Method for producing polycarbonate diol, polycarbonate diol and polyurethane using same

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Solution Overview

Problem

Conventional methods for producing polycarbonate diols using 1,10-decanediol result in low production efficiency, high costs, and poor physical properties of polyurethanes, such as limited flexibility, low-temperature performance, and chemical resistance, due to inadequate control over aldehyde derivative content and reactivity during polycondensation.

Innovation Solution

A method involving the polycondensation of 1,10-decanediol with an aldehyde derivative and a carbonate compound in a transesterification reaction, using a catalyst to produce a polycarbonate diol with a molecular weight of 250 to 5,000, which enhances reactivity and physical properties like flexibility, chemical resistance, and heat resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If 1,10-decanediol is used as a raw material for polycarbonate diol production, then flexibility and low-temperature properties are improved, but production efficiency decreases and costs increase

Engineering Contradiction:

ImproveflexibilityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent controls the aldehyde derivative content parameter within 0.01-1.0 wt% to optimize both flexibility and production efficiency. This parameter control enables satisfactory reactivity during polycondensation while maintaining good flexibility and low-temperature properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional production methods with a transesterification reaction system using specific catalysts and controlled aldehyde content, achieving both high production efficiency and good product performance simultaneously

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If polycarbonate diol with high crystallinity is used, then heat resistance and hydrolysis resistance are improved, but cohesion of soft segment increases and flexibility at low temperatures deteriorates

Engineering Contradiction:

Improveheat resistanceVSAvoidflexibility at low temperature

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent introduces aldehyde derivatives (0.01-1.0 wt%) to modify the crystallinity and molecular structure parameters, achieving a balance between heat resistance and low-temperature flexibility in the resulting polyurethane

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by incorporating aldehyde derivative-modified polycarbonate diol into polyurethane, achieving combined properties of heat resistance, flexibility, and chemical resistance

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If aldehyde derivative content is not controlled, then production cost decreases, but reactivity during polycondensation and color tone of polyurethane deteriorate

Engineering Contradiction:

Improveproduction costVSAvoidreactivity control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent establishes an optimal parameter range (0.01-1.0 wt% aldehyde derivative) that simultaneously achieves satisfactory reactivity, good color tone, and cost-effectiveness in polyurethane production

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses the aldehyde derivative content as a feedback-controlled parameter to optimize polycondensation reactivity and final product quality, ensuring consistent manufacturing precision

Inventive Principle:

Principle #23Feedback

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 method produces polycarbonate diols with improved reactivity and physical properties, suitable for various applications including elastic fibers, synthetic leathers, and coating materials, offering a balance of flexibility, low-temperature performance, and chemical resistance.

Implementation Method 1

a method involving the polycondensation of 1,10-decanediol with an aldehyde derivative and a carbonate compound in a transesterification reaction, using a catalyst to produce a polycarbonate diol

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentEP3447080B1Method for producing polycarbonate diol, polycarbonate diol and polyurethane using same

Publication Date: 2020.07.15 MITSUBISHI CHEM CORP

AI summary

A method for producing a polycarbonate diol, comprising subjecting a compound represented by the following formula (A) containing from 0.01 to 1.0 wt% of an aldehyde derivative, a compound represented by the following formula (B), and a carbonate compound to polycondensation by a transesterification reaction in the presence of a catalyst to produce a polycarbonate diol having a number average molecular weight of 250 to 5,000 measured as indicated in the description, wherein the amount of the catalyst remaining in the polycarbonate diol is 100 ppm by weight or less as the content in terms of catalyst metal: HO-(CH2)10-OH (A) HO-R1-OH (B) (wherein in the formula (B), R1 represents a substituted or unsubstituted divalent alkylene group having a carbon number of 3 to 20, wherein the compound of the formula (A) is not included by the formula (B)).