catalyst, 10-20% Crosslinker, 5-15% Blowing agent by weight.

[0014] An embodiment of the invention further comprises a Dispersion aid.

[0015] An embodiment of the invention comprises up to 0.1-20% Dispersion aid by weight.

[0016] In an embodiment of the invention, the Comonomer is Furfuryl Alcohol.

[0017] In an embodiment of the invention; the Catalyst is 65% p-Toluenesulfonic acid.

[0018] In an embodiment of the invention, the binder is 37%Formaldehyde.

[0019] In an embodiment of the invention, the Blowing agent is Diethyl ether.

[0020] In an embodiment of the invention, the dispersion aid is %50 Benzalkonium chloride and / or Polysorbat 80.

[0021] The invention is a method of producing environmentally friendly rigid foam from the above-mentioned composition and comprises the following process steps:i. Combining tannin, Comonomer, Crosslinker, Dispersion aid to obtain a homogeneous mixture and cooling the mixture,

[0022] ii. blowing agent is cooled and then added to the mixture followed by thorough mixing,

[0023] iii. catalyst is added, and the foam reaction is carried out.

[0024] Here, the mixing parameters in step (i) are 2 min, 600 rpm, room temperature; in step (ii), 20 s, 500 rpm, room temperature; in step (iii), 1.5 min, 1000 rpm, room temperature.

[0025] The structural and characteristic features of the invention and all its advantages will be understood more clearly by means of the detailed description given below, and therefore the evaluation needs to be made by taking this detailed description into consideration.

[0026] Detailed Description of the Invention

[0027] In this detailed description, the foam composition and preferred embodiments which are the subject of the invention are described only for the purpose of better understanding the subject.

[0028] The invention relates to a tannin-based rigid foam composition produced from environmentally friendly, biorenewable raw materials and a method for producing rigid foam from this composition. In particular, the invention relates to tannin-based composite systems formulated to provide an alternative to polyurethane rigid foams. Table 1 shows the components by weight of the foam compositions within the scope of the invention.

[0029] Table 1. Foam composition of the invention

[0030] Preferred amount Usable amount Content

[0031] by weight (%) by weight (%) Resin

[0032] Tannin 50 45-60

[0033] Comonomer

[0034] 11 10-15

[0035] Furfuryl Alcohol

[0036]

[0037] Catalyst

[0038] 16 10-20

[0039] p-Toluenesulfonic acid, 65%

[0040] Crosslinker

[0041] 12 10-20 Formaldehyde, 37%

[0042] Blowing agent

[0043] 7 5-15

[0044] Diethyl ether

[0045] Dispersion aid

[0046] 1 0,1-10 Benzalkonium chloride 50%

[0047] Dispersion aid

[0048] 3 0,1-10 Polysorbate 80

[0049]

[0050] Tanin, Tannin or Tanen is the general name of organic compounds with a phenolic structure that occur naturally in plants. It is found mainly in plant barks, leaves, fruits and seeds. Tannins are known for their astringent taste and exhibit antimicrobial, antioxidant and preservative properties by binding with proteins. It is also used in leather tanning, wine production and pharmaceutical applications. The invention is used as a resin in the foam composition.

[0051] Furfuryl alcohol is an organic compound obtained by hydrogenating furfural. It has a furan ring and a methanol group (C4H3OCH2OH). It is generally used as a reactive monomer or comonomer and is especially preferred in resin production, foundry sand binders, polymer composites and materials resistant to corrosive environments. It is important in sustainable chemistry applications due to its ability to be obtained from renewable resources. Furfuryl alcohol was preferred as a comonomer in the foam composition of the invention.

[0052] p-Toluenesulfonic acid (65%) is an acid catalyst widely used in polyurethane and phenolic foam formulations. Being a strong protonic acid, this compound accelerates polymerization or cross-linking reactions. It is commercially available in 65% form in aqueous solution and is particularly preferred for providing fast reaction time, controlled foam formation and good mechanical properties.

[0053] Formaldehyde (37%) is an aldehyde compound (CH2O) in aqueous form. It is used as a crosslinker in foam formulations and polymer production. Since it is a reactive molecule, it provides hardness, heat resistance and mechanical stability by forming chemical bonds between polymer chains in phenolic, urea-formaldehyde andmelamine-formaldehyde resins. Formaldehyde solution usually contains 37% stabilizer (e.g. methanol) and is preferred for controlled reactions.

[0054] Diethyl ether is a blowing agent used in the production of polyurethane and phenolic foam. Thanks to its low boiling point (34.60), it evaporates during the reaction and provides cell formation and forms the structure of the foam. It provides rapid foaming due to its volatility, but requires careful use as it is flammable.

[0055] Benzalkonium chloride (50%) is a dispersion aid and surfactant used in the production of polyurethane foam. Thanks to its cationic structure, it ensures homogeneous distribution of mixture components, increases reaction efficiency and improves foam quality. It is also known for its antimicrobial properties.

[0056] Polysorbat 80 (Tween 80) is a dispersion aid and nonionic surfactant used in the production of polyurethane foam. Thanks to its hydrophilic and lipophilic structure, it ensures homogeneous distribution of the mixture components, increases stability and improves the foam structure. It is also biocompatible and environmentally friendly.

[0057] The tannin-based environmentally friendly rigid foam production method, which is the subject of the invention, comprises the following process steps in its most basic form within the recipes given in Table 1 :

[0058] i. Tannin, Comonomer, Crosslinker, Dispersion aid are combined to obtain a homogeneous mixture and the mixture is cooled,

[0059] ii. blowing agent is cooled then added and mixed,

[0060] iii. Foam reaction is carried out by adding catalyst.

[0061] Within the scope of the invention, the production of environmentally friendly rigid foams is achieved through the synergistic effect that occurs as a result of carrying out the specific recipes given in Table 1 in the order of the above-mentioned process steps.

[0062] In a preferred embodiment of the invention, 50% Tannin, 11% Furfuryl Alcohol, 12% Formaldehyde, 1% Benzalkonium chloride, 3% Polysorbate 80 are combined at room temperature to obtain a homogeneous mixture at 600 rpm. The mixture is kept in the cold. 7% Diethyl ether is added to the mixture kept in the cold and mixed for 20seconds at 500 rpm. 16% p-Toluenesulfonic acid is added to the mixture and the reaction is carried out by mixing for 1.5 minutes at 1000 rpm. In order for the reaction to occur at a controllable rate, the ingredients must be added precisely in the specified proportions and cooled. Special care should be taken not to evaporate the diethyl ether while mixing. The reaction starts after adding p-Toluenesulfonic acid, and should be mixed without waiting.

Claims

CLAIMS1. An environmentally friendly rigid foam composition comprising a Comonomer, a Catalyst, a Crosslinker, a Blowing agent, characterized by comprising; Tannin as resin.

2. The foam composition according to claim 1 , characterized by comprising; 45- 60% Tannin, 10-15% Comonomer, 10-20% Catalyst, 10-20% Crosslinker, 5- 15% Blowing agent by weight.

3. The foam composition according to claim 1, characterized by comprising a dispersion aid.

4. The foam composition according to claim 1, characterized by comprising maximum 0.1-20% dispersion aid by weight.

5. The foam composition according to claim 1, characterized in that; the comonomer is Furfuryl Alcohol.

6. The foam composition according to claim 1 , characterized in that; the catalyst is p-Toluenesulfonic acid 65%.

7. The foam composition according to claim 1 , characterized in that; the crosslinker is Formaldehyde 37%.

8. The foam composition according to claim 1 , characterized in that; the Blowing agent is Diethyl ether.

9. The foam composition according to claim 1 , characterized in that; the Dispersion aid is Benzalkonium chloride 50% and / or Polysorbat 80.

10. A method of producing environmentally friendly rigid foam from the composition mentioned in any of the above claims, characterized by comprising the following process steps:i. Combining tannin, Comonomer, Crosslinker, Dispersion aid to obtain a homogeneous mixture and cooling the mixture,ii. blowing agent is cooled then added and mixing,iii. Foaming reaction is carried out by adding catalyst.

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