Bio-based polyols as replacements for petrochemical polyols for viscoelastic polyurethane foams

Technological Overview

A Polish research organisation has developed a group of bio-based polyols designed as sustainable alternatives to petrochemical polyols used in the production of viscoelastic polyurethane foams.

The polyols are based on polycarboxylate ethers (PCEs), which are high-molecular-weight organic compounds with a complex three-dimensional macromolecular architecture, such as comb-shaped or star-shaped structures. The functionalised PCEs carry terminal hydroxyl groups, which allows them to easily replace commercial polyols. Owing to their branched structure, the PCEs are also chemically versatile and offer potential for further structural modification, depending on the target application.

The PCEs are obtained in a precisely controlled, one-pot synthesis using bio-based raw materials. The synthesis allows the chemical composition and the molecular weight to be adjusted in a wide range of 5–120 kDa, depending on the requirements of a given application.

The bio-based PCEs enable up to 100% substitution of conventional petrochemical polyols in the production of polyurethane foams. The resulting materials show performance and properties comparable to their traditional petrochemical equivalents, which supports the development of safe-and-sustainable-by-design PU materials with a reduced dependence on fossil-based raw materials.

Advantages and innovations

The proposed technology offers the following advantages and innovative aspects:

• tailor-made bio-based alternative to petrochemical polyols, supporting the transition towards sustainable and circular polymer materials;

• up to 100% substitution of petrochemical polyols in the production of viscoelastic polyurethane foams;

• polyurethanes with properties comparable to their petrochemical counterparts;

• terminal hydroxyl groups enabling direct use as polyols in polyurethane chemistry;

• high density of functional groups due to the branched structure, resulting in enhanced chemical reactivity;

• chemical versatility and potential for further structural modification depending on the target application;

• laboratory-scale and synthesis scale-up up to 100 kg per batch;

• suitability for further laboratory and pilot-scale validation and technology transfer towards industrial applications.

Our Organization

Poznan Science and Technology Park (PPNT) is the first science and technology park in Poland, established in 1995 and operating within the Adam Mickiewicz University Foundation. We bridge the gap between academic breakthroughs and industrial application. As a research and technology organisation, we work in organic chemistry, advanced materials development and agrochemistry.

Our expertise includes:

• Design and synthesis of bio-based polyols: tailor-made polyols based on PCE, with tuning of molecular weight, architecture and chemical composition to the requirements of the PU system.

• Application-oriented formulation: formulation and optimisation of viscoelastic polyurethane foams with partial or full replacement of petrochemical polyols.

• Basic material characterization: of obtained polyols and of the resulting foams.

• Scale-up excellence: laboratory-scale synthesis and scale-up of production up to 100 kg per batch.

• SSbD contribution: support for safe-and-sustainable-by-design polymer development and for technology transfer towards industrial applications.

• Validation: support in laboratory- and pilot-scale validation.

• Science dissemination and popularization: organizing conferences, workshops and trade fairs.

Collaboration

We are looking for projects to join as research institution and consortium partner.