High-Activity DMC Catalyst Fabrication for Polyol Purity
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Solution Overview
Problem
Conventional double-metal-cyanide (DMC) catalysts produce polyols with high levels of high-molecular-weight compounds, leading to reduced workability and processing issues, such as tight foam or collapse, which existing methods struggle to address cost-effectively.
Innovation Solution
A high-activity DMC catalyst is developed using a mixture of a C2-C7 fatty alcohol and alicyclic carbonate as the organic complexing ligand, reducing the amount of high-molecular-weight compounds in polyols, comprising specific metal salts and cyanide salts, and a method for fabricating this catalyst involving the reaction of metal precursor solutions with a cyanide ligand and subsequent filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional DMC catalysts are used for polyol fabrication, then high reaction speed and low unsaturation level are achieved, but high-molecular-weight compounds increase leading to 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 modification alters the catalyst's interaction with the polymerization system, reducing high-molecular-weight compound formation while preserving high reaction speed and low unsaturation levels.
Solution Approach 2:
The patent creates a composite organic complexing ligand system combining alicyclic carbonate structures with other coordinating compounds. This composite approach allows the catalyst to maintain high activity while the specific molecular structure prevents excessive polymerization and high-molecular-weight compound formation, improving workability.
2Speed
If conventional DMC catalysts are used for polyol fabrication, then high reaction speed is achieved, but high-molecular-weight compounds increase leading to foam collapse and settling issues
Solution Approach 1:
The patent modifies the organic complexing ligand parameters by incorporating alicyclic carbonate structures with specific molecular weights (preferably 84-144 g/mol) and functional groups. This parameter change reduces the formation of high-molecular-weight compounds that cause foam collapse, while maintaining the high reaction speed characteristic of DMC catalysts.
Solution Approach 2:
The patent uses small-molecule alicyclic carbonates as transient ligands that coordinate with the DMC catalyst during the reaction but do not persist in the final product. These short-living complexing agents perform their function of controlling polymerization and then are eliminated, preventing long-term foam stability issues.
3Ease of operation
If existing methods are used to remove high-molecular-weight compounds or redesign polyurethane formulas, then workability improves, but manufacturing cost increases significantly
Solution Approach 1:
The patent takes preliminary action by modifying the catalyst system before the polymerization reaction occurs. The alicyclic carbonate-containing organic complexing ligand is incorporated into the DMC catalyst formulation at the outset, preventing high-molecular-weight compound formation during the reaction rather than requiring costly post-processing removal or formula redesign.
Solution Approach 2:
The patent extracts the problematic function from the conventional DMC catalyst system by replacing part of the organic complexing ligand with alicyclic carbonate structures. This extraction removes the tendency to form high-molecular-weight compounds while retaining the beneficial high activity and low unsaturation characteristics of DMC catalysts.
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 exhibits higher activity and generates polyols with an insignificant amount of high-molecular-weight compounds, improving workability and reducing processing issues while maintaining cost-effectiveness.
Implementation Method 1
uses an alicyclic carbonate as the constituent of the organic complexing ligand to enhance the activity of a DMC catalyst
Implementation Method 2
The double-metal-cyanide (DMC) catalyst can function as a superior catalyzing agent of the polymerization of epoxides
Implementation Method 3
The typical methods of fabricating DMC are using an aqueous solution reaction of metal salts and metal cyanide salts to form deposition of DMC
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.