Polyether-polysiloxane Copolymer Foam Stabilizer
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Solution Overview
Problem
Existing polyether-modified silicone compositions used in surfactants and foam stabilizers face challenges with industrial production due to the use of hazardous solvents like toluene, excessive dimethyl polysiloxane content, and limited market penetration due to performance and cost issues, along with stability and homogeneity problems in foam-forming compositions.
Innovation Solution
A polyether-polysiloxane block copolymer composition is developed, comprising a specific structural unit with terminal functional groups and a monool organic compound, which does not include dimethyl polysiloxane, allowing for improved homogeneity, stability, and phase solubility in foam-forming emulsions, and is synthesized without solvents or with minimal volatile organic solvents, reducing manufacturing costs and enhancing market viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If toluene or xylene is used as a solvent in the block copolymer composition, then the copolymer can be synthesized and processed, but the composition becomes flammable and hazardous
Solution Approach 1:
The patent removes the hazardous toluene or xylene solvent from the block copolymer composition, replacing it with a non-flammable alternative. This extraction of the harmful component eliminates the fire hazard while maintaining the functional properties of the copolymer in foam stabilizer applications
Solution Approach 2:
The patent changes the chemical composition parameter by substituting flammable aromatic hydrocarbons (toluene, xylene) with non-flammable alternatives. This parameter change maintains the solvent function necessary for copolymer processing while eliminating the harmful flammability property
2Reliability
If dimethyl polysiloxane is added to the polyether-modified silicone composition, then the foam stability is improved, but the manufacturing cost increases and market penetration is limited
Solution Approach 1:
The patent removes dimethyl polysiloxane from the composition, extracting this expensive component while maintaining foam stability through the optimized polyether-polysiloxane block copolymer structure alone. This eliminates the need for costly additives
Solution Approach 2:
The patent replaces expensive dimethyl polysiloxane with a more cost-effective polyether-polysiloxane block copolymer formulation that achieves the same foam stabilizing function at lower material cost, improving economic viability
3Reliability
If polypropylene glycol is used as a diluting agent after toluene removal, then the foam stability is maintained, but the manufacturing process becomes complex with multiple stripping operations
Solution Approach 1:
The patent removes the need for polypropylene glycol diluting agent and multiple stripping operations by using a simplified composition that achieves foam stability without these additional components and process steps
Solution Approach 2:
The patent combines the foam stabilizing function into the core polyether-polysiloxane block copolymer structure itself, eliminating the need for separate diluting agents and multiple processing steps, thereby simplifying the overall manufacturing process
4Ease of manufacture
If long chain alkylene benzene is used as a reaction solvent, then the copolymer can be synthesized, but the non-reactive solvent remains in the final product and migrates from the foam
Solution Approach 1:
The patent removes long chain alkylene benzene solvent from the final composition, eliminating the migration issue while maintaining synthesis capability through alternative processing methods that do not require such solvents in the final product
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 new composition effectively stabilizes foams, controls open cell ratios, and improves the homogeneity and stability of premixed solutions, making it suitable for high-density microcellular foams and other foam types, while reducing production costs and environmental impact.
Implementation Method 1
A polyether-polysiloxane block copolymer composition, containing the following component (A) and component (B) at a mass ratio of (A)/(B)=10/90 to 90/10, and not containing a dimethyl polysiloxane at more than the mass of component (A)... effectively stabilizes foams
Implementation Method 2
controls open cell ratios... making it suitable for high-density microcellular foams and other foam types
Data Source
AI summary
A polyether-polysiloxane block copolymer composition is disclosed. The copolymer composition comprises (A) a polyether-polysiloxane block copolymer having in a molecule structural units as expressed by General Formula (1) below:where a terminal group thereof is an alkenyl group or the like bonded to a polyether portion. The copolymer composition further comprises (B) a liquid monool organic compound, which is (B1) a glycol ether compound having a low degree of polymerization, a terminal hydrogen substituted with a hydrocarbon group, and a secondary alcoholic hydroxyl group provided on another terminal, or (B2) a higher alcohol compound having a branched alkyl group with 12 or more carbon atoms. The copolymer composition generally does not contain a dimethyl polysiloxane at more than the mass of component (A). A manufacturing method, foam stabilizer or the like containing the copolymer composition, and a polyurethane foam are also disclosed.