Polyurethane Foam Production Using Recycled Polyol

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Solution Overview

Problem

Existing methods for producing polyurethane foams using recycled polyols often result in a deterioration of foam quality, especially when large amounts of recycled materials are used, limiting their recyclability and practical application.

Innovation Solution

A process for producing polyurethane foams by reacting a polyol component, an isocyanate component, catalysts, foam stabilizers, and optional blowing agents, where the polyol component comprises a high proportion of recycled polyol, obtained through depolymerization processes like hydrolysis, glycolysis, or acidolysis, ensuring quality comparable to foams made with conventional polyols.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If large amounts of recycled polyol are used in PU foam production, then the proportion of recycled raw materials increases, but the quality of the resulting foams deteriorates

Engineering Contradiction:

Improveproportion of recycled polyolVSAvoidquality of PU foam

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by carefully controlling the molecular weight distribution, OH number, and viscosity of the recycled polyol to optimize foam quality. By adjusting these parameters within specific ranges and using multiple recycled polyols with different characteristics in combination, the invention achieves high recycled content while maintaining foam performance comparable to conventional polyols

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite materials by combining multiple recycled polyols with different molecular weights and properties, as well as blending recycled polyol with conventional polyol in specific ratios. This composite approach allows the system to achieve both high recycled content and consistent foam quality that would not be possible with a single recycled polyol source

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If recycled polyol is used in PU foam production, then recyclability of polyurethane foams increases, but the mechanical and physical properties of the foams deteriorate

Engineering Contradiction:

Improverecyclability of PU foamVSAvoidmechanical and physical properties of foam

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent maintains foam strength and mechanical properties by precisely controlling key parameters of the recycled polyol including molecular weight (500-15000 g/mol), OH number (10-1200 mg KOH/g), and viscosity. These parameter specifications ensure that the recycled polyol performs adequately in the foam reaction while maximizing recyclability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies local quality by selecting and combining recycled polyols with specific local characteristics - different molecular weights, OH numbers, and viscosity profiles - to achieve uniform overall foam performance. Each recycled polyol component contributes specific properties that complement the others, ensuring consistent mechanical and physical properties throughout the foam structure

Inventive Principle:

Principle #3Local quality

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

Enables the production of polyurethane foams with quality equivalent to those made with conventional polyols, even when using high percentages of recycled polyol, significantly increasing the recyclability of polyurethane foams and reducing waste.

Implementation Method 1

reacting (a) at least one polyol component, (b) at least one isocyanate component

Methodology Applied

Scientific EffectIsocyanate-polyol reaction: Chemical Bonding

Implementation Method 2

catalyse the isocyanate-polyol and/or isocyanate-water reactions

Methodology Applied

Scientific EffectIsocyanate-water reaction: Chemical Bonding

Implementation Method 3

one or more catalysts that catalyse the isocyanate-polyol and/or isocyanate-water reactions

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

at least one foam stabilizer

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Implementation Method 5

one or more chemical or physical blowing agents

Methodology Applied

Scientific EffectGas evolution:

Data Source

PatentUS20240368333A1Production of PU foams using recycled polyols

Publication Date: 2024.11.07 EVONIK OPERATIONS GMBH

AI summary

A process for producing polyurethane foams includes reacting at least one polyol component with at least one isocyanate component in the presence of one or more catalysts that catalyse the isocyanate-polyol and/or isocyanate-water and/or isocyanate trimerization reactions, at least one foam stabilizer and optionally one or more chemical or physical blowing agents. The polyol component includes recycled polyol.