Double-Metal-Cyanide Catalyst Ligand Design for Polyol Workability
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Solution Overview
Problem
Conventional DMC catalysts produce polyols with high amounts of high-molecular-weight compounds, leading to reduced workability and processing issues, such as tight foam or collapse, which existing methods to address this problem are costly and industrially impractical.
Innovation Solution
A high-activity double-metal-cyanide (DMC) catalyst is developed using a mixture of a C2-C7 fatty alcohol and alicyclic carbonate as the organic complexing ligand, reducing the concentration of high-molecular-weight compounds in polyols through a specific reaction and filtration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional DMC catalyst is used for polyol fabrication, then high catalytic activity is achieved, but high-molecular-weight compounds increase causing reduced workability and processing issues
Solution Approach 1:
The patent changes the chemical composition parameters of the organic complexing ligand by introducing alicyclic carbonate structures with specific molecular weights and functional groups. This modifies the catalyst's interaction with the polymerization system, reducing high-molecular-weight compound formation while preserving catalytic activity.
Solution Approach 2:
The patent creates a composite catalyst system combining DMC with specifically designed organic complexing ligands containing alicyclic carbonate moieties. This composite structure provides both the high activity of DMC and the workability benefits of the alicyclic carbonate ligand system.
2Productivity
If functionalized polymers are added to enhance DMC activity, then catalytic performance improves, but high-molecular-weight compounds increase further
Solution Approach 1:
Instead of adding functionalized polymers, the patent changes the ligand structure parameters to include alicyclic carbonate groups with controlled molecular weights (specifically C3-C7 cyclic carbonates). This structural modification enhances catalytic activity through the ligand's chelating effect while the cyclic structure prevents excessive polymerization that leads to high-molecular-weight compounds.
Solution Approach 2:
The patent uses small-molecule alicyclic carbonate ligands instead of large functionalized polymers. These small ligand molecules provide the necessary catalytic enhancement without contributing to high-molecular-weight compound formation, effectively replacing the problematic polymer additives.
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 catalyst achieves higher activity and reduces the amount of high-molecular-weight compounds in polyols, improving workability and processing efficiency while maintaining catalytic performance.
Implementation Method 1
The present invention uses an alicyclic carbonate as the constituent of the organic complexing ligand to fabricate a high-activity DMC catalyst
Implementation Method 2
The double-metal-cyanide (DMC) catalyst can function as a superior catalyzing agent of the polymerization of epoxides
Data Source
AI summary
A high-activity double-metal-cyanide catalyst, a method for fabricating the same, and applications of the same are disclosed. An organic complexing ligand, which is formed via mixing fatty alcohols and alicyclic carbonates, is used to generate a high-activity double-metal-cyanide catalyst. The high-activity double-metal-cyanide catalyst includes at least one double-metal-cyanide compound, at least one organic complexing ligand, and an optional functionalized compound. The double-metal-cyanide catalyst of the present invention has a higher activity than the conventional double-metal-cyanide catalysts. The polyols generated by the present invention has an insignificant amount of high-molecular-weight compounds.