Silicone Polyether Block Copolymers for Stable Polyurethane Foams
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Solution Overview
Problem
The existing polyurethane foam stabilizers face challenges due to raw material-related fluctuations in hydrophilic, lipophilic, and siliconophilic components, leading to poor compatibility with the reacting polyurethane matrix, which can result in foam collapse and limited universal usability across different formulations.
Innovation Solution
The development of silicone polyether block copolymers with specific molecular weight distributions and polydispersity ratios, produced using double metal cyanide catalysts, which allows for a broader range of processing capabilities and improved compatibility with polyurethane matrices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polysiloxane-polyoxyalkylene block copolymers with varying molecular weights and compositions are used as stabilizers, then foam stabilization performance is improved, but raw material fluctuations cause poor compatibility with polyurethane matrix leading to foam collapse
Solution Approach 1:
The patent applies parameter changes by precisely controlling the molecular weight distribution (polydispersity index between 1.05-2.00) and composition ratios of polyoxyalkylene blocks. This controlled variation in parameters allows the stabilizer to maintain both high foam stabilization performance and consistent compatibility with the polyurethane matrix, resolving the contradiction between performance improvement and compositional stability.
Solution Approach 2:
The patent uses composite materials by creating block copolymers with specific combinations of hydroxy-functional polyoxyalkylene blocks and end-capped polyoxyalkylene blocks. This composite structure integrates different functional segments that provide both foam stabilization capability and matrix compatibility, solving the contradiction between these two requirements.
2Reliability
If polyether siloxanes of different structures are used for different rigid foam formulations, then cell stabilization is optimized, but the complexity of selecting and developing stabilizers for each application increases
Solution Approach 1:
The patent applies universality by designing block copolymers with adjustable polydispersity and composition that can function across multiple foam types (flexible and rigid). The controlled molecular weight distribution and block composition enable a single stabilizer system to provide effective cell stabilization for different foam formulations, reducing the need for application-specific stabilizer development.
Solution Approach 2:
The patent uses parameter changes to create a versatile stabilizer platform where the polydispersity index and block composition can be adjusted to match different foam formulation requirements. This systematic parameter control allows one stabilizer family to serve multiple applications, simplifying the selection and development process while maintaining optimized cell stabilization performance.
3Object-affected harmful factors
If carbon dioxide is used as an environmentally friendly blowing agent, then environmental compatibility is improved, but the requirements for stabilizer performance and compatibility become more stringent
Solution Approach 1:
The patent applies parameter changes by optimizing the molecular weight distribution and block composition of the stabilizer specifically for use with carbon dioxide as a blowing agent. The controlled polydispersity and block ratios enhance the stabilizer's ability to work effectively with CO2, meeting the more stringent performance and compatibility requirements while maintaining environmental compatibility.
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
These silicone polyether block copolymers provide enhanced stability and processability, enabling the production of polyurethane foams with consistent properties across various formulations, including hot flexible foams, and offer improved cell structure and thermal insulation performance.
Implementation Method 1
produced using double metal cyanide catalysts
Implementation Method 2
silicone surfactants are mostly used due to their higher interface stabilization potential
Implementation Method 3
thermal insulation capacity
Data Source
AI summary
Silicon polyether block-copolymer (I) obtained by organomodification of linear/branched polysiloxane with terminal and/or side silicon-hydride functions with polyether and/or polyether mixture, is claimed, where the polyether has a polydispersity (weight average molecular weight (M w)/number average molecular weight (M n)) of 1-1.5. Silicon polyether block-copolymer of formula (R 1-Si(R) 2-O-(Si(R) 2-O) n-(Si(R)(R 3)-O) m-(Si(R 2)(O-(Si(R) 2) n 1-O-(Si(R)(R 3)) m 1-O-Si(R) 2(R 1))) k-Si(R) 2(R 1)) (I) obtained by organomodification of linear/branched polysiloxane with terminal and/or side silicon-hydride functions with polyether and/or polyether mixture, is claimed, where the polyether has a polydispersity (weight average molecular weight (M w)/number average molecular weight (M n)) of 1-1.5. R : cyclic, aliphatic or aromatic, optionally saturated 1-20C-hydrocarbon, preferably CH 3; either n, n1 : 0-500; or n+n1 : less than 500; either m, m1 : 0-60; or m+m1 : less than 600; k : 0-50; R 1R or R 3; R 2R, or functionalized, organic, optionally saturated residue, which is substituted by a heteroatom, preferably alkyl (preferably CH 3), chloroalkyl (preferably chloropropyl), chloroaryl, fluoroalkyl, cyanoalkyl, acryloxyaryl, acryloxyalkyl, methacryloxyalkyl (preferably methacryloxypropyl), methacryloxypropyl or vinyl; R 3R, CH 2-CH 2-CH 2-O-(CH 2-CH 2O-) x-(CH 2-CH(R1aO-)) y-(SO) z-R2a, CH 2-CH 2-O-(CH 2-CH 2O-) x-(CH 2-CH (R1a)O-) y-R2a, CH 2-R 4, CH 2-CH 2-(O) x 1-R 4, CH 2-CH 2-CH 2-O-CH 2-CH (OH)-CH 2OH, 2-propoxymethyl-oxirane or CH 2-CH 2-CH 2-O-CH 2-C(CH 2OH) 2-CH 2-CH 3; x, y, z : 0-100; x1 : 0 or 1; R1a : 1-12C-alkyl or aryl optionally substituted with alkyl, aryl, haloalkyl or haloaryl; R2a : H, 1-4C-alkyl or -C(O)-R3a; R3a : alkyl, -CH 2-O-R1a, alkylaryl e.g. benzyl group, or -C(O)NH-R1a; R 41-50C-hydrocarbon optionally substituted with halo; and SO : styrene oxide residue, provided that at least one substituent of R 1-R 3 is not R and at least a substituent of R 1-R 3 is polyether. Where k is greater than 0 and R 1 is not equal to R. Independent claims are included for: (1) a composition or a mixture of (I) and a mixture of foam stabilizer with further additives, such as nucleating agents, cell refining additives, cell openers, crosslinkers, emulsifiers, flame protective agents, antioxidants, antistatics, biocides, color pastes, solid fillers, amine catalyst, metal catalyst and/or buffer substance; (2) a composition comprising one or more polyurethane foam stabilizer with the further additives; and (3) a composition comprising (I) and solvents, preferably glycol, alkoxylate, carbonate, ether, ester, aliphatic or aromatic hydrocarbon, or an oil form synthetic and/or natural origin.