Polyester polycarbonate polyol
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Solution Overview
Problem
Existing synthetic leathers lack sufficient sweat resistance and durability, particularly in applications requiring high durability like automobile sheets, and they often require large amounts of organic solvents in their production, leading to environmental concerns.
Innovation Solution
A polyester polycarbonate polyol with specific repeating units and a hydroxyl value of 35 to 85 mgKOH/g, which is used to produce a polyurethane with excellent balance of physical properties including flexibility, chemical resistance, hydrolysis resistance, low-temperature characteristics, heat resistance, wear resistance, adhesiveness, and appearance, while minimizing the use of organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional polyester polyol is used to produce polyurethane resin, then flexibility is improved, but sweat resistance and durability deteriorate
Solution Approach 1:
The patent uses a composite polyol system comprising both polyester polyol and polycarbonate polyol in a specific ratio (70-95 wt% polyester polyol and 5-30 wt% polycarbonate polyol). This composite approach combines the flexibility benefits of polyester polyol with the sweat resistance and durability of polycarbonate polyol, resolving the contradiction between ease of operation and reliability.
2Reliability
If polycarbonate diol is used to improve sweat resistance, then durability is improved, but flexibility and low-temperature characteristics deteriorate
Solution Approach 1:
The patent optimizes the ratio of polyester polyol to polycarbonate polyol within specific ranges (70-95 wt% polyester polyol and 5-30 wt% polycarbonate polyol) to balance sweat resistance with flexibility and low-temperature characteristics. This parameter optimization allows the composition to achieve both durability and operational flexibility.
3Productivity
If existing synthetic leather production methods are used, then production efficiency is maintained, but environmental harm increases due to large amounts of organic solvents
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating polycarbonate polyol with specific molecular weight and hydroxyl value ranges, which enables reduced solvent usage while maintaining production efficiency. The specific parameter ranges specified in the patent allow for optimized reaction conditions that minimize harmful emissions.
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 proposed solution achieves a polyurethane with enhanced physical properties and reduced solvent usage, addressing the limitations of existing synthetic leathers in terms of durability and environmental impact.
Implementation Method 1
polymerization with polyester polyol such as polypropylene glycol or polytetramethylene glycol
Implementation Method 2
coagulating the solution in water
Implementation Method 3
transesterification reaction of an aliphatic diol and a dialkyl carbonate
Implementation Method 4
ring-opening addition polymerization of a cyclic ester compound with a compound having an active hydrogen group as an initiator
Data Source
AI summary
A polyester polycarbonate polyol having a repeating unit represented by specific formula (1) and a repeating unit represented by specific formula (2), having a hydroxyl value of 35 to 85 mgKOH/g, having a hydroxyl group at a terminal, and being in the form of a liquid at ordinary temperature.