Plant-Derived Polycarbonate Diols with Controlled Impurities
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Solution Overview
Problem
Petroleum-derived polycarbonate diols are superior in durability and resistance, but bio-derived alternatives suffer from impurities like cyclic esters and ether compounds, leading to inferior heat and chemical resistance, coloration, and reduced flexibility.
Innovation Solution
A polycarbonate diol with specific repeating units and a terminal hydroxyl group, characterized by a 1H-NMR integral value ratio of 0.01 to 1.0, is synthesized using plant-derived diols, ensuring excellent colorless transparency, flexibility, and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If plant-derived diol raw materials are used to synthesize polycarbonate polyols, then environmental load is reduced, but heat resistance and chemical resistance deteriorate due to ester compound impurities
Solution Approach 1:
The invention extracts and removes harmful impurities (cyclic ester compounds and ether compounds) from the plant-derived diol raw materials through purification steps before polymerization. This allows the use of bio-based materials while eliminating the components that cause poor heat and chemical resistance.
Solution Approach 2:
The invention changes the purity parameter of the raw materials by establishing specific impurity content limits (cyclic ester compounds ≤ 50 ppm, ether compounds ≤ 100 ppm). This parameter control ensures that the resulting polycarbonate diol achieves durability comparable to petroleum-derived materials while maintaining the environmental benefits of plant-derived sources.
2Quantity of substance
If plant-derived diol raw materials with cyclic ether compounds are used, then bio-based content is increased, but weather resistance deteriorates causing coloration
Solution Approach 1:
The invention specifically targets and removes ether compounds (which cause poor weather resistance and coloration) from the plant-derived diol raw materials through purification processes. This extraction allows high bio-based content to be achieved while preventing the weathering and coloration problems associated with ether bonds.
3Adaptability or versatility
If plant-derived diol raw materials containing cyclic ester impurities are used, then environmental sustainability is improved, but durability of polyurethane compositions deteriorates
Solution Approach 1:
The invention establishes strict parameter specifications for raw material purity (cyclic ester compounds ≤ 50 ppm, ether compounds ≤ 100 ppm) to ensure that the resulting polyurethane compositions achieve durability comparable to petroleum-derived materials. This parameter control enables environmental sustainability without sacrificing long-term performance.
4Manufacturing precision
If plant-derived short-chain diol is used to synthesize bio-polyurethane resin, then carbonate bond density is increased, but flexibility deteriorates and the material becomes difficult to handle
Solution Approach 1:
The invention optimizes the molecular weight and hydroxyl value parameters of the polycarbonate diol to balance carbonate bond density with flexibility. By controlling these parameters within specific ranges, the invention achieves high carbonate bond density for excellent chemical resistance while maintaining sufficient flexibility and ease of handling for practical applications.
Data Source
AI summary
To provide a polycarbonate diol or the like which, even if plant-derived, has an appearance excellent in colorless transparency comparable with that of petroleum-derived one. A polycarbonate diol having a repeating unit represented by the following formula (1) and a terminal hydroxyl group, in which an integral value of a signal at 2.50 to 2.70 ppm is 0.01 to 1.0 under the assumption that an integral value of a signal at 3.90 to 4.45 ppm is 1000 in a 1H-NMR spectrum measured with chloroform-d as a solvent and tetramethylsilane as a standard substance: wherein R1 represents a divalent aliphatic hydrocarbon having 2 to 20 carbon atoms.