Solvent-free aqueous polyurethane dispersions and methods of producing solvent-free aqueous polyurethane dispersions
AssigneeArkema France
InventorsJeffrey A. Klang, Jin Lu, Indu Vappala
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Abstract
A solvent-free aqueous curable polyurethane dispersion is derived from at least one isocyanate-terminated ethylenically unsaturated polyurethane pre-polymer in a reactive diluent. The polyurethane pre-polymer comprises at least one (meth)acrylate functional group and at least one isocyanate functional group. Methods for making a solvent-free aqueous polyurethane dispersion, curable compositions comprising the dispersion and resulting cured products are also disclosed.
Claims25
An aqueous curable polyurethane dispersion, comprising a polyurethane polymer in at least one reactive diluent (F), wherein said polyurethane polymer is formed by chain extending at least one isocyanate-terminated ethylenically unsaturated polyurethane pre-polymer (P), with at least one chain extender (E) bearing at least 2 isocyanate-reactive groups, wherein said pre-polymer is formed by reacting:
- (A) one or more isocyanate reactive components comprising (A1) a monoalcohol of formula (1) below bearing 3 (meth)acrylate groups and (A2) a diol of formula (2) below bearing 2 (meth)acrylate groups
- (B) one or more polyisocyanates;
- (C) one or more isocyanate reactive components containing ionic groups, potentially ionic groups or hydrophilic ether groups with said component (C) bearing two isocyanate reactive groups;
- and
- (D) optionally, one or more isocyanate reactive components other than component (A) or component (C), bearing two isocyanate reactive groups, such that the mole ratios of components (A), (B), (C) and (D) result in a polyurethane pre-polymer comprising terminal isocyanate groups,
- when A′ and B′ represent the residues of corresponding polyols (tetrols) partially esterified by acrylic acid and which may be linear, cyclic, or branched, substituted or unsubstituted hydrocarbon chains, the optional substituents including cyclic groups, heteroatoms or both and wherein the polyurethane dispersion is free of non-reactive solvent.
A method for producing an aqueous polyurethane dispersion, said method comprising:
- i) reacting in at least one reactive diluent (F) to form a polyurethane pre-polymer (P):
- (A) one or more isocyanate reactive components comprising:
- (A1) a monoalcohol of formula (1) below bearing 3 (meth)acrylate groups and (A2) a diol of formula (2) below bearing 2 (meth)acrylate groups
- (B) one or more di- or polyisocyanates:
- (C) one or more isocyanate reactive components containing ionic groups, potentially ionic groups or hydrophilic ether groups, with said component (C) bearing two isocyanate reactive groups;
- and
- (D) optionally, one or more isocyanate reactive components other than component (A) or component (C), bearing two isocyanate reactive groups, such that the mole ratios of components (A), (B), (C) and (D) result in a polyurethane pre-polymer comprising terminal isocyanate groups;
- ii) dispersing said polyurethane pre-polymer (P) in water;
- and
- iii) reacting isocyanate groups of the polyurethane pre-polymer (P) with a chain extender (F) bearing at least two isocyanate-reactive groups to form a polyurethane polymer aqueous dispersion
- wherein A′ and B′ represent the residues of corresponding polyols (tetrols) partially esterified by acrylic acid and which may be linear, cyclic, or branched, substituted or unsubstituted hydrocarbon chains, the optional substituents including cyclic groups, heteroatoms or both and wherein the polyurethane dispersion is free of non-reactive solvent.
An aqueous dispersion comprising an isocyanate-terminated ethylenically unsaturated polyurethane pre-polymer formed by reacting:
- (A) one or more isocyanate reactive components comprising:
- (A1) a monoalcohol of formula (1) below bearing 3 (meth)acrylate groups and (A2) a diol of formula (2) below bearing 2 (meth)acrylate groups
- (B) one or more polyisocyanates;
- (C) one or more isocyanate reactive components containing ionic groups, potentially ionic groups or hydrophilic ether groups with said component (C) bearing two isocyanate reactive groups;
- and
- (D) optionally, one or more isocyanate reactive components other than component (A) or component (C), bearing two isocyanate reactive groups, such that the mole ratios of components (A), (B), (C) and (D) result in a polyurethane pre-polymer comprising terminal isocyanate groups
- wherein A′ and B′ represent the residues of corresponding polyols (tetrols) partially esterified by acrylic acid and which may be linear, cyclic, or branched, substituted or unsubstituted hydrocarbon chains, the optional substituents including cyclic groups, heteroatoms or both and wherein the polyurethane dispersion is free of non-reactive solvent.
Dependencies are inferred from the claim text.