NCO Prepolymer Mixing and Reaction in Storage Vessel

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Solution Overview

Problem

Existing methods for preparing NCO prepolymers require controlled mixing and temperature conditions in a reaction vessel, making them inflexible and resource-intensive, especially when production plants are not available or when producing different prepolymers.

Innovation Solution

A method where an isocyanate group-containing component in hyperstoichiometric amounts and an isocyanate group-reactive component in hypostoichiometric amounts are continuously mixed at room temperature in a mixing device and introduced directly into a storage or transport vessel, allowing the reaction to complete without further mixing or temperature control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional reaction vessels with controlled mixing and temperature conditions are used, then complete reaction can be achieved, but the process becomes inflexible and resource-intensive

Engineering Contradiction:

Improveflexibility of production methodVSAvoidequipment requirements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention extracts the reaction function from the mixing function. The reaction components are mixed briefly in a simple mixing device, then the mixture is introduced into a storage or transport vessel where the reaction completes during storage or transport without further mixing or temperature control. This separates the mixing operation from the reaction operation, eliminating the need for complex reaction vessels with controlled mixing and temperature conditions.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The storage or transport vessel serves multiple functions: it stores the reaction mixture, allows the reaction to complete, and can transport the product. This multi-functional use of a simple vessel eliminates the need for dedicated complex reaction vessels, making the production method flexible and adaptable to different production scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If reaction components are mixed and allowed to react in a reaction vessel, then complete reaction can be achieved, but production time and resource consumption increase

Engineering Contradiction:

Improveproduction speedVSAvoidreaction time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The reaction continues continuously during storage and transport without interruption. The reaction components are mixed and then the reaction proceeds to completion during the normal storage or transport time, eliminating the need for separate reaction time in addition to storage or transport time. This continuous useful action improves productivity without increasing total time.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If different NCO prepolymers are produced using conventional methods, then product variety can be achieved, but extensive reactor cleaning is required

Engineering Contradiction:

Improveability to produce different prepolymersVSAvoidcleaning effort

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The production process is segmented into a simple mixing operation followed by reaction during storage/transport. The mixing device can be easily cleaned or replaced between different product runs, while the storage/transport vessel requires no cleaning since the reaction completes inside it. This segmentation makes it easy to produce different NCO prepolymers with minimal cleaning effort.

Inventive Principle:

Principle #1Segmentation

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

Enables the rapid and flexible production of NCO prepolymers with minimal equipment requirements, allowing for batchwise operation and variable isocyanate content without the need for additional reaction chambers or buffer tanks, while maintaining product quality with minimal temperature rise.

Implementation Method 1

DE69132613T2 describes how the reaction between a polyol and a polyisocyanate proceeds exothermically

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS8835591B2Method for preparing polyurethane prepolymers containing isocyanate groups

Publication Date: 2014.09.16 COVESTRO DEUTSCHLAND AG

AI summary

The present invention relates to the technical field of isocyanates. The present invention provides a method for preparing NCO prepolymers by reacting a stoichiometric excess of an organic isocyanate with an isocyanate-reactive component, the reaction components being mixed together and the mixture being introduced directly into a storage or transport vessel, where it reacts to completion.