Hydroformylated Polyols from Microbial Oils for Homogeneous Polyurethanes

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Solution Overview

Problem

The production of polyurethanes from conventional petroleum-derived polyols is unsustainable due to the increasing need for renewable materials, and existing methods for producing polyols from natural sources result in heterogeneous products with compromised physical properties.

Innovation Solution

A method involving the hydroformylation and hydrogenation of microbial oils with high unsaturated fatty acid content and low triacylglycerol diversity to produce highly reactive hydroformylated polyols, which are then used to create polyurethane materials with improved homogeneity and properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polyols are derived from petroleum feedstocks, then the production process is established and reliable, but the sustainability and environmental compatibility deteriorate

Engineering Contradiction:

Improveproduction process reliabilityVSAvoidenvironmental harm from petroleum use

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the source material parameter from petroleum-based feedstocks to microbial oil feedstocks. This parameter change maintains the chemical transformation process (hydroformylation and hydrogenation) while fundamentally altering the sustainability profile, thereby resolving the contradiction between established production reliability and environmental harm.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If polyols are produced from natural sources using existing methods, then renewable materials are utilized, but the product homogeneity and physical properties deteriorate

Engineering Contradiction:

Improverenewable material utilizationVSAvoidproduct homogeneity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The invention applies local quality by selecting microbial oils with specific characteristics (high unsaturated fatty acid content and low triacylglycerol diversity) as feedstocks. This targeted selection of specific local qualities in the raw material enables both renewable material utilization and improved product homogeneity, resolving the contradiction between adaptability and manufacturing precision.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If microbial oils with high unsaturated fatty acid content and low triacylglycerol diversity are used, then polyurethane homogeneity and physical properties improve, but the feedstock selection requirements and process complexity increase

Engineering Contradiction:

Improvepolyurethane homogeneityVSAvoidfeedstock selection and process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention applies preliminary action by pre-selecting and characterizing specific microbial oil feedstocks with desired properties (high unsaturated fatty acid content and low triacylglycerol diversity) before the hydroformylation and hydrogenation process. This preliminary characterization and selection step simplifies the overall process by ensuring consistent feedstock quality, thereby resolving the contradiction between manufacturing precision and process complexity.

Inventive Principle:

Principle #10Preliminary action

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

This approach yields polyurethane materials with superior stability, durability, and rigidity, and reduces the environmental impact by utilizing renewable microbial oils, enhancing the sustainability of polyurethane production.

Implementation Method 1

hydroformylating and hydrogenating the one or more unsaturated fatty acids

Methodology Applied

Scientific EffectHydroformylation:

Implementation Method 2

hydroformylating and hydrogenating the one or more unsaturated fatty acids

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS11673850B2Hydroformylated triglycerides and uses thereof

Publication Date: 2023.06.13 CHECKERSPOT INC

AI summary

This disclosure provides methods for the chemical modification of triglycerides that are highly enriched in specific fatty acids and subsequent use thereof for producing functionally versatile polymers.