Binary Polyol Mixture for Flame-Retardant Polyurethane

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Solution Overview

Problem

The production of polyurethanes and polyisocyanurates faces challenges with aromatic dial-type polyols, such as bisphenol A, which are solid and have poor heat resistance, and ethoxylated or propoxylated bisphenol F, which are pasty and not pumpable, leading to processability issues and increased flammability due to internal scorching and the need for halogenated flame retardants.

Innovation Solution

A binary mixture of ethoxylated bisphenol F and propoxylated bisphenol F in a weight ratio of 20:80 to 80:20 is used, which is soluble in various solvents and miscible with isocyanates, enhancing processability and flame retardancy, thus reducing the need for halogenated compounds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ethoxylated or propoxylated bisphenol F is used as aromatic diol, then flame retardancy is improved, but processability deteriorates due to pasty consistency and poor pumpability

Engineering Contradiction:

Improveflame retardancyVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent combines ethoxylated bisphenol F and propoxylated bisphenol F in a binary mixture to achieve both flame retardancy and improved processability. The mixture ratio is controlled to balance the pasty consistency issue while maintaining the flame-resistant properties of both components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the compositional parameters by creating a binary mixture with specific weight ratios (20:80 to 80:20) of ethoxylated and propoxylated bisphenol F. This parameter adjustment transforms the material from pasty and pumpable to having optimal flow properties for polyurethane production.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If aromatic dial-type polyols such as bisphenol A are used, then polyurethane production is enabled, but heat resistance deteriorates and internal scorching occurs

Engineering Contradiction:

Improvepolyurethane productionVSAvoidheat resistance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent extracts the problematic aromatic structure from bisphenol A and replaces it with modified bisphenol F derivatives. This removal of the specific aromatic core structure eliminates the internal scorching issue while maintaining the polyurethane production capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a composite approach by combining ethoxylated and propoxylated bisphenol F in a binary mixture, creating a material that exhibits both good processability and improved thermal stability compared to conventional aromatic polyols.

Inventive Principle:

Principle #40Composite materials

3Reliability

If halogenated flame retardant additives are added to reduce flammability, then fire performance is improved, but environmental harm increases

Engineering Contradiction:

Improvefire performanceVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the inherent flame-resistant properties of bisphenol F derivatives into a beneficial feature, eliminating the need for harmful halogenated flame retardants. The molecular structure itself provides fire resistance without environmental contamination.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The polyol component itself provides flame retardancy through its chemical structure (ethylated and propoxylated bisphenol F), making the system self-protecting against fire without requiring additional harmful additives. The material serves its own flame protection function.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The binary mixture improves the solubility and miscibility of polyols with isocyanates, enhances flame retardancy, and maintains storage stability, allowing for the production of polyurethane and polyisocyanurate-based polymers with improved thermal and fire performance without the use of halogenated flame retardants.

Implementation Method 1

which are soluble in various solvents and miscible with isocyanates

Methodology Applied

Scientific EffectSolubility: Solvation

Implementation Method 2

miscible with isocyanates, enhancing processability

Methodology Applied

Scientific EffectMiscibility: Solvation

Implementation Method 3

impart the end product with good flame retardancy, thus making it possible to eschew the use of halogenated compounds

Methodology Applied

Scientific EffectFlame retardancy:

Implementation Method 4

isocyanates are crosslinked by a polyaddition reaction using polyols

Methodology Applied

Scientific EffectPolyaddition reaction: Chemical Bonding

Implementation Method 5

the highly exothermic reaction between polyols and isocyanates leads to internal scorching

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS11479631B2Composition containing modified bisphenol F

Publication Date: 2022.10.25 HEXION INC

AI summary

The invention relates to a composition that contains a binary mixture of bisphenol F and propoxylated bisphenol F. The aim of the invention is to provide aromatic polyols for preparing polyurethane-based and polyisocyanurate-based polymers, which ensure good handling from a technical point of view and good miscibility with the isocyanate component and render the end product flameproof. For this purpose, the invention devises a composition, which contains a binary mixture of ethoxylated bisphenol F and propoxylated bisphenol F in a weight ratio of 20:80 to 80:20.