Copper Catalyst in Dialkyl Sulfoxide for Polyurethane Foam
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Solution Overview
Problem
The use of nickel-based catalysts in polyurethane foam production poses health risks due to nickel's carcinogenic properties, and alternative metal catalysts face limitations in solubility and tunable reactivity, necessitating a safer and more effective catalyst solution.
Innovation Solution
A polyurethane foam-forming composition incorporating a copper (II) compound dissolved in a dialkyl sulfoxide solvent, along with a surfactant, serves as a catalyst, offering similar performance to nickel-based catalysts while reducing toxicity and enhancing reactivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nickel-based catalysts are used in polyurethane foam production, then catalytic activity and foam formation are effective, but health risks increase due to nickel's carcinogenic properties
Solution Approach 1:
The patent changes the chemical identity of the metal catalyst from nickel to copper, fundamentally altering the toxicological parameters while maintaining catalytic function. The copper compound is dissolved in dialkyl sulfoxide solvent, creating a new chemical system with different safety properties but similar catalytic performance in polyurethane foam formation
Solution Approach 2:
The patent employs a copper-based catalyst system that can be used at lower concentrations and potentially replaced more easily than nickel catalysts, reducing long-term exposure risks. The catalyst is incorporated into a solvent system that facilitates controlled application and potential removal or degradation after use
2Object-affected harmful factors
If alternative metal catalysts are used to replace nickel, then health risks are reduced, but solubility and tunable reactivity are limited
Solution Approach 1:
The patent introduces dialkyl sulfoxide as a solvent intermediary that mediates between the copper catalyst and the polyol/isocyanate system. This solvent enables the copper compound to dissolve effectively and provides a medium for tuning reactivity, bridging the gap between the alternative metal catalyst and the polyurethane foam formation process
Solution Approach 2:
The patent utilizes the dialkyl sulfoxide solvent to adjust and optimize multiple parameters including solubility of the copper catalyst, reactivity of the catalytic system, and compatibility with foam components. The solvent allows for fine-tuning of catalyst performance to match or exceed nickel-based systems while maintaining the safety advantages of copper
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 copper-based catalyst system provides stable foam production with tunable reactivity, comparable to nickel catalysts, and reduces health risks associated with nickel use, while maintaining effective curing properties.
Implementation Method 1
a catalyst composition comprising a copper (II) compound dissolved in a solvent, wherein the solvent is a dialkyl sulfoxide
Data Source
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AI summary
The present technology provides a foam-forming composition comprising at least one polyol, at least one isocyanate, at least one copper catalyst composition, and at least one surfactant. The copper catalyst composition may comprise a copper (II) compound dissolved in a solvent. In one embodiment, the copper catalyst composition comprises (Cu(II)(acac)2) dissolved in DMSO.