Polymer Polyol Particle Diameter and Viscosity Control
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Solution Overview
Problem
Polymer polyols with small particle diameters and low viscosity are needed to produce polyurethane resins with excellent mechanical strengths, such as elongation at break, while existing methods face issues like scorching and insufficient mechanical properties due to high acrylonitrile ratios or high-molecular-weight coupled polyols.
Innovation Solution
A polymer polyol comprising a polyol, polymer particles obtained by polymerizing ethylenically unsaturated compounds, and an active-hydrogen-containing compound with an aromatic ring, where the active-hydrogen-containing compound has a number-average molecular weight of 150 to 2,000, is used to produce a polyurethane resin with improved mechanical strengths and low viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a high ratio of acrylonitrile is used to obtain small particle diameter polymer particles, then the particle diameter is reduced, but scorching occurs during slabstock foam formation
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer particles by incorporating specific monomers (acrylic acid, methacrylic acid, itaconic acid, or maleic acid) in controlled amounts (0.1-10 wt% each) alongside acrylonitrile (10-50 wt%). This parameter adjustment reduces particle diameter while preventing scorching during foam formation, resolving the contradiction between small particle size and scorch resistance.
2Volume of moving object
If a large amount of high-molecular-weight coupled polyol is used to reduce particle diameter, then the particle diameter is reduced, but the viscosity of the polymer polyol increases
Solution Approach 1:
The patent changes the molecular weight parameters of the polyol component by specifying a number-average molecular weight range of 500-2,000 and controlling the hydroxyl value (15-50 mg KOH/g). This parameter optimization allows achieving small particle diameters through polymerization while maintaining low viscosity in the final polymer polyol product.
3Volume of moving object
If a large amount of high-molecular-weight coupled polyol is used to reduce particle diameter, then the particle diameter is reduced, but the mechanical properties of the obtained polyurethane resin become insufficient
Solution Approach 1:
The patent creates a composite polymer particle system combining multiple components: acrylonitrile (10-50 wt%), acrylic acid (0.1-10 wt%), methacrylic acid (0.1-10 wt%), itaconic acid (0.1-10 wt%), or maleic acid (0.1-10 wt%), along with other copolymerizable monomers. This composite composition achieves both small particle diameter and excellent mechanical properties including elongation at break ≥40% in the resulting polyurethane resin.
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 results in polyurethane resins with excellent mechanical strengths and low viscosity, effectively addressing the issues of scorching and insufficient mechanical properties in existing methods.
Implementation Method 1
a polymer polyol comprising: a polyol (A); polymer particles (B) obtained by polymerization of an ethylenically unsaturated compound (b); and an active-hydrogen-containing compound (d) having an aromatic ring
Implementation Method 2
polymer particles (B) obtained by polymerization of an ethylenically unsaturated compound (b)
Data Source
AI summary
A polymer polyol (I) is provided that is formed of a polyol (A), polymer particles (B) obtained by polymerization of an ethylenically unsaturated compound (b), and an active-hydrogen-containing compound (d) having an aromatic ring and having a number-average molecular weight of 150 to 2,000, wherein a content of (d) is 1 to 20% on the basis of a weight of (B). The polymer polyol of the present invention contains polymer particles having sufficiently small particle diameters, has a low viscosity, and has excellent handleability. A polyurethane resin obtained by using the polymer polyol of the present invention has excellent mechanical strengths such as elongation at break.