Aromatic Polyester Polyol Cyclopentane Solubility
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Solution Overview
Problem
Current polyurethane foam manufacturing using aromatic polyester polyols faces challenges with low pentane solubility, leading to separation issues and inadequate properties for low-density foams, as existing methods are either costly or compromise on physical properties.
Innovation Solution
A method involving the reaction of glycols, dicarboxylic acids or esters, functionality enhancers, and natural oils at elevated temperatures to produce an aromatic polyester polyol with enhanced cyclo pentane solubility, achieving a composition with at least 25% cyclo pentane solubility and a hydroxyl number of 150 or higher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional aromatic polyester polyols are used in polyurethane foam manufacturing, then the foam production process is established, but the pentane solubility is insufficient leading to separation issues
Solution Approach 1:
The patent modifies the chemical composition parameters of the aromatic polyester polyol by incorporating specific ratios of glycols (diethylene glycol, triethylene glycol, tetraethylene glycol), dicarboxylic acids (terephthalic acid, phthalic anhydride), and natural oils (corn oil, soybean oil, cottonseed oil) to achieve at least 25% cyclo pentane solubility while maintaining hydroxyl number of 150 or higher
Solution Approach 2:
The patent creates a composite polyol system combining multiple components: aromatic polyester base polymer, glycols, dicarboxylic acids, and natural oils in specific proportions to achieve both high pentane solubility and desired physical properties for low-density foam production
2Stability of the object's composition
If existing methods increase pentane solubility, then separation issues are reduced, but the cost increases or physical properties are compromised
Solution Approach 1:
The patent optimizes the composition parameters by controlling the hydroxyl number (≥150) and incorporating natural oils (≤25 wt%) with specific fatty acid compositions to achieve high pentane solubility while maintaining cost-effectiveness and desired physical properties
Solution Approach 2:
The patent applies different functional components to specific purposes: glycols and dicarboxylic acids provide the polyester backbone with controlled solubility, while natural oils provide hydrophobicity and pentane solubility, creating a multi-functional composite material
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 approach results in a polyol with improved pentane solubility and viscosity, enabling the production of high-quality, low-density polyurethane foams with enhanced physical properties and cost-effectiveness.
Implementation Method 1
a polyol with improved pentane solubility
Data Source
AI summary
Methods and compositions for forming polyurethane foam. A method for manufacturing an aromatic polyester polyol comprises heating a glycol, a dicarboxylic acid or ester, functionality enhancing agent, and a natural oil to about 480° F. to form a reaction product, allowing the reaction product to cool to about 140° F., and adding additional glycol to form an aromatic polyester polyol composition, wherein the total glycol comprises less than about 36 weight percent of the polyol composition. An aromatic polyester polyol composition comprises a glycol, a dicarboxylic acid or ester, functionality enhancing agent, and a natural oil, wherein the total glycol comprises less than about 36 weight percent of the aromatic polyester polyol composition. An aromatic polyester polyol composition comprising a cyclopentane solubility of at least about 25 percent, a hydroxyl number of at least about 150, the natural oil comprising less than about 25 weight percent, and/or the dicarboxylic acid or ester comprising more than about 29 weight percent of the polyol composition.