Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4887—Polyethers containing carboxylic ester groups derived from carboxylic acids other than acids of higher fatty oils or other than resin acids
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C69/00—Esters of carboxylic acids; Esters of carbonic or haloformic acids
  • C07C69/34—Esters of acyclic saturated polycarboxylic acids having an esterified carboxyl group bound to an acyclic carbon atom
  • C07C69/40—Succinic acid esters
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/0804—Manufacture of polymers containing ionic or ionogenic groups
  • C08G18/0819—Manufacture of polymers containing ionic or ionogenic groups containing anionic or anionogenic groups
  • C08G18/0823—Manufacture of polymers containing ionic or ionogenic groups containing anionic or anionogenic groups containing carboxylate salt groups or groups forming them
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
  • C08G18/12—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step using two or more compounds having active hydrogen in the first polymerisation step
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
  • C08G18/4236—Polycondensates having carboxylic or carbonic ester groups in the main chain containing only aliphatic groups
  • C08G18/4238—Polycondensates having carboxylic or carbonic ester groups in the main chain containing only aliphatic groups derived from dicarboxylic acids and dialcohols
  • C08G18/4241—Polycondensates having carboxylic or carbonic ester groups in the main chain containing only aliphatic groups derived from dicarboxylic acids and dialcohols from dicarboxylic acids and dialcohols in combination with polycarboxylic acids and/or polyhydroxy compounds which are at least trifunctional
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
  • C08G18/72—Polyisocyanates or polyisothiocyanates
  • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
  • C08G18/75—Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic
  • C08G18/758—Polyisocyanates or polyisothiocyanates cyclic cycloaliphatic containing two or more cycloaliphatic rings

Definitions

• the present invention relates generally to low viscosity polyols suitable for use in the synthesis of polyurethanes, and, more particularly, to carboxyl-containing polyols.
• carboxyl-containing polyols are made by reacting a low molecular weight polyol with a dicarboxylic acid anhydride in the presence of 5-500 ppm of a catalyst selected from the group consisting of organic acids, inorganic acids, and combinations thereof.
• polyurethanes are generally manufactured by reacting a polyisocyanate and a polyol.
• the resulting polyurethane may have unique chemical and/or mechanical properties depending on the reacting conditions, as well as other additives such as catalysts, solvents, surfactants, blowing agents, fillers, and the like.
• the polyols used in manufacturing polyurethanes are typically low molecular weight poly- hydroxyl-containing polymers, such as those containing polyethers, polyesters, polyacrylics, polycarbonates, and the like. These polyols are generally provided with at least two hydroxyl groups so that they can be easily incorporated into a lengthening polymer in an ordered fashion.
• acid groups are attached to the main chain via an ester bond in the absence of catalysts, including acid catalysts.
• catalysts including acid catalysts.
• a high reaction temperature was used and resulted in highly viscous polyols.
• highly viscous polyol is reacted with a diisocyanate, a viscous prepolymer is obtained, and this result is not desired since the viscous prepolymer is difficult to process.
• U.S. Patent No. 4,207,2267 to Wulf von Bovin discloses a process for preparation of stable suspensions of inorganic fillers in poly-hydroxyl compounds by grafting olefinically unsaturated carboxylic acid onto polyol.
• acrylic acid and peroxide type initiators are used for this process.
• U.S. Patent No. 4,250,077 to Wulf von Bovin et al. discloses a suspension which is stable and contains inorganic filler and graft polymer which was produced by free radical polymerization of olefinically unsaturated carboxylic acid.
• U.S. Patent No. 4,460,738 to Frentzel et al. discloses a process for grafting carboxyl groups to mono and polyether polyols by reacting maleic acid, fumaric acid, itaconic acid or their mixtures with polyether polyols in presence of peroxy-type free radical initiator.
• U.S. Patent No. 4,521,615 to Frentzel discloses carboxy-containing polyols made by a free radical type addition reaction of fumaric or maleic acid with a monoether or a polyether diol or triol.
• U.S. Patent No. 6,103,822 to Housel et al. discloses a process for incorporating carboxyl groups into main polyester chain by reacting polyether or polyester polyol with an aliphatic dianhydride.
• U.S. Patent Nos. 5,242,954 and 5,250,582 to Hire et al. disclose a process for making cellular and microcellular polyurethane foams using a carboxylic acid-grafted polyol.
• U.S. Patent No. 5,880,250 discloses the reaction of polyols with dianhydride "to form an acid functionalized polyol in which there are reactive hydroxyl groups, and neutralizable or reactive carboxylic acid groups.” See Formula II at column 7 of the '250 patent.
• carboxyl groups can be introduced into the polyol component: 1. Free Radical addition of unsaturated dicarboxylic acids to polyol through C-C double bond (U.S. Patent Nos. 4,207,2267; 4,250,077; 4,460,738; 4,521,6155; 242,954 and 5,250,582)
• a common result of introduction of a carboxyl group into the polyol component, in accordance with the U.S. Patent No. 5,863,980 is that undesirable side reactions occur between the carboxyl group and nearby hydroxyl groups.
• the side reactions typically causing oligomers to form, markedly increase the viscosity of the monomer mixture, resulting in a decreased amount of usable monomers suitable for use in the final aqueous urethane dispersion.
• the "side" reacted carboxyl group results in reduced hydrophilicity of the final urethane dispersion.
• the present invention is directed to a low viscosity carboxyl- containing polyol composition having a viscosity in the range of 3,000 - 100,000 centipoise, and having an oligomer content of less than 30 g KOH/gm.
• This composition is obtained by reacting a polyol containing between two and four hydroxyl groups with an anhydride of a dicarboxylic acid.
• the polyol reactant is a triol
• the carboxyl-containing polyol has one ester group and one carboxyl group per molecule.
• the carboxyl-containing polyol is suitable for use in preparing low viscosity polyurethane prepolymers.
• the present invention is directed to a method of producing this carboxyl-containing polyol composition by reacting a low molecular weight polyol containing between two and four hydroxyl groups and preferably a triol with a dicarboxylic acid anhydride in the presence of 5-500 ppm of an inorganic or organic acid catalyst, forming an ester bond containing the carboxyl group.
• the organic or inorganic acid is preferably selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, formic acid, proprionic acid, p-toluenesulfonic acid, oxalic acid, and combinations thereof.
• the present invention is directed to a method of preparing a carboxyl-containing monomer for use in preparation of a polyurethane polymer, comprising the step of combining a low molecular weight polyol compound and an dicarboxylic acid anhydride in the presence of 5-500 ppm of an organic or inorganic acid (advantageously selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, formic acid, proprionic acid, p-toluenesulfonic acid, oxalic acid, and combinations thereof, in order to produce the carboxyl-containing monomer, the carboxyl- containing monomer having a viscosity in the range of about 3,000 to about 100,000 cps and having an oligomer content of less than about 30 mg KOH/g.
• an organic or inorganic acid advantageously selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, formic acid, proprionic acid, p-tolu
• the present invention relates to a prepolymer that is formed by reacting the carboxyl-containing polyol, or a partially or fully neutralized amine salt thereof, with a polyisocyanate.
• the present invention is directed to a water-borne polyurethane polymer, the water-borne polyurethane polymer being the reaction product of (1) the prepolymer described above, and (2) an amine compound.
• a low viscosity carboxyl-containing polyol composition having a viscosity in the range of about 3,000-100,000 centipoise, and having an oligomer content of less than 30 mg KOH/g, is suitably prepared in a straightforward fashion.
• the carboxyl-containing polyol has one ester group per molecule.
• the carboxyl-containing polyol is suitable for use in preparing low viscosity polyurethane prepolymers.
• the present inventors have surprisingly discovered that the reaction of a low molecular weight polyol with an dicarboxylic acid anhydride, suitably effected in the presence of an organic or inorganic acid catalyst, suitably provides a low viscosity carboxyl-containing polyol that can be advantageously employed in the production of low viscosity polyurethane prepolymers for waterborne polyurethane dispersions. Also, the present inventors have unexpectedly discovered that organic and inorganic acid catalysts are very efficient in catalyzing polyol-anhydride addition reactions with anhydride ring opening mechanism, while exhibiting little or no acceleration of acid and polyol condensation side reactions.
• the present invention provides a process for introducing carboxyl groups to polyol monomers, and the low-viscosity carboxyl-containing polyol monomers made by the process.
• the carboxyl-containing polyols are prepared by reacting a polyol monomer, preferably containing three hydroxyl groups per molecule, with a dicarboxylic acid anhydride under conditions such that an organic acid group is introduced into the polyol monomer. Because the polyol monomer is preferably selected to have three hydroxyl groups per molecule and is reacted with only one molecule of anhydride, the resulting carboxyl-containing monomer possesses two free hydroxyl groups per molecule and one carboxyl group attached to the polyol.
• the two free hydroxyl groups of the carboxyl-containing monomer are used in subsequent reactions that form the ultimate polyurethane, while the carboxyl group aids in hydration of the polyurethane dispersion and prevents generation of highly viscous, unwanted side reactions and undesirable by-products.
• polyol refers to compounds having between two and four free hydroxyl (-OH) groups per molecule, and preferably three hydroxyl groups.
• low molecular weight polyol refers to those polyols having a molecular weight less than 8,000, more preferably less than 2,000, and most preferably less than 500.
• carboxyl-containing monomer refers to a polyol having a carboxyl group added to one of the hydroxyl groups of the polyol.
• oligomer refers to a product where more than one polyol molecule is reacted with an acid anhydride.
• the present invention is directed to a carboxyl- containing polyol that is suitable for use in preparing a polyurethane polymer.
• the carboxyl-containing polyol is the reaction product of a low molecular weight polyol compound and a dicarboxylic acid anhydride, and the resulting carboxyl-containing monomer has a viscosity in the range of 3,000-100,000 centipoise (cps) and has oligomer content in the range of 2-30 mg KOH/g.
• cps centipoise
• polyols examples include low molecular weight polyols having from two to four hydroxyl groups.
• the polyol contains three free hydroxyl groups (hereinafter termed "triol").
• Triols suitable for use in the present invention are generally based on the structure of glycerol, trimethylolpropane, trimethylolethane, triethanolamine, triisopropanolamine and the like.
• Preferred triols include Poly-G 76-635 (a polyether triol of nominal molecular weight 265, available from Arch Chemicals, h e.) and Poly-G 35-610 (a polyether triol of nominal molecular weight 275), and their mixtures with trimethylolpropane or pure trimethylolpropane.
• polyalkylene polyether polyols produced by the poly-addition of any of the mentioned above triols and an alkylene oxide such as ethylene oxide, propylene oxide, butylene oxide, epoxybutene, and the like, may also be used. These triols generally have molecular weight from less than 100 to about 6000.
• Suitable acid anhydrides used in the present invention include any dicarboxylic acid anhydride that results in the addition of a carboxyl group to the polyol molecule.
• Useful acid anhydrides include maleic anhydride, phthalic anhydride, succinic anhydride, glutaric anhydride, and mixtures thereof.
• a preferred acid anhydride is succinic anhydride.
• the preparation of the carboxyl-containing polyol is generally accomplished by reacting the low molecular weight triol compound with a dicarboxylic acid anhydride in the presence of an inorganic or an organic acid catalyst.
• the resulting product has one ester bond per molecule.
• the polyol is suitably heated with anhydride to about 80-105°C in presence of the inorganic acid (preferably about 25-500 ppm of hydrochloric acid, sulfuric acid, or nitric acid, more preferably from about 50-250 ppm hydrochloric acid, sulfuric acid, or nitric acid, and most preferably from about 100-200 ppm hydrochloric acid, sulfuric acid, or nitric acid).
• Suitable organic acids include formic acid, propionic acid, p-toluenesulfonic acid, oxalic acid, and combinations thereof, and these organic acids are suitably employed within the preferred ranges of amounts as described above for the inorganic acids.
• the organic acid catalysts act as a proton source, which adds to the anhydride of dicarboxylic acid and creates a cation. The cation then quickly reacts by adding to the electronegative oxygen of the polyol.
• addition of 5-500 ppm of the organic or inorganic acid catalyzes the selective reaction between polyol and dicarboxylic acid anhydride, and an acid group is introduced into the polyol molecule.
• a triol is selected that has three hydroxyl groups per molecule.
• Each triol molecule is reacted with one molecule of anhydride to generate a product that has two hydroxyl groups per molecule and one ester group in the form of a carboxyl group attached to the polyol. It is preferred that the molecule produced in such addition reaction contains two hydroxyl groups, one carboxyl group and one ester group.
• Such chemical structure is ideal to produce low viscosity carboxyl polyols.
• Figure 1 illustrates the relationship between carboxyl polyol viscosity and the number of ester groups in the molecule of carboxyl polyol.
• Carboxyl polyols in Figure 1 were made by reacting 1 mole of glycerolpropoxylate (Arch Chemicals product Poly-G 76-635) with 1 mole of succinic anhydride.
• the Carboxyl polyols in Figure 2 were obtained by reacting 1 mole of trimethylolpropane with 1 mole of succinic anhydride.
• the Acid number of carboxyl polyol was determined by titration with sodium hydroxide solution using phenolphtalein indicator. Ester group content per one molecule was calculated from ester group content in carboxyl polyol and molecular weight (ester content as mgKOH/g times molecular weight divided by constant 56100). Molecular weight used in calculations was number average molecular weight as determined by GPC method. Carboxyl polyol in Figure 1 containing 1.696 ester groups per molecule was obtained using method described in U.S. Patent No. 5,863,980. Carboxyl polyol in Figure 2 containing 5.162 ester groups per molecule also was obtained using method described in U.S. Patent No. 5,863,980. These graphs demonstrate advantages of present invention in producing the desired low viscosity carboxyl polyols.
• the carboxyl group is suitably at least partially neutralized with an amine, such as triethylamine("TEA").
• an amine such as triethylamine("TEA").
• other useful amines for neutralizing the carboxyl group on the carboxyl-containing polyol include: trimethylamine, tripropylamine, tributylarnine, triisopropylamine, dimethylamine, diethylamine, dipropylarnine, dibutylamine, monoethanol amine, dimethylethanolamine, aminoalcohols, morpholine, n- methylmorpholine, n- ethyhnorpholine, and combinations thereof, alone or in combinations with other organic amines.
• the neutralizing amine is a tertiary amine that will not react with isocyanate.
• neutralized carboxyl polyols is that reaction of these neutralized carboxyl polyols with isocyanate proceeds fast even at 60- 70C temperature range. All of these advantages in using neutralized carboxyl polyols amount to substantial time and energy savings.
• the carboxyl-containing monomers are liquid at room temperature because liquids are easy to handle as compared to solids.
• a useftil range of viscosities for the carboxyl-containing monomers is generally less than 100,000 cps at 25°C.
• the viscosity of the carboxyl-containing monomers is from about 3,000 to about 100,000 cps, more preferably from about 3,000 to about 50,000 cps, and most preferably from about 3,000 to about 20,000 cps.
• the carboxyl-containing polyols made as described above contain minimal amounts of oligomers.
• oligomers are molecules which result from the reaction of the carboxyl function with another hydroxyl function, which can lead to oligomerization of the monomer products. Oligomers are undesirable due to their propensity to cause increased viscosity of the monomer product.
• the carboxyl-containing monomers have less than 30 mg KOH/g oligomers, preferably between 2 and 30 mg KOH/g oligomers, more preferably between 2 and 20 mg KOH/g oligomers, and most preferably between about 2 and 15 mg KOH/g oligomers.
• Oligomer content in the carboxyl-containing monomer can be measured by calculating the difference between theoretical acid number and acid number determined by chemical analysis as known in the art. Briefly, acid number is determined using 1-2 grams of sample.
• the carboxyl-containing polyols prepared above may be used in the production of a "prepolymer".
• the prepolymer is made by combining the carboxyl-containing polyols prepared above with a polyisocyanate compound.
• Organic polyisocyanates useful as reactants in the production of the prepolymer include any aromatic, cyclo aliphatic and aliphatic diisocyanates and higher polyisocyanates. Diisocyanates are the preferred class of polyisocyanates.
• Suitable aliphatic diisocyanates include hexamethylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate; isophorone diisocyanate; l,4'-tetramethylene diisocyanate; and 1,10-decamethylene disiocyanate and 1,12-dodecamethylene diisocyanate.
• Suitable aromatic diisocyanates include tolulene-2,4- or 2,6-diisocyanate; 1,5 -naphthalene diisocyanates; 4-methoxy-l,3-phenylene diisocyanate; 4-chloro-l,3-phenylene diisocyanate; 2,4'-diisocyanatodiphenyl ether; 5,6- dimethyl- 1,3-phenylate diisocyanate; 2,4-diemthyl-l,3-phenylene diisocyanate; 4,4'diisocyanatodiphenylether; benzidene diisocyanate, 4,4'-diisocyanataodibenzyl; methylene-bis(4-phenylisocyanate); and 1,3-phenylene diisocyanate.
• Particularly useful polyisocyanates for use in preparing the polyurethane prepolymers include toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'- diphenylmethane diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 1,12-dodecanediisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, xylylene diisocyanate, tetramethyl-xylylene diisocyanate and other polyisocyanates such as polymethylene polyphenyl isocyanate and isocyanate prepolymers having at least two isocyanate groups which are produced by reacting an isocyanate with a polyhydroxyl compound such as polyoxyalkylene polyol or polyester polyol or mixtures thereof.
• a polyhydroxyl compound such as polyoxy
• the reaction in which hydroxyl groups are reacted with isocyanate groups and polyurethane prepolymer is produced is usually performed at 50-100°C for 1-5 hours under an inert atmosphere such as nitrogen gas and at atmospheric pressure. Preferably the reaction is performed at 60-90°C for 2-3 hours.
• the ratio of isocyanate to carboxyl-containing polyol is such as to have the desired amount of carboxyl groups per molecule of polyurethane prepolymer.
• the carboxyl-containing monomer is added to result in an acid number for the prepolymer of 10-30 mg KOH/g.
• the preferred procedure for producing the prepolymer is to react the selected polyisocyanate with regular polyether or polyester polyol for 1-2 hours at 80- 90°C, and then add carboxyl-containing monomers and react until the theoretical isocyanate group content has been reached.
• catalysts such as dibutyltin dilaurate, stannous octoate, or amine-type catalysts like triethylamine or triethylene diamine, may be used to assist prepolymer formation.
• the prepolymer composition may also include solvents such as acetone, methylethylketone, N-methylpyrrolidinone, and the like.
• the chemical structure of an exemplary prepolymer made from 1 mole of 1000 molecular weight propylene oxide based diol (Poly-G 20-112 from Arch Chemicals, Inc., Norwalk, CT), three moles of 4,4' dicyclohexylmethane diisocyanate, and one mole of trimethylolpropane with succinic anhydride added to a side chain is as follows:
• This prepolymer is easy to disperse in water by converting side pendant carboxyl groups into salt groups and then reacting free NCO groups with diamine to obtain a high molecular weight urethane dispersion in water. Because, according to the present invention, there is one carboxyl group added to each triol molecule, the resulting prepolymer has low viscosity, low oligomer content, and is very easy to disperse in water. The dispersion process proceeds easily and water-borne dispersions may be prepared without the use of high shear/high speed mixers.
• prepolymers made with carboxyl polyols have low viscosity and dicarboxylic acid monoesters which are on a side chain of polyurethane molecule act as internal coalescing agents. Therefore, it is very easy to form solvent free polyurethane dispersions utilizing these prepolymers.
• the prepolymer may be combined with an amine compound to extend the prepolymer and further disperse the polymer in water.
• Suitable amines for dispersing prepolymer in water and chain extending the prepolymer include triethylamine, tripropylamine, ethylene diamine, n-butylamine, diethylamine, trimethylamine, monoethanol amine, dimethylethanolamine, aminoalcohols, hydrazine, hexamethylene diamine, isophorone diamine, cyclohexane diamine, dimethylcyclohexylamine, tris(3- aminopropyl)amine, 2-methylpentamethylenediamine, 1,12-dodecanediamine and combinations thereof.
• the chain extension reaction occurs when free isocyanate groups of water dispersed prepolymer react with amino groups and is described in the art.
• the reaction between isocyanate groups and amine groups is very fast and chain extension step can be carried out in water.
• fillers, plasticizers, pigments, and the like may be utilized as desired.
• Example 3 formulations and properties are provided for compositions prepared in accordance with Example 1 above, and these compositions are identified in Table 3 as Examples 1, 5, 6, 7, and 12.
• the preparation for Example 8 is described below, and Examples 9, 10 and 11 were prepared in accordance with the protocol given in Example 8.
• TMP trimethylolpropane
• Example 13 Preparation of Water-Borne Polyurethane Dispersion. 38 grams of 4,4'-dicyclohexylmethane diisocyanate ("DESMODUR W" from by
• This carboxyl polyol was obtained by reacting 1 mol of trimethylolpropane with 1 mol of succinic anhydride as described in Example 8 and had equivalent weight 127.9 for each OH group and equivalent weight 268.4 for each carboxyl group. After adding carboxyl polyol heating was continued for 2 more hours at 85°C. The NCO content of prepolymer was analyzed and found to be 2.34%. Warm prepolymer was mixed fast and mixture of 10.82 grams of triethylamine and 200 grams of water was added and mixed for 5 minutes to insure complete dispersion. No heating to flask was applied at this stage. Temperature in flask after adding of triethylamine and water was 49-50°C.
• Table 4 shows comparative results in the production of carboxyl polyols using phosphoric acid (Examples 1 and 5 above), hydrochloric acid (Example 15), sulfuric acid (Example 16), and nitric acid (Example 17) as catalysts.
• This carboxyl polyol was obtained by reacting 1 mol of polyether polyol 76-635 with 1 mol of succinic anhydride in presence of hydrochloric acid as described in Example 15 and had equivalent weight 168.8 for each OH group and equivalent weight 358.7 for each carboxyl group. After adding polyol with carboxyl groups heating was continued for 3 more hours at 85°C. The NCO content of prepolymer was analyzed and found to be 2.16%. Warm prepolymer was mixed fast and mixture of 10.9 grams of triethylamine and 300 grams of water was added and mixed for 5 minutes to insure complete dispersion. No heating to flask was applied at this stage.
• This polyol with carboxyl groups was obtained by reacting 1 mol of polyether polyol 76-635 with 1 mol of succinic anhydride in presence of sulfuric acid as described in Example 16 and had equivalent weight 167.8 for each OH group and equivalent weight 353.7 for each carboxyl group. After adding polyol with carboxyl groups, heating was continued for 3 more hours at 85°C. The NCO content of prepolymer was analyzed and found to be 2.26%. Warm prepolymer was mixed fast and mixture of 11 grams of triethylamine and 300 grams of water was added and mixed for 5 minutes to insure complete dispersion. No heating to flask was applied at this stage. Temperature in flask after adding of triethylamine and water was 49-50°C.
• This polyol with carboxyl groups was obtained by reacting 1 mol of polyether polyol 76-635 with 1 mol of succinic anhydride in presence of nitric acid as described in Example 17 and had equivalent weight 167.8 for each OH group and equivalent weight 363.3 for each carboxyl group. After adding polyol with carboxyl groups heating was continued for 3 more hours at 85°C. The NCO content of prepolymer was analyzed and found to be 2.55%. Viscosity at 25 °C was 42560 cP. This prepolymer was cooled to room temperature and used for preparation of water borne polyurethane dispersions as described in the following Examples.
• Prepolymer was made as described in Example 20. 300 grams of water at room temperature were placed in 1-liter flask equipped with mechanical stirrer, 0.1 grams of surfactant BYK 020 (BYK Chemie) and 5.4 grams of triethylamine (Aldrich) were added to water. The contents of the flask was stirred and 91.1 grams of prepolymer was slowly added to the flask. After all prepolymer has been dispersed in water, 2.87 grams of cyclohexyl diamine was dissolved in 30 grams of water and drop wise added to dispersed prepolymer. The flask was stirred without heating for 4 hours.
• BYK 020 BYK Chemie
• triethylamine Aldrich
• the resulting dispersion was an opalescent liquid which after drying produced film with following physical properties: Sward Hardness 24, Tensile Strength 2603 psi, Elongation at break 830%, 100% modulus 381 psi, Tear resistance 88 p/in.
• Example 22 Preparation Of Water Borne Polyurethane Dispersion Prepolymer was made as described in Example 20. 300 grams of water at room temperature was placed in 1 -liter flask equipped with mechanical stirrer, 0.1 grams of surfactant BYK 020 (BYK Chemie) and 5.4 grams of triethylamine (Aldrich) were added to the water. Contents of the flask was stirred, and 103.4 grams of prepolymer was slowly added to the flask. After all the prepolymer has been dispersed in water 1.71 grams of ethylenediamine was dissolved in 30 grams of water and drop wise added to disperse prepolymer. The flask was stirred without heating 4 hours.
• BYK 020 BYK Chemie
• Triethylamine Aldrich
• the resulting dispersion was an opalescent liquid which after drying produced film with following physical properties: Sward Hardness 22, Tensile Strength 1280 psi, Elongation at break 685%, 100% modulus 240 psi, Tear resistance 77 p/in.
• Prepolymer was made as described in Example 20. 300 grams of water at room temperature were placed in 1 -liter flask equipped with mechanical stirrer, 0.1 grams of surfactant BYK 020 (BYK Chemie) and 5.4 grams of triethylamine (Aldrich) were added to the water. The contents of the flask were stirred, and 99.7 grams of prepolymer was slowly added to the flask. After all prepolymer has been dispersed in water, 4.7 grams of isophorone diamine was dissolved in 30 grains of water and drop wise added to the dispersed prepolymer. The flask was stirred without heating 4 hours.
• the resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 24, Tensile Strength 1745 psi, Elongation at break 526%, 100% modulus 291 psi, Tear resistance 87 p/in.
• Prepolymer was made as described in Example 20. 300 grams of water at room temperature were placed in a 1 -liter flask equipped with mechanical stirrer, and 0.1 grams of surfactant BYK 020 (BYK Chemie) and 5.4 grams of triethylamine (Aldrich) were added to the water. The contents of flask were stirred, and 114.5 grams of prepolymer was slowly added to the flask. After all prepolymer had been dispersed in water, 2.88 grams of 35%o hydrazine was dissolved in 30 grams of water and drop wise added to the dispersed prepolymer. The flask was stirred without heating 4 hours.
• BYK 020 BYK Chemie
• Triethylamine Aldrich
• the resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 20, Tensile Strength 1020 psi, Elongation at break 860%, 100% modulus 218 psi, Tear resistance 73 p/in.
• Example 26 Preparing Carboxyl Polyol in Presence of Propionic Acid To a flask equipped with a thermometer, stirrer and reflux condenser were added
• Example 28 Preparing Carboxyl Polyol in Presence of Oxalic Acid To a flask equipped with a thermometer, stirrer and reflux condenser were added
• the illustrative organic acids can be used to produce carboxyl polyols with oligomer content less than 2 mgKOH/g. These polyols with carboxyl groups are particularly useful in waterborne polyurethane dispersions.
• Example 30 Preparing polyurethane dispersion using 100%) neutralized Carboxyl Polyol 52.5 grams of isophorone diisocyanate ("LUXATE IM" from Lyondell
• the NCO content of prepolymer was analyzed and found to be 3.67%. This prepolymer was cooled to 65C temperature and 250 grams of room temperature water was added in 2-3 minutes with good mixing. Prepolymer dispersion in water was later reacted with solution of 5.99 ethylene diamine in 131.5 grams of water. This ethylene diamine- water solution was slowly added thru addition funnel during 8-10 minutes with good agitation. Mixing was continued till no isocyanate groups could be found by IR method. The resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 20, Tensile Strength 4180 psi, Elongation at break 790%, 100% modulus 660 psi, Tear resistance 240 p/in.
• Example 31 Preparing of 50 % neutralized Carboxyl Polyol To a flask equipped with a thermometer, stirrer, reflux condenser and nitrogen inlet were added 506.9 grams of polyol Poly-G 76-635 (polyether triol with OH number 635 made by Arch Chemicals, Norwalk, CT) and 0.14 grams of 95% phosphoric acid (Aldrich Chemical, St. Louis, MO). The mixture was stirred at room temperature for 10 minutes and then 192.9 grams of succinic anhydride were added (Aldrich). With agitation the working temperature was increased to 100°C and the mixture was heated for 4 hours. After 4 hours, a sample for acid number was taken.
• polyol Poly-G 76-635 polyether triol with OH number 635 made by Arch Chemicals, Norwalk, CT
• 95% phosphoric acid Aldrich Chemical, St. Louis, MO
• Example 32 Preparing polyurethane dispersion using 50 % neutralized Carboxyl Polyol 200 grams of 4,4'-dicyclohexylmethane diisocyanate ("DESMODUR W” from Bayer), 257 grams of polyether diol with molecular weight 2000 (Poly-G 20-56 made by Arch Chemicals, Norwalk, CT), 0.2 grams of dibutyltin dilaurate (Dabco T-12 from Air Products, Allentown, PA), 137 grams of N- methylpyrrolidinone was mixed and heated to 85°C and maintained at that temperature for 2 hours. After 2 hours 105.9 grams of 50%) neutralized carboxyl polyol obtained as in example 53 was added.
• DESMODUR W 4,4'-dicyclohexylmethane diisocyanate
• This carboxyl polyol had equivalent weight 209.5 for each OH group and equivalent weight 424 for each carboxyl group.
• Reaction mixture was cooled to 60C. After adding polyol with carboxyl groups heating was continued for 5 more hours at 60°C.
• Prepolymer was cooled to room temperature and kept under nitrogen blanket over night. The NCO content of prepolymer was analyzed and found to be 4.86 %. Viscosity at 25C temperature was 2520 cp. 210 grams of this prepolymer were added to 240 grams of room temperature with good mixing.
• Prepolymer dispersion in water was later reacted with solution of 6.93 g ethylene diamine in 53 grams of water. This ethylene diamine- water solution was slowly added thru addition funnel during 8-10 minutes with good agitation.
• the resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 32, Tensile Strength 5500 psi, Elongation at break 410%, 100% modulus 2100 psi, Tear resistance 435 p/in.
• Reaction mixture was cooled to 60C. After adding polyol with carboxyl groups heating was continued for 2 more hours at 60°C. Prepolymer was cooled to room temperature and kept under nitrogen blanket over night. The NCO content of prepolymer was analyzed and found to be 3.65 %. Viscosity at 25C temperature was 5680 cp. 315 grams of this prepolymer were added to 360 grams of room temperature with good mixing. Prepolymer dispersion in water was later reacted with solution of 16.64 g isophorone diamine in 80 grams of water. This isophorone diamine- water solution was slowly added thru addition funnel during 8-10 minutes with good agitation. Mixing was continued till no isocyanate groups could be found by IR method.
• the resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 26, Tensile Strength 5550 psi, Elongation at break 315%, 100%> modulus 2150 psi, Tear resistance 270 p/in.
• the resulting dispersion was an opalescent liquid which after drying produced a film with following physical properties: Sward Hardness 16, Tensile Strength 4670 psi, Elongation at break 455%, 100% modulus 990 psi, Tear resistance 185 p/in.

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