JP6584423B2 - Polyurethane adhesive for reverse osmosis module - Google Patents

Description

  The present invention generally relates to polyurethane adhesives. More specifically, the present invention relates to polyurethane adhesives used to manufacture reverse osmosis (RO) modules.

  Reverse osmosis is the process of pushing solvent through a semipermeable membrane from a high solute concentration region to a low solute concentration region. This process is performed by applying a pressure above the osmotic pressure. Reverse osmosis is the separation of pure water from seawater or brackish water, where seawater or brackish water is pressurized against one surface of the membrane, causing the transfer of salt-depleted water across the membrane and the generation of potable drinking water from the low pressure side. It has a number of uses, including but not limited to. Other uses of reverse osmosis include the concentration of food liquids such as orange juice, the production of maple syrup, and the production of hydrogen.

  There are typically two types of semipermeable membrane arrangements used for reverse osmosis: a spiral cartridge and a hollow core. The membrane has a dense layer in the polymer matrix where solute separation from the solvent occurs. In most cases, the membrane is designed to allow only a solvent (such as water) to pass through this dense layer while preventing the passage of solutes (such as salt ions). As discussed in U.S. Pat. No. 4,842,736, the spiral cartridge includes an adhesive for sealing gaps or voids in the membrane, which provides fluid to the permeate collection tube Prevent leakage. In certain instances, such as those discussed in US Pat. No. 7,303,675, the adhesive may be used to treat the upstream surface of the membrane material where the downstream surface is prevented from flowing therethrough. Can be applied to. The adhesive can be applied to other locations of the membrane material as required by the structure and / or application in which the membrane is utilized, such as folds in the membrane along the longitudinal edges, downstream surfaces, etc.

  Because the cartridge is subjected to high water pressure, a fully cured adhesive must be strong and durable. If the hardness of the fully cured adhesive is too low, the water pressure can cause broken adhesive bonds and ultimately broken cartridges. However, if the hardness of a fully cured adhesive is too high, the adhesive can become brittle and also cause failure. The hardness of the adhesive can be measured on a Shore hardness scale, and methods for obtaining such measurement results are known in the art. It is further pointed out that the tensile strength of the fully cured adhesive is used as a measure of the adhesive's suitability in the reverse osmosis module. One skilled in the art will appreciate that an additional property of a good adhesive is the ability of the adhesive to penetrate the membrane material to establish a sufficient adhesive bond.

  As pointed out in US Pat. No. 7,303,675, the adhesive can crack or blister over time and through the use of traditionally used cleaning fluids. (Often referred to as “permeable blister formation”), resulting in side seal leaks and end seal leaks in the feed fluid to the permeate collection tube (often with “baining” or “lightning bolt” breakage) It has been found to bring about. Osmotic blister formation can also promote bacterial growth and also cause membrane dimensional changes, making removal and replacement difficult. Osmotic blister formation is amplified, for example, by the use of an alkaline cleaning fluid such as sodium hydroxide solution that is frequently used in the industry. Thus, there is a need for improved adhesive compositions that have increased or improved resistance to alkaline fluids while retaining the performance requirements set forth above.

The present invention is believed to be a solution to the need to provide an adhesive that is durable and resistant to alkaline fluids in reverse osmosis applications.

  The adhesive composition of the present invention surprisingly reduces or eliminates the permeable blister formation and baining and lightning bolt breakage often exhibited by known adhesive compositions. The adhesive composition of the present invention also minimizes the width of bond lines used in reverse osmosis module applications while demonstrating improved rheology, viscosity and flow control compared to known adhesive compositions. .

  In one aspect, the invention is an adhesive composition suitable for a reverse osmosis module comprising (I) a polyurethane composition of about 65 wt% to 99 wt% based on the total wt% of the adhesive composition. (A) (i) castor oil or a derivative thereof; and (ii) a polyisocyanate; and (iii) an isocyanate group-containing prepolymer optionally comprising a reaction product of a second polyol; and (B) ( (ii) based on the total weight percent of the adhesive composition; i) a polybutadiene polyol; and (ii) a urethane catalyst; and (iii) an isocyanate-reactive polyol mixture optionally containing a second polyol; And about 1% to about 35% by weight plasticizer, and is essentially free of diluent oil and solvent.

  A further aspect of the invention is an adhesive composition suitable for a reverse osmosis module, wherein (I) about 65% to about 99% by weight polyurethane composition, based on the total weight% of the adhesive composition. Wherein the polyurethane composition comprises (A) (i) castor oil or a derivative thereof; and (ii) an isocyanate group-containing prepolymer comprising a reaction product of a polyisocyanate; and (B) (i) a polybutadiene polyol; (Ii) a urethane catalyst; and (iii) a polyurethane composition comprising an isocyanate-reactive polyol mixture comprising a second polyol; and (II) from about 1% to about 35% by weight, based on the total weight percent of the adhesive composition. % Of plasticizer, essentially free of diluent oil and solvent, and the adhesive composition should have a low tensile strength when fully cured. Is 1,000 psi, and a Shore hardness of the adhesive composition when fully cured is approximately 35D~ about 75D, relates to an adhesive composition.

  A further aspect of the invention relates to a reverse osmosis module comprising an adhesive composition according to any of the adhesive compositions described herein.

  Furthermore, a further aspect of the invention is a method of constructing a reverse osmosis module, wherein at least a portion of the membrane present in the reverse osmosis module is bonded to any of the adhesive compositions described herein. It relates to a method comprising the step of applying a composition.

  These and other aspects are discussed in more detail herein.

It is a perspective view of the reverse osmosis module which has a film | membrane of the state to which the adhesive composition was applied.

In general, the present invention relates to an adhesive composition comprising a polyurethane composition and a plasticizer. The adhesive composition is essentially free of diluent oil and solvent. The term “essentially free” as used herein means that the composition contains an inevitable level, but no more. Diluent oil and solvent are not part of the adhesive composition, and the term “diluent oil and solvent” means a composition that does not include a polyurethane adhesive, ie, they are polyisocyanate and It does not react and includes, but is not limited to, hydrocarbons such as petroleum spirit, kerosene, mineral oil and corn oil, rapeseed oil, and olive oil. The adhesive composition can be used, for example, in a reverse osmosis module, and the inventors surprisingly found that the adhesive composition according to embodiments herein has permeable blister formation and leakage in the reverse osmosis module. Has been found to be reduced or eliminated.

  The adhesive composition includes a two-part polyurethane composition (hereinafter referred to as “polyurethane composition”) and a plasticizer. In one embodiment, the adhesive composition comprises about 65% to about 99% (or any amount therebetween) polyurethane composition and about 1% by weight, based on the total weight percent of the adhesive composition. Up to about 35% by weight (or any amount therebetween) plasticizer. For example, other amounts of the polyurethane composition may be present in an amount of about 75 wt.% To 99 wt.%, Or any amount therebetween, based on the total weight of the adhesive composition. It is contemplated that it may be present in the adhesive composition. In another example, the polyurethane may be present in an amount of about 85% to 99% by weight, or any amount therebetween, based on the total weight of the adhesive composition. The plasticizer may be present in the adhesive composition in an amount of about 1% to 35% by weight, or any amount therebetween, based on the total weight of the adhesive composition. In one example, the plasticizer may be present in the adhesive composition in an amount of about 20 wt% to about 30 wt%, or any amount therebetween, based on the total weight of the adhesive composition.

  The polyurethane composition used in the adhesive composition is an isocyanate group-containing prepolymer comprising castor oil or a derivative thereof and a polyisocyanate and optionally a reaction product of a second polyol, part (A); and polybutadiene Part (B), which is an isocyanate-reactive polyol mixture comprising a polyol and a urethane catalyst and optionally a second polyol. Part (A) and part (B) of the polyurethane composition can be combined by any method known in the art including, but not limited to, manual mixing, static mixing, and dynamic mixing. . It is also pointed out that part (A) can be added to part (B), or vice versa, or that part (A) and part (B) can be added simultaneously to the same vessel.

  Castor oil, i.e., ricinoleic acid triglyceride, present in the isocyanate group-containing prepolymer of Part (A) is a widely available renewable raw material. Castor oil derivatives include any polyol derived from castor oil, including hydrolysis products, ethoxylation products, transesterification products, or esterification products, or polyamide products. It is.

The polyisocyanate used to prepare the prepolymer of part (A) of the polyurethane composition is any compound having at least two isocyanate moieties. Diisocyanates are 1,5-naphthalene diisocyanate, 4,4′-diphenylmethane diisocyanate (4,4′-MDI), 2,4′-diphenylmethane diisocyanate (2,4′-MDI), 4,4′-diphenyldimethylmethane. Diisocyanate, 4,4'-dibenzyl diisocyanate, dialkyldiphenylmethane diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, toluene diisocyanate, butane-1,4-diisocyanate, hexamethylene diisocyanate, isopropylene diisocyanate, naphthalene diisocyanate , Methylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, cyclohexane-1,4-diisocyanate, xylylene Isocyanate, hydrogenated xylylene diisocyanate, isophorone diisocyanate, lysine diisocyanate, dicyclohexylmethane-4,4′-diisocyanate, 1,3-bis (isocyanatomethyl) cyclohexane, methyl-cyclohexane diisocyanate, m-tetramethylxylylene diisocyanate, 2 , 4,6-triisopropylbenzene diisocyanate, isopropylidenebis (4-cyclohexylisocyanate), and mixtures thereof. An exemplary mixture of diisocyanates includes a mixture of 4,4′-MDI and 2,4-MDI.

  The polyisocyanate used to prepare the part (A) prepolymer is also, for example, a polyisocyanate prepared by reacting a diisocyanate with a diisocyanate reactive compound such as a polyol, for example a diol or a polyamine, for example a diamine. It can be an isocyanate. Exemplary polyisocyanates used to prepare Part A prepolymers include the polymeric form of MDI. The polyisocyanate used to prepare the part (A) prepolymer can also be a carbodiimide modified diisocyanate, such as a carbodiimide modified MDI. The polyisocyanate used to prepare the prepolymer of Part (A) has an isocyanate (NCO) content that varies from 15% to 40% (weight percent) as measured by ASTM D2572.

  The isocyanate (NCO) content of the part (A) prepolymer varies from 5% to 25% (mass percent). In another embodiment, the isocyanate (NCO) content of the part (A) prepolymer is 10% to 20% (mass percent), more preferably 13% to 19% (mass percent) as measured by ASTM D2572. )

  The part (A) prepolymer of the polyurethane composition may contain a second polyol. In general, the optional second polyol in part (A) of the polyurethane composition is any polyol that can react with an isocyanate group (ie, a compound having two or more hydroxyl groups attached thereto). More specifically, the second polyol is preferably selected from the group of polyols having a molecular weight of less than about 600. In one example, the second polyol is selected from the group of polyols having a molecular weight of about 80 to about 300. In another example, the second polyol is selected from the group of polyols having a molecular weight of about 80 to about 200. In a further example, the second polyol is selected from the group of polyols having a molecular weight of about 300 to about 600.

  Examples of second polyols include glycols, ie diols containing 1,2 dihydroxy groups such as ethylene glycol or propylene glycol and their derivatives, and glycerol, ie glycerin and its derivatives. Examples of the second polyol include polypropylene glycol and polytetramethylene ether glycol. In certain embodiments, the second polyol is a diol having 3 to 20 carbon atoms. In another embodiment, the second polyol is a diol having 4 to 12 carbon atoms. In a further embodiment, the second polyol is a diol having 5-10 carbon atoms. Examples of such diols include 2-ethyl-1,3-hexanediol; 1,2-propanediol; 1,3-butanediol; 2,2,4-trimethyl-1,3-pentanediol, , 12-octadecanediol; 1,2-hexanediol; 1,2-octanediol; and 1,2-decanediol, but are not limited thereto. Further examples of the second polyol include tetraols such as pentaerythritol. The second polyol can be a polyether polyol prepared from either ethylene oxide and / or propylene oxide optionally reacted with another polyol such as glycol or glycerol.

The polybutadiene polyol of part (B) of the polyurethane composition is a low molecular weight, hydroxyl-terminated homopolymer of butadiene. Examples of polybutadiene polyols are the names Poly bd® R-45HTLO and Poly bd® R-20LM, both commercially available from Cray Valley USA, LLC, Exton, PA, USA, and CVC Thermoset Special
Examples include, but are not limited to, liquid hydroxyl-terminated polymers of butadiene sold under the name Hypro ™ 2800 × 95 HTB, commercially available from ties, Mooretown, NJ, USA.

  The urethane catalyst of part (B) of the polyurethane composition may be any urethane catalyst. Examples of urethane catalysts include tin catalysts such as dialkyltin dialkanoates, such as Fomrez catalyst UL-28 (dimethyltin), which provide very short gel and tack free times and good solubility in polyurethane systems. Dineodecanoate). Other examples of urethane catalysts include stannous octoate commercially available as Dabco® T-9 from Air Products, Allentown, Pa., USA; Dabco (from Air Products, Allentown, PA, USA) Organotin, commercially available as registered trademark 131; 1,4-diazabicyclooctane available as Dabco® Crystalline Catalyst from Air Products, Allentown, PA, USA; Air Products, Allentown, PA, N-cetyl-n, n-dimethylamine available from USA as Dabco® B-16; Da from Air Products, Allentown, PA, USA dibutyltin dilaurate available as co (R) T-12; dibutyltin diacetate available as MetacureTM T-1 catalyst from Air Products, Allentown, PA, USA; as BiCat 8 from Shepherd Chemical Company, Norwood, OH, USA A blend of zinc neodecanoate and bismuth neodecanoate and neodecanoic acid; iron (III) acetylacetonate available as Amspec GCR-56 from Amspec Chemical Corporation, Bear, DE, USA; and the Acme-Hardesty Company Available as Oleic Acid 105 from Blue Bell, PA, USA Include oleic acid, but not limited thereto.

  Optional second polyols that may be used in part (B) of the polyurethane composition include the same second polyols described in connection with part (A) above. When both (A) and (B) of the polyurethane composition contain a second polyol, the second polyol may be the same or different.

  Either or both of part (A) and part (B) of the polyurethane composition may also contain an antifoaming agent. In one embodiment, the antifoam is added to Part (A) in an amount of about 0.01 to about 0.1% by weight. In another embodiment, the antifoam is added to Part (B) in an amount of about 0.01 to about 0.1. In a further embodiment, the antifoaming agent is added to Part (A) in an amount of about 0.005 to about 0.05 and to Part (B) in an amount of about 0.005 to about 0.05. The antifoaming agent utilized in either or both of part (A) and part (B) of the polyurethane composition may be any antifoaming agent known in the art. In one example, the antifoaming agent is a silicone-based antifoaming agent, such as, for example, an alkylaryl silicone polymer-based antifoaming additive, commercially available as SF8843 from Momentive Performance Materials Holding LLC, Columbus, OH, USA. In another embodiment, the antifoaming agent is BYK USA, Inc. Defoamers that do not contain silicone, such as isoparaffinic defoamers such as BYK 054, available from Wallingford, CT, USA.

The viscosity of part (A) of the polyurethane composition is at least 600 cps. In one embodiment, the viscosity of part (A) of the polyurethane composition is from about 600 cps to about 50,000 cps, including any values therebetween. In another embodiment, the viscosity of part (A) of the polyurethane composition, including any value therebetween, is about 10,000 cps.
~ About 50,000 cps. In a further embodiment, the viscosity of part (A) of the polyurethane composition is from about 20,000 cps to about 40,000 cps, including any values therebetween. In a still further embodiment, the viscosity of part (A) of the polyurethane composition is from about 30,000 cps to about 35,000 cps, including any values therebetween. The viscosity of part (A) of the polyurethane composition is measured after all of the components of part (A) have been combined.

  The viscosity of part (B) of the polyurethane composition is at least 600 cps. In one embodiment, the viscosity of part (B) of the polyurethane composition is from about 600 cps to about 50,000 cps, including any values therebetween. In another embodiment, the viscosity of part (B) of the polyurethane composition is from about 1,000 cps to about 50,000 cps, including any values therebetween. In a further embodiment, the viscosity of part (B) of the polyurethane composition is from about 1,000 cps to about 40,000 cps, including any values therebetween. In a still further embodiment, the viscosity of part (B) of the polyurethane composition is from about 1,000 cps to about 30,000 cps, including any values therebetween.

  It is contemplated that the polyurethane composition of the adhesive composition can contain any ratio or amount of part (A) and part (B). In one example, the polyurethane composition contains from about 10% to about 90% by weight part (A) and from about 10% to about 90% by weight part (B). The polyurethane composition comprises from about 20% to about 80% by weight part (A) and from about 20% to about 80% by weight part (B); from 30% to about 75% by weight part (A) and about Other examples are contemplated which contain 25% to about 70% by weight of part (B), and any amount therebetween. In a particular example, the polyurethane composition contains about 50% by weight part (A) and about 50% by weight part (B), ie, part (A) and part (B) are in a 1: 1 ratio. Mixed in.

  As pointed out above, the second polyol is optional in part (A) and part (B) of the polyurethane composition. It is believed that neither part (A) nor part (B) of the polyurethane composition need contain a second polyol. It is also contemplated that either one or both of part (A) and part (B) may comprise a second polyol. In one embodiment of the polyurethane composition, part (A) or part (B) comprises at least 4% by weight of a second polyol, based on the total weight% of part (A) and part (B). In another embodiment of the polyurethane composition, part (A) or part (B) comprises at least 6% by weight of a second polyol, based on the total weight% of part (A) and part (B). In another embodiment of the polyurethane composition, part (A) or part (B) comprises at least 10% by weight of the second polyol, based on the total weight% of part (A) and part (B). In a further embodiment, part (A) and part (B) of the polyurethane composition comprise from about 4% to about 30% by weight of a second polyol, based on the total weight percent of part (A) and part (B). Have.

  In addition to the polyurethane composition described above, the adhesive composition also includes a plasticizer. In one embodiment, the plasticizer is added to Part (B), and then Part (B) containing the plasticizer is mixed with Part (A). In another embodiment, the plasticizer is added to part (A), and then part (A) containing the plasticizer is mixed with part (B). In another embodiment, the plasticizer is added to both in part (A) and part (B) and then mixed to form the polyurethane composition.

The plasticizer can be any plasticizer that can be used in the adhesive composition. Suitable plasticizers include azelaic acid ester, sebacic acid ester, maleic acid ester, succinic acid ester, phthalic acid ester, adipic acid ester, dicarboxylic acid / tricarboxylic acid ester plasticizer, phosphate, trimellitic acid ester, glutaric acid Examples include, but are not limited to, esters, citrate esters, dipropylene glycol dibenzoate, diethylene glycol dibenzoate, epoxidized soybean oil, soybean oil esters, or any combination of the foregoing plasticizers. In one embodiment, the plasticizer has a maximum moisture content of 0.04% by weight, based on the total weight of the plasticizer.

  Examples of phthalate ester plasticizers include bis (2-ethylhexyl) phthalate, diisononyl phthalate, phthaldi-n-butyl, butylbenzyl phthalate, diisodecyl phthalate, do-n-octyl phthalate, diisooctyl phthalate , Diethyl phthalate, diisobutyl phthalate, dioctyl phthalate, diundecyl phthalate, and di-n-hexyl phthalate.

  Examples of trimellitic acid esters include trimethyl trimellitic acid, trimellitic acid tri- (2-ethylhexyl), trimellitic acid tri- (n-octyl, n-decyl), trimellitic acid tri- (heptyl, nonyl) And n-octyl trimellitic acid, but are not limited thereto.

  Examples of adipic acid ester, glutaric acid ester, dicarboxylic acid, phosphate, sebacic acid ester, and maleic acid ester include 1,2-benzenedicarboxylic acid, polyester glutarate, o-isopropylphenyldiphenyl phosphate, tri-n-citrate -Butyl, dialkyl diether glutarate, bis (2-ethylhexyl) adipate, dioctyl adipate, polyester adipate, dimethyl adipate, monomethyl adipate, diisodecyl adipate, diisononyl adipate, bis (2-ethylhexyl sebacate), Bis (2-ethylhexyl) azelate, tri (2-ethylhexyl) trimellitic acid, di (C7-9-alkyl) adipate, butyl fumarate, diisobutyl fumarate, fumaric acid Scan (2-ethylhexyl), diethyl maleate, dimethyl maleate, diheptyl adipate, dioctyl adipate, dinonyl adipate, dibutyl sebacate, dibutyl maleate, although diisobutyl maleate include, but are not limited to.

  Examples of soy oil esters include soy methyl, soy ethyl and soy propyl. An example of a benzoate includes, but is not limited to, 1- [2- (benzoyloxy) propoxy] propan-2-ylbenzoate, commercially available as Benzoflex ™ from Eastman Chemical Company, Kingsport, TN, USA.

  Other examples of plasticizers include dioctyl terephthalate, 1,2-cyclohexanedicarboxylic acid diisononyl ester, epoxidized vegetable oil, alkylsulfonic acid phenyl ester, N-ethyltoluenesulfonamide (ortho and para isomers), N- (2 -Hydroxypropyl) benzenesulfonamide, N- (n-butyl) benzenesulfonamide, tricresyl phosphate, tributyl phosphate, glycol / polyether, organophosphate, triethylene glycol dihexanoate, tetraethylene glycol diheptanoate , Polymer plasticizer, polybutene, acetylated monoglyceride, alkyl citrate, triethyl citrate, triethyl citrate, tributyl citrate, tributyl acetyl citrate, Trioctyl, trioctyl acetyl citrate, trihexyl citrate, trihexyl acetylcitrate, including but Buchirirukuen acid trihexyl and trimethyl citrate, and the like.

Suitable commercially available plasticizers are also Exxon Mobil Chemi
and diisodecyl phthalate sold as Jayflex DIDP from Cal, Houston, TX, USA. Other acceptable phthalate plasticizers include other Jayflex ™ plasticizers from Exxon Mobil Chemical, Houston, TX, USA (eg, Jayflex DOP), Monsanto, St. DIOCTYL ™, SANTICIZER®, and DIBUTYL ™ plasticizers commercially available from Louis, Missouri, USA, and ADIMOL®, DISFLAMOL®, MESAMOLL, commercially available from Bayer Corporation, Germany. (Registered trademark), UNIMOLL (registered trademark), TEGDATM, TRIACETINTM, and ULTRAMOLTM plasticizer. Preferred plasticizers have low volatility such as long chain, branched phthalates (eg, ditridecyl phthalate, di-L-nonyl phthalate and di-L-undecyl phthalate). Useful dibenzoates are available as BENZOFLEX® 1988, BENZOFLEX® 50 and BENZOFLEX® 400 commercially available from Velsicol Chemical Corporation, Rosemont, IL, USA. Soybean oil is commercially available from Dow Chemicals, DE, USA under the trade name FLEXOLTM EPO.

  The polyurethane composition and plasticizer can be combined or mixed in any manner acceptable to form an adhesive composition, including but not limited to manual mixing, static mixing, and dynamic mixing. May be. It is pointed out that the polyurethane composition may be added to the plasticizer, or vice versa, or the polyurethane composition and the plasticizer may be added simultaneously to the container to form the adhesive composition. Is done.

  The adhesive composition is a rheology modifier or filler, preferably a thixotropic agent (“thixotropic agent”), which may be added to part (A) and / or part (B) of the polyurethane composition May be included. The filler may be any suitable filler known in the art including, but not limited to, talc, calcium carbonate, barium sulfate, magnesium hydroxide, clay, mica, titanium dioxide, or any combination of the foregoing. It may be. Rheology modifiers include all synthetic and natural sag-preventing additives from BYK Additives / Elements Specialties, Wallingford, CT, USA, along with primary amine-terminated polyether compounds. Primary amine-terminated polyether compounds include molecular weights from about 110 or 200, preferably up to about 500 (although molecular weights up to about 2000 are preferred) and about 2-3, preferably about 2, amine functionality. But is not limited to polyoxypropyleneamine. Such primary amino-terminated polyethers are manufactured and sold under the name Jeffamine by Huntsman Corporation, Salt Lake City, UT. Particularly preferred is Jeffamine D-230, which is a polyoxypropylene glycol terminated with a primary amine and having an amine functionality of 2 and a molecular weight of about 230. Crosslinking in the adhesive composition is described in BASF Corp. Further acceleration can be achieved by adding a hydroxyl-containing tertiary amine, such as diisopropanolamine, commercially available as QUADROL by Germany. Thixotropic grows rapidly when parts (A) and (B) of the polyurethane composition are combined in the presence of such amines. Thixotropic agents can include, but are not limited to, inorganic additives such as fumed silica, amorphous silicon dioxide, clay, bentonite, talc, and combinations thereof.

When the polyurethane composition and plasticizer are combined to form the adhesive composition, the adhesive composition typically has an initial mixed viscosity of at least about 10,000 cps. The term “initial mixing” as used in “initial mixing viscosity” relates to the viscosity of the adhesive composition when both the polyurethane part (A) and part (B) and the plasticizer are combined. In another example, the initial blend viscosity of the adhesive composition is from about 10,000 cps to about 40,000 cps, including any values therebetween. In another example, the initial blend viscosity of the adhesive composition is from about 10,000 cps to about 25,000 cps, including any values therebetween. In a further example, the initial mixed viscosity of the adhesive composition, including any value therebetween, is from 20,000 cps to about 35,000 cps. In another example, the initial mixed viscosity of the adhesive composition is between 30,000 cps and 40,000 cps, including any values therebetween. While a certain range of initial mixing viscosity is provided above, it is believed that the initial mixing viscosity of the adhesive composition can be any value above 20,000 cps. The initial blend viscosity can range from 5000 cps to 70,000 cps based on processing requirements.

  The adhesive composition should be flexible to penetrate the gaps or voids in the membrane of the reverse osmosis module, but also strong enough to provide the high pressure that the membrane is subjected to using it Should be things. After mixing the aforementioned components to form an adhesive composition, the adhesive composition is applied to the membrane of the reverse osmosis module. The adhesive composition is cured after application to the film. An example reverse osmosis module 10 is illustrated in FIG. 1, in which an adhesive composition 12 is shown applied to at least a portion of a membrane 14. The example shown in FIG. 1 is used for illustrative purposes only and is not intended to limit the scope of the present invention.

  The adhesive composition can be cured by room temperature curing or heat curing. When the adhesive composition is fully cured, the adhesive will have certain properties that will help impart beneficial properties to the adhesive composition when used in a reverse osmosis module. Adhesive compositions typically have a Shore hardness of greater than about 20A when fully cured. In another example, the adhesive composition has a Shore hardness of at least about 30 A when fully cured, while in another example, the adhesive composition has a Shore hardness of at least about 40 A when fully cured. Have In yet a further example, the adhesive composition has a Shore hardness of at least about 35D when fully cured. In a further example, the adhesive composition has a Shore hardness of 35D to 80D when fully cured. In another example, the adhesive composition has a Shore hardness of 60A-80D.

  When fully cured, the adhesive composition should have a tensile strength of greater than 100 psi, preferably greater than 500 psi. In another example, the adhesive composition has a tensile strength of greater than 1,000 psi, preferably greater than 2,000 psi when fully cured. The tensile strength can be measured by, for example, an Instron tensiometer.

  It is contemplated that the adhesive composition can be applied to the desired film using any technique known in the art for applying such adhesives. For example, the adhesive composition can be applied to the membrane of the reverse osmosis module using any commercially available coater, such as a slit die coater. The adhesive composition can be applied as a layer having any desired thickness. In one example, the adhesive composition is applied to a layer about 0.2 to about 4 mils thick, although other thicknesses may be applied.

The present invention includes at least the following embodiments:
Embodiment 1. FIG. An adhesive composition suitable for a reverse osmosis module,
(I) a polyurethane composition of about 65 wt% to 99 wt% based on the total weight% of the adhesive composition,
(A) (i) castor oil or derivative thereof; and (ii) polyisocyanate; and (iii) an isocyanate group-containing prepolymer optionally comprising the reaction product of a second polyol; and (B) (i) polybutadiene A polyurethane composition comprising: (ii) a urethane catalyst; and (iii) an isocyanate-reactive polyol mixture optionally comprising a second polyol;
(II) about 1% to about 35% by weight of a plasticizer based on the total weight% of the adhesive composition;
An adhesive composition essentially free of diluent oil and solvent.

  Embodiment 2. FIG. The adhesive composition of embodiment 1, wherein the adhesive composition has an initial mixed viscosity of at least 10,000 cps.

  Embodiment 3. FIG. Embodiment 3. The adhesive composition of any one of embodiments 1-2, wherein the adhesive composition has an initial mixed viscosity of from about 10,000 cps to about 40,000 cps.

  Embodiment 4. FIG. Embodiment 4. The adhesive composition according to any one of embodiments 1-3, wherein the adhesive composition has an initial mixed viscosity of about 30,000 cps to about 40,000 cps.

  Embodiment 5. FIG. Embodiment 5. The adhesive composition according to any one of embodiments 1-4, wherein the initial mixed viscosity of the adhesive composition is about 20,000 cps to about 35,000 cps.

  Embodiment 6. FIG. Embodiment 6. The adhesive composition according to any one of embodiments 1-5, wherein the adhesive composition has an initial mixed viscosity of about 10,000 cps to about 25,000 cps.

  Embodiment 7. FIG. Embodiment 7. The adhesive composition of any one of Embodiments 1-6, further comprising a Shore hardness of greater than about 20 A when fully cured.

  Embodiment 8. FIG. Embodiment 8. The adhesive composition of any one of Embodiments 1 through 7, further comprising a Shore hardness of at least about 30A when fully cured.

  Embodiment 9. FIG. Embodiment 9. The adhesive composition of any one of Embodiments 1-8, further comprising a Shore hardness of at least about 40 A when fully cured.

  Embodiment 10. FIG. Embodiment 10. The adhesive composition of any one of embodiments 1-9, further comprising a Shore hardness of 60A-80D when fully cured.

  Embodiment 11. FIG. The adhesive composition of any one of embodiments 1-6 and 9-10, further comprising a Shore hardness of at least about 35D when fully cured.

  Embodiment 12. FIG. The adhesive composition of any one of embodiments 1-6 and 9-10, further comprising a Shore hardness of 35D to 80D when fully cured.

  Embodiment 13. FIG. The adhesive composition according to any one of embodiments 1-12, wherein the adhesive composition has a tensile strength greater than about 100 psi.

  Embodiment 14. FIG. Embodiment 14. The adhesive composition of any one of embodiments 1-13, wherein the tensile strength of the adhesive composition is at least 1,000 psi when fully cured.

  Embodiment 15. FIG. Embodiment 15. The adhesive composition according to any one of embodiments 1-14, wherein the adhesive composition has a tensile strength of at least 2,000 psi when fully cured.

  Embodiment 16. FIG. Embodiment 1 Any of Embodiments 1-15, wherein either Part (A) or Part (B) comprises at least 4% by weight of the second polyol, based on the total weight percent of Part (A) and Part (B). 2. Adhesive composition as described in one.

  Embodiment 17. FIG. Embodiment 1 Any of Embodiments 1-16, wherein either Part (A) or Part (B) comprises at least 6% by weight of the second polyol, based on the total weight percent of Part (A) and Part (B). 2. Adhesive composition as described in one.

  Embodiment 18. FIG. Any one of embodiments 1-17, wherein either part (A) or part (B) comprises at least 10% by weight of the second polyol, based on the total weight of part (A) and part (B). The adhesive composition described in 1.

  Embodiment 19. FIG. Embodiment 19. The adhesive composition of any one of Embodiments 1 through 18, wherein the second polyol is selected from the group of polyols having a molecular weight of less than about 600.

  Embodiment 20. FIG. Embodiment 20. The adhesive composition according to any one of Embodiments 1 to 19, wherein the second polyol is a polyol having a molecular weight of 80 to 300 Daltons.

  Embodiment 21. FIG. Embodiment 21. The adhesive composition of embodiment 20, wherein the second polyol is a diol.

  Embodiment 22. FIG. The second polyol is 2-ethyl-1,3-hexanediol; 1,2-propanediol; 1,3-butanediol; 2,2,4-trimethyl-1,3-pentanediol, 1,12-octadecane Embodiment 20. The adhesive composition according to embodiment 19, selected from the group consisting of: diol; 1,2-hexanediol; 1,2-octanediol; and 1,2-decanediol.

  Embodiment 23. FIG. Embodiment 20. The adhesive composition of embodiment 19, wherein the second polyol is polypropylene glycol or polytetramethylene ether glycol.

  Embodiment 24. FIG. Embodiment 24. The adhesive composition of any one of embodiments 1 through 23, wherein at least one of part (I) (A) and part (I) (B) further comprises a filler, a thixotropic agent, or a combination thereof. object.

  Embodiment 25. FIG. At least one of Part (I) (A) and Part (I) (B) is selected from the group consisting of talc, calcium carbonate, barium sulfate, magnesium hydroxide, clay, mica, titanium dioxide, and combinations thereof 25. The adhesive composition according to embodiment 24, comprising a filler.

  Embodiment 26. FIG. 25. The adhesive composition of embodiment 24, wherein part (I) (B) of the adhesive composition further comprises a thixotropic agent.

  Embodiment 27. FIG. 27. The adhesive composition of embodiment 26, wherein the thixotropic agent is selected from the group consisting of fumed silica, amorphous silicon dioxide, talc, clay, and combinations thereof.

Embodiment 28. FIG. Part (I) of the adhesive composition is about 10% by weight based on the total weight of Part (A) and Part (I) from about 10% to about 90% by weight based on the total weight of Part (I) Embodiment 28. The adhesive composition according to any one of the preceding embodiments, comprising ˜about 90% by weight of Part (B).

  Embodiment 29. FIG. Part (I) of the adhesive composition is about 20% by weight based on the total weight of part (A) and part (I) from about 20% to about 80% by weight, based on the total weight of part (I). The adhesive composition according to any one of the preceding embodiments, comprising ˜about 80 wt% Part (B).

  Embodiment 30. FIG. Part (I) of the adhesive composition is about 30% by weight based on the total weight of part (A) and part (I) from about 30% to about 70% by weight, based on the total weight of part (I). The adhesive composition according to any one of the preceding embodiments, comprising ˜about 70 wt% Part (B).

  Embodiment 31. FIG. Part (I) of the adhesive composition is about 50% by weight Part (A) based on the total weight of Part (I) and about 50% by weight Part (B) based on the total weight of Part (I) The adhesive composition according to any one of Embodiments 1 to 30, comprising:

Embodiment 32. FIG. An adhesive composition suitable for a reverse osmosis module,
(I) from about 65% to about 99% by weight polyurethane composition, based on the total weight of the adhesive composition,
(A) (i) castor oil or a derivative thereof; and (ii) an isocyanate group-containing prepolymer comprising a reaction product of polyisocyanate; and (B) (i) a polybutadiene glycol; (ii) a urethane catalyst; and (iii) A polyurethane composition comprising an isocyanate-reactive polyol mixture comprising a second polyol;
(II) about 1% to about 35% by weight of a plasticizer, based on the total weight% of the adhesive composition;
Essentially free of diluent oil and solvent, the tensile strength of the adhesive composition when fully cured is at least 1,000 psi, and the Shore hardness of the adhesive composition when fully cured is about An adhesive composition that is from 35D to about 75D.

  Embodiment 33. FIG. Plasticizers include azelaic acid ester, sebacic acid ester, maleic acid ester, succinic acid ester, phthalic acid ester, adipic acid ester, dicarboxylic acid / tricarboxylic acid ester plasticizer, phosphate, trimellitic acid ester, glutaric acid ester, citric acid ester The adhesive of any one of embodiments 1-32, selected from the group consisting of acid esters, dipropylene glycol dibenzoate, diethylene glycol dibenzoate, epoxidized soybean oil, soybean oil esters, and combinations thereof. Composition.

  Embodiment 34. FIG. An embodiment wherein the plasticizer is selected from the group consisting of dipropylene glycol dibenzoate, diethylene glycol dibenzoate, epoxidized soybean oil, soybean oil ester, diheptyl adipate, dioctyl adipate, dinonyl adipate, and combinations thereof 1-3. The adhesive composition as described in any one of 1-33.

  Embodiment 35. FIG. The reverse osmosis module containing the adhesive composition as described in any one of Embodiments 1-34.

  Embodiment 36. FIG. A reverse osmosis module comprising the adhesive composition according to embodiment 32.

  Embodiment 37. FIG. A method of constructing a reverse osmosis module, comprising applying the adhesive composition according to any one of embodiments 1-32 to at least a portion of a membrane present in the reverse osmosis module.

  Embodiment 38. FIG. 35. A method of constructing a reverse osmosis module, comprising applying the adhesive composition of embodiment 32 to at least a portion of a membrane present in the reverse osmosis module.

  The adhesive compositions described in one or more of the foregoing embodiments are further discussed in the examples provided below.

  The following ingredients listed in Table 1 are used in Examples I-IX, detailed in Tables 2 and 3 below.

  Table 2 provides the components and plasticizers for the polyurethane compositions part (A) and part (B) of the adhesive compositions in Examples I-II, which are adhesive compositions according to the present invention. Table 2 also provides the ingredients for Examples III-IV (Comparative Adhesive Composition). In Examples I-IV, part (B) of the polyurethane composition does not contain a second polyol.

  Parts (A) and (B) of the adhesive composition in Examples I-IX are synthesized according to the following procedure.

Synthesis Protocol for Part (A) in Examples I-IX The weighed diisocyanate is charged to a reaction vessel equipped with equipment for stirring, vacuum, heating and cooling. Add SF 8843 antifoam to the reaction vessel. While stirring, 90 mol% castor oil (based on isocyanate) is added to the reaction vessel at such a rate that the temperature rise does not exceed 85 ° C. After the castor oil is added, the reaction vessel is sealed under vacuum (at least about 27 inches Hg) and then heated at a temperature of about 80 ° C. to about 85 ° C. for 4 hours to heat the isocyanate of part (A) A group-containing prepolymer is formed.

A sample of the isocyanate group-containing prepolymer of Part (A) is analyzed according to ASTM D 2572 to determine the NCO content. If necessary, add additional castor oil and react under vacuum at a temperature of about 80 ° C. to about 85 ° C. for 2 hours to target NCO value, ie 5% to 25% (mass percent) NCO content Reduce NCO content. If the calculated NCO content is lower than the target value, additional diisocyanate is added to increase the NCO content. The NCO content is measured again to ensure that the NCO content is within the target value before use.

Synthesis Protocol for Part (B) in Examples I-IV In the adhesive compositions of Examples I-IV, part (B) of the polyurethane composition does not contain a second polyol and a thixotropic agent. Each of the adhesive compositions in Examples I-IV is synthesized by blending polybutadiene diol, plasticizer and antifoam in a container for 30 minutes. The water is then stripped from the mixture such that the moisture content of the mixture is less than 0.04% by weight. The catalyst is then added and the mixture is stirred for 40-45 minutes to provide a homogeneous mixture.

Synthesis Protocol of Part (B) in Examples VI-IX In the adhesive compositions of Examples VI-IX, part (B) of the polyurethane composition comprises a second polyol and a thixotropic agent. Each of the adhesive compositions in Examples VI-IX is synthesized by blending polybutadiene diol, plasticizer and antifoam in a container for 30 minutes. The water is then stripped from the mixture such that the moisture content of the mixture is less than 0.04% by weight. A second polyol, a second diol EH diol, is added to the mixture after stripping water from the mixture so that the water content is 0.04 wt% or less, and blended with the mixture. The catalyst is then added to the mixture at room temperature and mixed, followed by a thixotropic agent. A thixotropic agent is added to the mixture at room temperature and mixed for 40-45 minutes until a uniform mixture is obtained.

  Table 3 provides the components and plasticizers for the polyurethane composition part (A) and part (B) of the adhesive composition in Examples V to IX, which are adhesive compositions according to the present invention. In Examples V-IX, part (B) of the polyurethane composition comprises a second polyol.

  As shown in Tables 2 and 3 above, the hardness, tensile strength and tear strength of the adhesive compositions according to the present invention (Examples I, II and V-VIII) are the same as those of Comparative Examples III, IV and IX. Improved compared to the composition.

Claims (36)

An adhesive composition for a reverse osmosis module,
(I) 65% to 99% by weight of a polyurethane composition based on the total weight% of the adhesive composition,
(A) (i) castor oil or derivative thereof; and (ii) polyisocyanate; and (iii) an isocyanate group-containing prepolymer optionally comprising the reaction product of a second polyol; and (B) (i) polybutadiene A polyurethane composition comprising: (ii) a urethane catalyst; and (iii) an isocyanate-reactive polyol mixture optionally comprising the second polyol;
(II) 1% to 35% by weight of a plasticizer based on the total weight% of the adhesive composition;
Essentially free of diluent oil and solvent;
The initial mixing viscosity of the adhesive composition, defined as the viscosity when parts (I) (A), (I) (B), and (II) are combined, is 5,000 to 70,000 cps. An adhesive composition.   The adhesive composition according to claim 1, wherein the initial mixed viscosity of the adhesive composition is 10,000 cps to 40,000 cps.   The adhesive composition according to claim 1 or 2, wherein the initial mixed viscosity of the adhesive composition is 30,000 cps to 40,000 cps.   The adhesive composition according to any one of claims 1 to 3, wherein the initial mixed viscosity of the adhesive composition is 20,000 cps to 35,000 cps.   The adhesive composition according to any one of claims 1 to 4, wherein the initial mixed viscosity of the adhesive composition is 10,000 cps to 25,000 cps. The adhesive composition according to any one of claims 1 to 5, wherein the adhesive composition has a Shore hardness exceeding Shore A hardness 20 when completely cured. The adhesive composition according to claim 1, further having a Shore A hardness of at least 30 when fully cured. The adhesive composition according to claim 1, further having a Shore A hardness of at least 40 when fully cured. The adhesive composition according to any one of claims 1 to 8, further having a Shore hardness of Shore A hardness 60 to Shore D hardness 80 when fully cured. The adhesive composition according to any one of claims 1 to 8, further having a Shore D hardness of at least 35 when fully cured. The adhesive composition according to any one of claims 1 to 10, further comprising a Shore D hardness of 35 to a Shore D hardness of 80 when completely cured. The adhesive composition according to claim 1, wherein the adhesive composition has a tensile strength of more than 100 psi (70307 kg / m ² ) . The adhesive composition according to claim 1, wherein the adhesive composition has a tensile strength of at least 1,000 psi (703070 kg / m ² ) when fully cured. The adhesive composition according to claim 1, wherein the adhesive composition has a tensile strength of at least 2,000 psi (1406140 kg / m ² ) when fully cured.   15. Any of part (A) or part (B), comprising at least 4% by weight of the second polyol, based on the total weight percent of part (A) and part (B). The adhesive composition according to one item.   16. Any of part (A) or part (B), comprising at least 6% by weight of the second polyol, based on the total weight percent of part (A) and part (B). The adhesive composition according to one item.   17. Either one of part (A) or part (B) comprises at least 10% by weight of the second polyol, based on the total weight of part (A) and part (B). The adhesive composition according to item.   The adhesive composition according to any one of claims 15 to 17, wherein the second polyol is selected from the group of polyols having a molecular weight of less than 600 Daltons.   The adhesive composition according to any one of claims 15 to 17, wherein the second polyol is a polyol having a molecular weight of 80 to 300 daltons.   The adhesive composition according to claim 19, wherein the second polyol is a diol. The second polyol is 2-ethyl-1,3-hexanediol; 1,2-propanediol; 1,3-butanediol; 2,2,4-trimethyl-1,3-pentanediol ; The adhesive composition of claim 18, selected from the group consisting of octadecanediol; 1,2-hexanediol; 1,2-octanediol; and 1,2-decanediol.   The adhesive composition according to claim 18, wherein the second polyol is polypropylene glycol or polytetramethylene ether glycol.   23. Adhesive composition according to any one of the preceding claims, wherein at least one of part (I) (A) and part (I) (B) further comprises a filler, a thixotropic agent or a combination thereof. object.   At least one of Part (I) (A) and Part (I) (B) is selected from the group consisting of talc, calcium carbonate, barium sulfate, magnesium hydroxide, clay, mica, titanium dioxide, and combinations thereof 24. The adhesive composition according to claim 23, comprising a filler.   24. The adhesive composition of claim 23, wherein part (I) (B) of the adhesive composition further comprises a thixotropic agent.   26. The adhesive composition of claim 25, wherein the thixotropic agent is selected from the group consisting of fumed silica, amorphous silicon dioxide, talc, clay, and combinations thereof.   Part (I) of the adhesive composition is 10 wt% to 90 wt% based on the total weight of Part (I) and 10 wt% to 90 wt% based on the total weight of Part (I) 27. The adhesive composition according to any one of claims 1 to 26, comprising 90% by weight of part (B).   Part (I) of the adhesive composition is 20 wt% to 80 wt% based on the total weight of Part (I) and 20 wt% based on the total weight of Part (I) 28. The adhesive composition according to any one of claims 1 to 27, comprising -80 wt% part (B).   Part (I) of the adhesive composition is 30% to 70% by weight based on the total weight of part (I) and 30% by weight based on the total weight of part (A) and part (I). 29. The adhesive composition according to any one of claims 1 to 28, comprising -70 wt% Part (B).   Part (I) of the adhesive composition comprises 50 wt% Part (A) based on the total weight of Part (I) and 50 wt% Part (B) based on the total weight of Part (I) The adhesive composition according to any one of claims 1 to 29, comprising: Part (I) (B) further comprises a second polyol, the adhesive composition for reverse osmosis module according to claim 1. The adhesive composition has a tensile strength of at least 1,000 psi (703070 kg / m ² ) when fully cured, and a Shore D hardness of 35 when the Shore hardness of the adhesive composition is fully cured. The adhesive composition according to claim 31, which has a Shore D hardness of 75 .   The plasticizer is azelaic acid ester, sebacic acid ester, maleic acid ester, succinic acid ester, phthalic acid ester, adipic acid ester, dicarboxylic acid / tricarboxylic acid ester plasticizer, phosphate, trimellitic acid ester, glutaric acid ester, 35. Adhesion according to any one of claims 1-32, selected from the group consisting of citrate esters, dipropylene glycol dibenzoate, diethylene glycol dibenzoate, epoxidized soybean oil, soybean oil esters, and combinations thereof. Agent composition.   The plasticizer is selected from the group consisting of dipropylene glycol dibenzoate, diethylene glycol dibenzoate, epoxidized soybean oil, soybean oil ester, diheptyl adipate, dioctyl adipate, dinonyl adipate, and combinations thereof. The adhesive composition according to any one of Items 1 to 33.   The reverse osmosis module containing the adhesive composition as described in any one of Claims 1-34.   35. A method of constructing a reverse osmosis module, comprising the step of applying an adhesive composition to at least a portion of the membrane present in the reverse osmosis module, wherein the adhesive composition is any one of claims 1-34. A method as described in paragraphs.

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