Recycled Polyol Foam Quality via Polydispersity Control
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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 high amounts are used, due to varying polydispersity levels.
Innovation Solution
A process for producing polyurethane foams using recycled polyols with a polydispersity of less than 2, preferably less than 1.5, in combination with isocyanate components, catalysts, foam stabilizers, and blowing agents, allowing for high proportions of recycled polyols without compromising foam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If high amounts of recycled polyols are used in PU foam production, then the proportion of recycled raw materials increases, but the quality of the resulting foams deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the polydispersity of recycled polyols to be less than 2 (preferably less than 1.5). This parameter control enables the use of high proportions of recycled polyols (more than 30%, preferably more than 50%, further preferably more than 70%, in particular more than 95% by weight) while maintaining foam quality comparable to conventional polyols.
2Adaptability or versatility
If recycled polyols with varying polydispersity levels are used, then the availability of recycled materials increases, but the consistency and quality of foam products deteriorates
Solution Approach 1:
The patent establishes a specific parameter threshold for polydispersity (D < 2, preferably D < 1.5) to ensure composition stability. This parameter control allows the system to accommodate recycled polyols from various sources while maintaining consistent foam quality, thereby achieving both adaptability and stability.
3Ease of repair
If conventional recycling processes are used to produce recycled polyols, then the recycling of polyurethane waste is enabled, but the quality of resulting polyols varies and compromises foam quality
Solution Approach 1:
The patent introduces a critical parameter threshold (polydispersity < 2) that transforms the recycling process from producing variable-quality polyols to producing consistent, high-quality recycled polyols. This enables extensive recyclability (more than 95% recycled content) while maintaining manufacturing precision comparable to conventional polyols.
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 comparable to those made from conventional polyols, even with high percentages of recycled polyols, thereby increasing the recyclability of polyurethane foams and maintaining foam quality.
Implementation Method 1
one or more catalysts that catalyse the isocyanate-polyol and/or isocyanate-water and/or isocyanate trimerization reactions
Implementation Method 2
one or more chemical or physical blowing agents
Data Source
AI summary
A process for producing polyurethane foams is developed by reacting at least one polyol component that includes recycled polyol 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 polydispersity of the respective recycled polyol is <2. A composition is made that is suitable for production of a polyurethane foam, including at least one polyol component, at least one isocyanate component, a catalyst, a foam stabilizer, a blowing agent and optionally auxiliaries. The at least one polyol component includes a recycled polyol with a polydispersity of <2. A polyurethane foam is made using the above process, and a process is developed for manufacturing goods that include the polyurethane foam.