Biosourced Polyester Polyol for Rigid Foam
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Solution Overview
Problem
The polyisocyanurate (PUIR) foam industry relies on petro-sourced polyols, which lack biosourced alternatives, limiting the development of sustainable insulation materials with mechanical and thermal properties comparable to traditional PUIR foams.
Innovation Solution
A rigid polyurethane foam is developed using a biosourced polyester polyol obtained through a two-step polycondensation process involving a sugar alcohol and diacids, followed by reaction with diols, creating a polymer with a specific molecular structure and hydroxyl number, enabling the production of foams with properties similar to petro-sourced PUIR foams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based polyols are used in PUIR foam production, then mechanical and thermal properties are achieved, but sustainability and environmental compatibility deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters of the polyol from petroleum-based to biosourced polyester polyol with specific molecular weight (500-2000 g/mol) and hydroxyl number (300-900 mg KOH/g), maintaining the required mechanical and thermal properties while improving environmental sustainability
Solution Approach 2:
The invention uses composite formulation combining biosourced polyester polyol with specific additives (catalysts, blowing agents, flame retardants) to create a foam material that achieves both sustainability and performance requirements, comparable to traditional petroleum-based PUIR foams
2Object-affected harmful factors
If bio-based polyester polyol is used in PUIR foam, then sustainability is improved, but mechanical and thermal properties may deteriorate
Solution Approach 1:
The invention optimizes critical parameters of the biosourced polyester polyol including molecular weight (500-2000 g/mol), hydroxyl number (300-900 mg KOH/g), and chemical structure to ensure the foam achieves mechanical strength and thermal stability comparable to petroleum-based alternatives
Solution Approach 2:
The invention controls the foam's cellular structure with 80-95% closed-cell content, optimizing cell size (50-500 μm) and distribution to achieve thermal conductivity of 20-30 mW/(mK) and mechanical strength, demonstrating that proper porosity control compensates for the biosourced origin of the polyol
3Temperature
If high crosslinking density is achieved through isocyanurate ring formation, then thermal stability and fire resistance are improved, but brittleness increases
Solution Approach 1:
The invention adjusts the isocyanate index (NCO/OH ratio) to 1.05-1.5, optimizing the balance between isocyanurate ring formation for thermal stability and polyurethane chain formation for flexibility, thereby reducing brittleness while maintaining fire resistance
Solution Approach 2:
The invention creates a composite polymer network containing both polyurethane segments (providing flexibility) and polyisocyanurate segments (providing thermal stability), achieving a balance between brittleness and thermal 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 biosourced PUIR foam achieves comparable mechanical and thermal properties to petro-sourced foams, including thermal stability and fire resistance, while offering a sustainable alternative for insulation applications.
Implementation Method 1
a biosourced polyester polyol, in particular obtained by a polycondensation (a) of a sugar alcohol Z in C3 to C8 and two identical or different diacids Y and Y' in C4 to C36 and a polycondensation (b) of the product obtained in (a) with two identical or different diols X and X' in C2 to C12
Implementation Method 2
One of the best materials for building insulation is rigid polyurethane (PUR) foam... The thermal conductivity of PUR foams varies between 20 mW/(mK) and 30 mW/(mK)
Implementation Method 3
The thermal stability range of the isocyanurate group also depends on the surrounding chemical environment but is estimated to be between 365°C and 500°C. The superior thermal stability of the isocyanurate groups present in PUIR foams is the reason for their better fire resistance
Data Source
Figure 1a~1c
Figure 2~3c
Figure 4~5
AI summary
The present invention concerns a rigid foam or a composition allowing a rigid foam to be obtained, comprising a polyester polyol or a polymer comprising a polyester polyol, said polyester polyol being obtained by a first polycondensation (a) of a C3 to C8 alcohol sugar Z and two identical or different C4 to C36 diacids Y and Y' and a second polycondensation (b) of the product obtained in (a) with two identical or different C2 to C12 diols X and X'.