Non-Metal Catalyst for Polyester Polyol Synthesis
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Solution Overview
Problem
Conventional catalysts used in the polymerization of polyester polyols containing high isosorbide content lead to side reactions, resulting in deep-colored reaction products and increased costs, while also potentially producing harmful side products.
Innovation Solution
The use of a non-metal inorganic acidic catalyst, such as phosphinic acid, in the reaction mixture comprising anhydrohexitols, polyfunctional carboxylic acids, and optionally other polyols, to prevent degradation of isosorbide and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used in the polymerization of polyester polyols containing high isosorbide content, then the polymerization reaction can proceed, but side reactions occur resulting in deep-colored reaction products and increased costs
Solution Approach 1:
The patent changes the chemical parameter of the catalyst from conventional metal-based catalysts to non-metal inorganic acidic catalysts (specifically phosphoric acid and its derivatives). This parameter change eliminates side reactions that cause deep coloring while maintaining efficient polymerization, producing light-colored polyester polyols with high isosorbide content
Solution Approach 2:
The patent employs inexpensive non-metal inorganic acidic catalysts (phosphoric acid and its derivatives) that can be easily handled and do not require complex handling procedures. These catalysts achieve the desired polymerization without the need for expensive metal catalysts, reducing production costs while avoiding harmful side products
2Productivity
If conventional catalysts are used, then polymerization can proceed, but production costs increase due to the need for costly metal catalysts and additional processing
Solution Approach 1:
The patent replaces expensive metal catalysts with inexpensive non-metal inorganic acidic catalysts (phosphoric acid and its derivatives). This substitution significantly reduces raw material costs while maintaining effective polymerization, making the production process more cost-efficient without compromising reaction rate
3Manufacturing precision
If the reaction time is extended to maintain forward reaction direction, then conversion rate increases, but costs increase and properties may deteriorate
Solution Approach 1:
The patent changes the catalyst parameter to non-metal inorganic acidic catalysts, which provide superior catalytic activity compared to conventional catalysts. This enables the reaction to achieve high conversion rates more quickly, reducing both time and cost while maintaining product quality
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 allows for the production of polyester polyols with high isosorbide content in high conversion rates, avoiding harmful side products and achieving cost-efficient large-scale production while maintaining desired product specifications and minimizing side reactions.
Implementation Method 1
at least one non-metal inorganic acidic catalyst, selected from a non-metal inorganic acidic compound having phosphorus atom in oxidation state of +1, a non-metal inorganic acidic compound having phosphorus atom in oxidation state of +3, and mixture thereof
Data Source
AI summary
The present invention relates to a polyester polyol derived from a reaction mixture comprising: at least one anhydrohexitol, at least one polyfunctional carboxylic acid, and at least one non-metal inorganic acidic catalyst selected from a non-metal inorganic acidic compound having phosphorus atom in oxidation state of +1, a non-metal inorganic acidic compound having phosphorus atom in oxidation state of +3, and mixture thereof. Further, the present invention relates to method of manufacturing the polyester polyol and its use in polyurethane adhesive composition.