Bio-based Polyurethane Dispersion with Vegetable Oil Soft Segments
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Solution Overview
Problem
Conventional polyurethane dispersions (PUDs) rely heavily on petrochemical resources, leading to a high carbon footprint and increasing costs, necessitating the development of sustainable, bio-based alternatives with improved performance and environmental sustainability.
Innovation Solution
The development of water-dispersible polyurethane polymers incorporating hydrophobic oligomeric polyether soft segments derived from epoxidized vegetable oil fatty acid esters, combined with hydrophilic hard segments and chain extending hard segments, to create a bio-based polymer with up to 70% carbon content, offering enhanced mechanical and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional petrochemical-based polyurethane dispersions are used, then performance and versatility are maintained, but carbon footprint increases and costs rise
Solution Approach 1:
The patent changes the chemical composition parameters by replacing petrochemical polyols with bio-based polyols derived from vegetable oils, while adjusting the isocyanate index and molecular weight parameters to maintain the desired performance characteristics of the polyurethane dispersion
Solution Approach 2:
The patent creates a composite material system combining bio-based polyol components with conventional isocyanate hard segments, resulting in a hybrid polyurethane dispersion that integrates the sustainability benefits of bio-based materials with the performance characteristics of conventional systems
2Object-affected harmful factors
If bio-based polyols are used to reduce carbon footprint, then environmental sustainability improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by using bio-based polyols specifically in the soft segment portion of the polyurethane molecule, while maintaining conventional hard segment chemistry, thereby localizing the bio-based content to where it provides maximum environmental benefit without disrupting the overall manufacturing process
Solution Approach 2:
The patent segments the polyurethane molecule into distinct soft and hard segments, with the bio-based polyol confined to the soft segment region. This segmentation allows independent optimization of each segment's properties and simplifies the manufacturing approach by treating the bio-based component as a replaceable module
3Object-affected harmful factors
If high bio-based content is achieved through ring-opening polymerization, then sustainability increases, but process complexity increases
Solution Approach 1:
The patent performs preliminary action by pre-synthesizing the bio-based polyol through ring-opening polymerization of epoxidized vegetable oil fatty acid esters before the main polyurethane formation step. This preliminary preparation of the polyol component separates the complex bio-based chemistry from the routine polyurethane synthesis, simplifying the overall manufacturing process
4Ease of operation
If conventional PUD formulations are used, then processing ease is maintained, but environmental friendliness decreases due to VOC content
Solution Approach 1:
The patent changes the formulation parameters by using bio-based polyols with inherent low VOC characteristics, while adjusting the dispersion composition parameters (particle size, charge density, viscosity) to maintain the ease of processing and application properties of conventional PUDs
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 bio-based polyurethane dispersions demonstrate excellent water and acid resistance, mechanical properties, and ease of processing, providing a sustainable and environmentally friendly binder for coatings with reduced volatile organic compounds (VOCs).
Implementation Method 1
The 1,2-di-substituted oxyethylene repeating units are derived from unsaturated fatty acid esters, such as from a distribution of epoxidized vegetable oil fatty acid esters subjected to a ring-opening polymerization process for oligomeric polyether polyol formation
Implementation Method 2
Polyurethanes are segmented polymers comprising of alternating sequences of soft segments and hard segments, which constitute a microphase separation structure
Data Source
AI summary
The disclosure relates to water-dispersible polyurethane polymers as well as related polyurethane dispersion (PUD) compositions including the same, methods of making the same, methods of using the same, and articles coated with the same. The water-dispersible polyurethane polymer includes hydrophobic oligomeric polyether soft segments that include 1,2-di-substituted oxyethylene repeating units. The 1,2-di-substituted oxyethylene repeating units are derived from unsaturated fatty acid esters, such as from a distribution of epoxidized vegetable oil fatty acid esters subjected to a ring-opening polymerization process for oligomeric polyether polyol formation. The water-dispersible polyurethane polymer further includes hard segments common to other PUD compositions.