Copolymer Polyol Purification Using Molecular Sieve Adsorption
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Solution Overview
Problem
Existing copolymer polyol (CPP) products contain significant residual monomers and volatile compounds (VOC) emissions in existing technologies have not addressed the challenges of effectively removing residual monomers and VOC emissions in the production of polyurethane foams, which contribute to VOC emissions and fogging effects in automobile interiors, and VOC emissions in the production of polyurethane foam products.
Innovation Solution
The use of molecular sieve adsorbents, specifically zeolite, to remove remaining residual monomers and volatile constituents from the CPP product by using a molecular sieve adsorbent, such as a zeolite, to reduce the content of residual monomers and volatile components from the CPP product, which has already been processed through a stripping operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional stripping methods are used to remove residual monomers from CPP, then some volatile components are removed, but significant residual monomers and VOC emissions remain
Solution Approach 1:
The patent extracts residual monomers and volatile organic compounds from copolymer polyol using molecular sieve adsorbents. The molecular sieves selectively adsorb small molecules (residual monomers) from the polyol matrix, effectively removing harmful substances while preserving the bulk polymer structure and properties.
Solution Approach 2:
The patent employs molecular sieve adsorbents with controlled porous structures to remove residual monomers. The porous material provides high surface area and selective adsorption sites that trap volatile organic compounds and residual monomers within its pore structure, achieving thorough purification.
2Object-generated harmful factors
If high process temperatures are used for purification, then residual monomers are removed, but product discoloration (yellowing) occurs
Solution Approach 1:
The patent replaces thermal purification methods with adsorption-based purification using molecular sieves. Instead of relying on heat to volatilize and remove residual monomers (which causes yellowing), the molecular sieves adsorb residual monomers at lower temperatures, eliminating the discoloration problem while achieving effective removal.
Solution Approach 2:
The patent changes the purification mechanism from thermal-driven volatilization to adsorption-driven separation. By using molecular sieve adsorbents, the process operates at lower temperatures and removes residual monomers through adsorption rather than evaporation, preventing thermal degradation and yellowing of the polyol product.
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
Achieves efficient and effective removal of residual monomers and volatiles in CPP products, achieving a more purified CPP composition, reducing VOC emissions and VOC emissions in the production of polyurethane foam products.
Implementation Method 1
removing at least a portion of the residual monomers and volatile components from the copolymer polyol composition using a molecular sieve adsorbent
Data Source
AI summary
A process for preparing a copolymer polyol containing a reduced content of residual monomers and volatiles including the steps of: (a) providing at least one copolymer polyol containing a first initial content of residual monomers and volatiles; (b) providing at least one molecular sieve adsorbent; (c) contacting the at least one copolymer polyol with the at least one molecular sieve adsorbent for a period of time and at a temperature sufficient for the at least one molecular sieve adsorbent to adsorb at least a portion of the first initial content of residual monomers and volatiles present in the at least one copolymer polyol to reduce the first initial content of residual monomers and volatiles of the at least one copolymer polyol to form at least one copolymer polyol containing a second reduced content of residual monomers and volatiles; and (d) separating the at least one molecular sieve adsorbent containing a portion of the first initial content residual monomers and volatiles from the at least one copolymer polyol to form at least one copolymer polyol containing a second reduced content of residual monomers and volatiles.