Polyurethane Foams Using Ionic Liquids for Burn Resistance
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Solution Overview
Problem
Conventional polyurethane foams pose environmental and safety concerns due to their petroleum-based composition, flammability, and toxic gas emissions when burned, limiting their commercial development and insulation applications.
Innovation Solution
The development of polyurethane foams using natural or plant-based polyols, such as sucrose, dissolved in ionic liquids or deep eutectic solvents, which reduces water usage, enhances urethane index, and produces foams with higher densities, strength, and burn resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional petroleum-based polyols are used to manufacture polyurethane foams, then the foams achieve good physical properties and ease of manufacture, but they exhibit high flammability and toxic gas emissions when burned
Solution Approach 1:
The patent changes the chemical composition parameters by replacing petroleum-based polyols with natural polyols (sucrose, starch, cellulose, glycerol, sorbitol, mannitol). This substitution fundamentally alters the foam's combustion characteristics, reducing flammability and toxic emissions while maintaining manufacturing feasibility through established polyurethane formulation processes
Solution Approach 2:
The patent creates composite foam structures by combining natural polyol-based polyurethane with traditional polyurethane components. This composite approach allows the natural polyol component to provide fire resistance and reduced toxicity while the overall foam structure maintains the desired physical properties and manufacturability of conventional polyurethanes
2Object-affected harmful factors
If natural polyols are used as the primary polyol component, then burn resistance is improved, but manufacturing complexity increases due to the need for green solvents and process modifications
Solution Approach 1:
The patent introduces green solvents (ionic liquids, deep eutectic solvents) as intermediary substances to dissolve natural polyols and enable their incorporation into polyurethane formulations. These solvents act as mediators that facilitate the reaction between natural polyols and isocyanates, allowing burn resistance to be achieved without requiring complex manufacturing process modifications
Solution Approach 2:
The patent modifies the solvent system parameters by replacing conventional organic solvents with green alternatives (ionic liquids, deep eutectic solvents). This parameter change enables the use of natural polyols while simplifying the manufacturing process by eliminating the need for extensive process modifications, as the green solvents are directly incorporated into the existing polyurethane formulation framework
3Shape
If water is used as a blowing agent to create cells, then the foam structure is formed, but the density and strength are reduced
Solution Approach 1:
The patent changes the physical-chemical parameters of the foam by controlling the cell structure through the interaction of water-blown cells with the natural polyol-based matrix. The unique properties of natural polyols and green solvents allow for optimized cell morphology that maintains porosity for foam structure while enhancing the matrix strength to support higher density and mechanical strength
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 use of natural polyols and green solvents results in polyurethane foams with improved physical properties, increased burn resistance, and reduced environmental impact, expanding their application range beyond current limitations.
Implementation Method 1
utilizes ionic liquids and/or deep eutectic solvents as a solvent for the polyol system
Implementation Method 2
The blowing agent creates the cells in the polyurethane foam article as described above
Implementation Method 3
Through the process of nucleation, the gas foams the reaction mixture thereby forming voids or cells in the polyurethane foam article
Implementation Method 4
As the urethane polymerization reaction occurs, the reaction mixture cross-links to form the polyurethane
Data Source
AI summary
Polyurethane foams are described, as well as the production of such polyurethane foams by the reaction between a natural polyol, such as sucrose or a blend of mono- or disaccharides in place of the standard hydrocarbon-based polyol component, an ionic liquid or a deep eutectic solvent, a polyisocyanate and water in the presence of a suitable polyurethane forming catalyst and optionally a flame retardant, and optionally one or more components such as surfactants and/or emulsifiers. The resultant polyurethane foam can exhibit a bio-based solid content ranging from about 17% to 30%, may be formulated in a variety of foam densities for a variety of applications, and in the instance where a flame retardant has been added in an appropriate amount, exhibits a high degree of fire and burn resistance, as exhibited by the flame spread index and/or the smoke spread values.