Polyurethane Aerogels from Recycled Polyols
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Solution Overview
Problem
Existing methods for producing polyurethane foams and aerogels rely on petrochemical starting materials, which are unsustainable due to resource scarcity and environmental pollution. Additionally, recycling of polyurethanes is limited by the contamination and heterogeneity of recycled polyols, restricting their application in producing high-quality foams and aerogels.
Innovation Solution
A method for producing polyurethane foams and aerogels using recycled polyols obtained from contaminated and unsorted plastic waste, such as disposed mattresses or production waste, through processes like glycolysis. The method involves mixing recycled polyols with solvents, adding polyisocyanates, forming a gel, and removing solvents to produce high-quality foams with specific porosity and thermal conductivity characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If recycled polyols from contaminated and unsorted plastic waste are used, then sustainability and resource efficiency are improved, but the quality and homogeneity of the polyurethane foam deteriorate due to contamination and heterogeneity
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the recycled polyol through controlled degradation processes (glycolysis, alcoholysis, or aminolysis). These processes convert contaminated polyurethane waste into recycled polyols with specific OH numbers, viscosities, and molecular weight distributions that are suitable for foam production, thereby transforming the quality parameters to resolve the contradiction between using recycled materials and maintaining foam quality
Solution Approach 2:
The patent uses composite materials by combining recycled polyols with fresh polyols or other additives in specific ratios. This composite approach allows the recycled component to contribute to sustainability while the fresh components compensate for heterogeneity and contamination issues, achieving both environmental benefits and consistent foam quality
2Adaptability or versatility
If glycolysis or other degradation processes are used to obtain recycled polyols, then the availability of alternative educts is improved, but the process complexity and production cost increase
Solution Approach 1:
The patent applies self-service by designing degradation processes where the recycled polyol production is integrated into the foam manufacturing process itself. The glycolysis or alcoholysis reactions are performed in-reactors that are then directly used for foam production, eliminating separate purification and processing steps, thereby reducing overall process complexity while maintaining alternative educt availability
Solution Approach 2:
The patent achieves universality by developing a multi-functional process that can handle various types of polyurethane waste (foams, fibers, coatings) and convert them into suitable recycled polyols using the same degradation methodology. This universal approach simplifies the overall process infrastructure compared to having separate processing lines for different waste types
3Loss of substance
If recycled polyols with high viscosity and heterogeneity are used, then the utilization of waste materials is improved, but the workability and processing ease deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the degradation conditions (temperature, time, catalyst, solvent ratio) to produce recycled polyols with optimized viscosity and molecular weight distributions. By adjusting these parameters, the recycled polyols achieve workable viscosity ranges despite originating from heterogeneous waste materials, thus maintaining both waste utilization and processing ease
Solution Approach 2:
The patent uses intermediaries such as solvents (glycols, alcohols, amines) and catalysts to mediate between the heterogeneous recycled polyol and the foam processing system. These intermediaries facilitate uniform mixing, control reaction rates, and ensure consistent foaming behavior despite the inherent heterogeneity of the recycled 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 method enables the production of high-quality polyurethane foams and aerogels with desired porosity, thermal conductivity, and surface area, effectively utilizing recycled materials and reducing environmental impact.
Implementation Method 1
adding at least one polyisocyanate and optionally at least one adjuvant to the mixture obtained in step (i) or (ii), (iv) forming a gel from the mixture obtained in step (iii)
Implementation Method 2
at least partially removing the at least one solvent L1 and/or L2
Implementation Method 3
at least partially removing the at least one solvent L1 and/or L2
Data Source
AI summary
The present invention relates to a method for preparing a polyurethane foam, in particular an aerogel, from at least one polyisocyanate and at least one optionally recycled polyol, and to the use thereof.