# US 11,608,495 B2 · Biodegradable polyester-based polyurethane foams

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- Number: US 11,608,495 B2
- Document ID: US11608495B2
- Status: Granted
- Kind: B2
- Application number: 17/546,433
- Filed: 2021-12-09
- Published: 2022-03-31
- Granted: 2023-03-21
- Earliest claimed: 2019-11-29
- Assignees: Evoco Limited
- Applicants: Evoco Ltd.
- Inventors: Jason James Robinson; Natalie Beth Ashdown; Gregory Allan Whitton
- Web page: https://patentgrep.com/patent/US11608495B2

## CPC

- C12N 11/093: Polyurethanes
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/22: containing metal compounds
- C08G 18/4238: {derived from dicarboxylic acids and dialcohols}
- C08G 18/6633: {Compounds of group C08G18/42}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08K 11/00: Use of ingredients of unknown constitution, e.g. undefined reaction products
- C08L 75/06: from polyesters
- C08L 101/16: the macromolecular compounds being biodegradable
- C12N 1/20: Bacteria; Culture media therefor
- C12N 11/04: entrapped within the carrier, e.g. gel or hollow fibres
- C12N 11/08: the carrier being a synthetic polymer
- C12N 11/098: formed in the presence of the enzymes or microbial cells
- C12N 11/14: Enzymes or microbial cells immobilised on or in an inorganic carrier
- C08G 2101/00: Manufacture of cellular products
- C08G 2110/0008: flexible
- C08G 2110/0041: having specified density
- C08G 2110/005: < 50kg/m3
- C08G 2110/0058: ≥50 and <150kg/m3
- C08G 2110/0066: ≥ 150kg/m3
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08G 2230/00: Compositions for preparing biodegradable polymers
- C12R 2001/07: Bacillus
- C12N: MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA (microbiological testing media C12Q1/00)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C12R: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES C12C - C12Q, RELATING TO MICROORGANISMS

## Abstract

A biodegradable foam which includes a poly-ester-based polyurethane foam and a mixture comprised of a soil-dwelling carbon-digesting bacteria embedded in a carrier compound. The mixture of the soil-dwelling carbon-digesting bacteria is homogenously dispersed throughout the polyester-based polyurethane foam. This biodegradable foam exhibits biodegradation rates higher than a polyester-based polyurethane foam absent the soil-dwelling carbon-digesting bacteria.

## Claims

### Claim 1

A biodegradable foam, comprising:
a) polyester-based polyurethane foam; and
b) a soil-dwelling carbon-digesting bacteria, or a mixture comprised of a soil-dwelling carbon-digesting bacteria embedded in a carrier compound, said soil-dwelling carbon-digesting bacteria or mixture substantially homogeneously dispersed throughout said polyester-based polyurethane foam, said polyester-based polyurethane foam containing said soil-dwelling carbon-digesting bacteria characterized in that it exhibits biodegradation rates higher than the same polyester-based polyurethane foam absent the soil-dwelling carbon-digesting bacteria.

### Claim 2 (depends on 1)

The biodegradable foam according to claim 1, wherein said soil-dwelling carbon-digesting bacteria comprises at least one strain of the genus Bacillus.

### Claim 3 (depends on 1)

The biodegradable foam according to claim 1, wherein said soil-dwelling carbon-digesting bacteria is Bacillus subtilus, Bacillus pumilus, Bacillus licheniformis, Bacillus megaterium, Bacillus cerus, Bacillus alvei, Bacillus coagulans, Bacillus simplex, Bacillus brevis, or Bacillus amyloliquefaciens.

### Claim 4 (depends on 1)

The biodegradable foam according to claim 1, wherein said carrier compound is Calcium carbonate, Sodium Bicarbonate or Zeolite.

### Claim 5 (depends on 1)

The biodegradable foam according to claim 1, wherein said soil-dwelling carbon-digesting bacteria is present in the carrier compound in an amount of at least 0.001 wt % of said mixture.

### Claim 6 (depends on 1)

The biodegradable foam according to claim 1, wherein said soil-dwelling carbon-digesting bacteria embedded in a carrier compound is present in said polyester-based polyurethane foam, in a range from about 0.0001 wt % to about 25.0 wt % of the total foam.

### Claim 7 (depends on 1)

The biodegradable foam according to claim 1, wherein said soil-dwelling carbon-digesting bacteria embedded in a carrier compound is present in said polyester-based polyurethane foam, in a range from about 0.01 to about 0.5 wt % of the total foam.

### Claim 8 (depends on 1)

The biodegradable foam according to claim 1, characterized by a tensile modulus in a range from about 5.0 kg/cm2 to about 100 kg/cm2.

### Claim 9 (depends on 1)

The biodegradable foam according to claim 1, characterized by a density in a range from about 5 kg/m3 to about 1000 kg/m3.

### Claim 10 (depends on 1)

The biodegradable foam according to claim 1, characterized by an elongation at break in a range from about 15 to about 700%.

### Claim 11 (depends on 1)

The biodegradable foam according to claim 1, having a percent modern carbon in a range from about 0 to about 100%.

### Claim 12 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11)

The biodegradable foam as in any one of claims 1 to 11, characterized in that it has a modulus equal to or greater than 50 kg/cm2.

### Claim 13 (depends on 1)

A method of producing a biodegradable foam according to claim 1, comprising:
a) mixing polyester polyol with
i) one or more catalysts,
ii) water and
iii) soil-dwelling carbon-digesting bacteria, or a soil-dwelling carbon-digesting bacteria embedded in a carrier compound,
to produce a mixture, and
b) mixing isocyanate into said mixture to induce a chemical reaction between the isocyanate and the water to produce carbon dioxide gas, and simultaneously induce a chemical reaction between the isocyanate and the polyester polyol to produce a polyester based polyurethane polymer with carbon dioxide bubbles trapped within to produce said biodegradable polyester-based polyurethane foam, said biodegradable polyester-based polyurethane foam characterized in that it exhibits biodegradation rates which are higher than the same polyester-based polyurethane foam absent the soil-dwelling carbon-digesting bacteria.

### Claim 14 (depends on 13)

The method according to claim 13, wherein said carrier compound is calcium carbonate, zeolite, or sodium bicarbonate.

### Claim 15 (depends on 13)

The method according to claim 13, wherein said soil-dwelling carbon-digesting bacteria embedded in the carrier compound is present in said mixture in a range from about 0.001 to about 10.0 wt % of the total foam.

### Claim 16 (depends on 13)

The method according to claim 13, wherein said isocyanate is 4,4′-Methylene diphenyl diisocyanate, 2,4-Methylene diphenyl diisocyanate, 2,2′-Methylene diphenyl diisocyanate, 2,4-Toluene diisocyanate, 2,6-Toluene diisocyanate, polymeric methylene diphenyl diisocyanate, or carbodiimide-modified methylene diphenyl diisocyanate.

### Claim 17 (depends on 13)

The method according to claim 13, wherein the one or more catalysts are selected to catalyze the reaction between isocyanate and water and simultaneously between isocyanate and polyester polyol.

### Claim 18 (depends on 13)

The method according to claim 13, wherein said one or more catalysts are a tertiary amine catalyst.

### Claim 19 (depends on 13)

The method according to claim 13, wherein said one or more catalysts are triethylenediamine, N-methylmorpholine, N-methylimidazole, bis(dimethylaminopropyl)amine, dimethylaminoethoxyethanol, Bis-(2-diemthylaminoethyl)-ether, dimethylaminopropylurea, N-dimethylaminopropyl-N-(2-hydroxyethyl)-N-methylamine, or N-dimethylaminoethyl-N-(2-hydroxyethyl)-N-methylamine.

### Claim 20 (depends on 13)

The method according to claim 13, wherein said one or more catalysts are dibutyltin dilaurate, Tin(II) 2-ethylhexanoate bismuth neodecanoate, potassium octoate, potassium acetate, zinc carboxylates, or nickel carboxylates.

### Claim 21 (depends on 13)

The method according to claim 13, wherein said soil-dwelling carbon-digesting bacteria comprises at least one strain of the genus Bacillus.

### Claim 22 (depends on 13)

The method according to claim 13, wherein said soil-dwelling carbon-digesting bacteria is Bacillus subtilus, Bacillus pumilus, Bacillus licheniformis, Bacillus megaterium, Bacillus cerus, Bacillus alvei, Bacillus coagulans, Bacillus simplex, Bacillus brevis, or Bacillus amyloliquefaciens.

### Claim 23 (depends on 13)

The method according to claim 13, further including mixing into said mixture surfactants, plasticizers and chain extenders.

### Claim 24 (depends on 13)

The method according to claim 13, further including mixing into said mixture flame retardants, anti-oxidants, cell openers, emulsifiers, hardening agents, non-functional fillers, cross-linking agents, dyes, pigments, or other hydroxy or amine functionalized materials.

### Claim 25 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a modulus in a range from about 2 kg/cm2 to about 100 kg/cm2.

### Claim 26 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a density in a range from about 5 kg/m3 to about 1000 kg/m3.

### Claim 27 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having an elongation at break in a range from about 15 to about 700%.

### Claim 28 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a percent modern carbon in a range from about 0 to about 100%.

### Claim 29 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having an isocyanate index in a range from about 70 to about 200.

### Claim 30 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having an average isocyanate functionality in a range from about 2.0 to about 6.0.

### Claim 31 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a polyester polyol molecular weight in a range from about 500 to about 5000 g/mol.

### Claim 32 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a polyester polyol average hydroxyl functionality in a range from about 1.1 to about 6.0.

### Claim 33 (depends on 13)

The method according to claim 13, wherein said biodegradable polyurethane foam is characterized by having a polyester polyol hydroxyl number in a range from about 20 to about 300 mg KOH/g polyol.