Polyurethane Waste Aminolysis for Reliable Polyol Separation
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Solution Overview
Problem
Existing recycling processes for polyurethanes, polyurethane ureas, and polyisocyanurates face challenges in the separation of polyols from isocyanate derivatives, which are often contaminated and limited in applicability.
Innovation Solution
A process involving aminolysis reaction followed by cleavage and purification to separate polyurea-containing compounds and polyols, using primary amines and catalysts to produce polymers like polyurethanes, polyurethane ureas, and polyisocyanurates from waste materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phase decay separation is used to separate polyols from isocyanate derivatives, then separation is achieved for selected polyurethanes, but the process fails due to contamination in waste material and has limited applicability
Solution Approach 1:
The patent introduces an amine as an intermediary substance that reacts with polyisocyanates to form polyurea compounds. This intermediary reaction enables selective separation of polyols from contaminated waste materials by converting isocyanate-containing components into separable polyurea compounds, thereby resolving the limitation of direct phase decay separation methods that fail with contaminated materials
Solution Approach 2:
The patent changes the chemical state of isocyanate derivatives by reacting them with amines to form polyurea compounds. This parameter change (from isocyanate group to polyurea compound) enables effective separation and purification, expanding the method's applicability to various contaminated waste materials while maintaining high separation reliability
2Reliability
If recycling processes are limited to selected polyurethanes, then separation is more controllable, but the quantity of recyclable material is reduced
Solution Approach 1:
The patent creates a universal recycling method that can handle various types of polyurethane waste materials including flexible foams, rigid foams, elastomers, and coatings. The amine-based approach serves multiple functions: it reacts with different isocyanate derivatives, forms separable polyurea compounds, and enables purification of polyols from diverse contaminated sources, thereby increasing the quantity of recyclable material while maintaining separation control
3Device complexity
If direct separation of polyols from isocyanate derivatives is attempted, then the process is simpler, but contamination reduces separation effectiveness
Solution Approach 1:
The patent applies preliminary action by first reacting amines with polyisocyanates to form polyurea compounds before attempting separation. This preliminary chemical transformation simplifies the subsequent separation process while ensuring high purity, as the polyurea compounds can be easily separated from polyols through filtration or decantation, thereby achieving both process simplicity and high separation purity
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 process effectively separates and recycles polyols and isocyanates from contaminated waste, enabling the production of high-purity polymers, overcoming limitations of prior methods.
Implementation Method 1
subjecting the mixture obtained according to (i.2) in RA to aminolysis reaction conditions, obtaining a mixture M comprising one or more polyurea-containing compounds, and further comprising one or more polyols
Implementation Method 2
subjecting the mixture U obtained according to (ii) to cleavage reaction conditions in a reactor unit RC, obtaining either one or more corresponding polyamines or one or more corresponding polyisocyanates
Data Source
AI summary
The present invention relates to a process for producing one or more polymers, selected from the group consisting of polyurethanes, polyurethane ureas, polyisocyanurates, and a mixture of two or more thereof, from a solid material W.