Bioresin Composition for Rigid Polyurethane Foam Adhesion
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Solution Overview
Problem
Conventional polyurethane foam articles face issues with adhesion to thermoplastic substrates due to the absence of aprotic solvents that decompose in the presence of water, leading to pressurization of storage containers and inadequate wetting, and are made from petroleum-based polyols with environmental and financial drawbacks.
Innovation Solution
A bioresin composition is developed, comprising a first biopolyol with a natural oil component and a second biopolyol derived from a natural carbohydrate and alkylene oxide, in excess relative to the first, along with an aprotic solvent that does not chemically decompose in water, reacting with an isocyanate in the presence of a blowing agent to form a rigid polyurethane foam article with enhanced adhesion and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aprotic solvents that decompose in the presence of water are used to improve adhesion to thermoplastic substrates, then adhesion is improved, but storage containers are pressurized and may fail
Solution Approach 1:
The patent removes the problematic aprotic solvents (dimethyl carbonate, diethyl carbonate, dioxolane, dioxane) from the resin composition while maintaining adhesion performance through alternative formulation approaches using bio-based polyols and conventional solvents that do not decompose in water
Solution Approach 2:
The patent replaces expensive specialized containers required for storing decomposable aprotic solvents with standard containers by eliminating the decomposable solvents from the formulation, reducing packaging costs and complexity
2Strength
If aprotic solvents are used to facilitate wet out of the reaction mixture, then wetting of thermoplastic substrates is improved, but the solvents chemically decompose generating carbon dioxide
Solution Approach 1:
The patent eliminates the harmful decomposition reaction by removing the unstable aprotic solvents, and uses alternative wetting agents (bio-based polyols and conventional solvents) that provide the same wetting function without generating carbon dioxide or pressurizing containers
Solution Approach 2:
The patent changes the chemical composition parameters by eliminating decomposable aprotic solvents and replacing them with stable alternative solvents and bio-based polyols, fundamentally changing the chemical stability profile of the resin composition
3Ease of manufacture
If petroleum-based polyols are used to make polyurethane foam articles, then manufacturing is established and consistent, but environmental and financial drawbacks occur
Solution Approach 1:
The patent changes the feedstock source from petroleum-based to bio-based materials, maintaining manufacturing consistency through careful selection and formulation of bio-based polyols with controlled molecular weights, functionalities, and viscosity ranges
Solution Approach 2:
The patent uses a composite resin composition containing multiple bio-based polyols (soybean oil-based, castor oil-based, sunflower oil-based) combined with conventional polyols to achieve the desired balance of environmental sustainability and manufacturing performance
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 bioresin composition reduces the risk of container pressurization, improves adhesion to thermoplastic substrates, and provides a bio-based polyurethane foam with exceptional thermal resistance and cell structure, eliminating the need for specialized containers and promoting environmental sustainability.
Implementation Method 1
Generally, when the resin composition is mixed with the isocyanate to form a reaction mixture in the presence of the blowing agent, a urethane polymerization reaction occurs. As the urethane polymerization reaction occurs, the reaction mixture cross-links to form the polyurethane
Implementation Method 2
As the urethane polymerization reaction occurs, the reaction mixture cross-links to form the polyurethane and gas is simultaneously formed and released. Through the process of nucleation, the gas foams the reaction mixture thereby forming voids or cells in the polyurethane foam article
Implementation Method 3
The adhesion promoting agent (e.g. an aprotic solvent) facilitates wet out of the reaction mixture and promotes adhesion of the polyurethane foam article to substrates upon which the polyurethane foam article is disposed
Data Source
AI summary
A bioresin composition is used to form a rigid polyurethane article that includes a first and a second biopolyol and is substantially free of aprotic solvents that chemically decompose in the presence of water. The first biopolyol includes a natural oil component. The second biopolyol includes the reaction product of a natural carbohydrate and an alkylene oxide. The rigid polyurethane foam article includes the reaction product of the bioresin composition and an isocyanate which are reacted in the presence of a chemical blowing agent.