US 7,253,228 B2 · Method for producing polyurethane emulsion

Abstract

The present invention provides a process for producing a polyurethane emulsion, capable of continuously producing a polyurethane emulsion which contains substantially no organic solvent and also has excellent storage stability over time. Disclosed is a process for producing a polyurethane emulsion by emulsifying a urethane prepolymer, which contains substantially no organic solvent and also has at least two isocyanate groups per one molecule, with water and completing chain extension, the process comprising (1) a first step of supplying the urethane prepolymer and water in an emulsifying apparatus comprising a stator section 5 fixed inside a cylindrical casing 1 and a rotor section 3 fixed to a rotational shaft 2 in the casing 1, the rotor section 3 having multiple rotor teeth 4, the stator section 5 having multiple stator teeth 6, which stand face to face with the rotor teeth 4, the stator section 5 having an inlet 8 and an outlet 10, from the inlet 8, continuously emulsifying them to obtain an emulsion of the urethane prepolymer having an average particle size of 0.1 to 2.5 μm, and discharging the emulsion from the outlet 10, and (2) a second step of reacting the emulsion of the urethane prepolymer obtained in the first step with a chain extender, thereby completing chain extension of the urethane prepolymer.

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Drawings

Claims5

Dependent claims

A process for producing a polyurethane emulsion by emulsifying a urethane prepolymer, which contains substantially no organic solvent and also has at least two isocyanate groups per one molecule, with water and then completing chain extension, the process comprising:

a preliminary step of assembling an emulsifying apparatus comprising one pair of a stator section (A) having a surface (a) and a rotor section (B) having a surface (b), in which the surfaces (a) and (b) face and are parallel to each other, the stator section (A) being fixed inside a cylindrical casing and the rotor section (B) being fixed to a rotational shaft provided in the casing, wherein
the stator section (A) has the surface (a) wherein multiple stator teeth are arranged on the surface along with two or more concentric circles, and
the rotor section (B) has the surface (b) wherein multiple rotor teeth are arranged on the surface along with two or more concentric circles, in which a ring axis of the circles is the same as the ring axis of the circles of the stator section (A), but diameters of the concentric circles of the rotor section (B) are different from those of the stator section (A), side surfaces of said rotor teeth being parallel to an axis of rotation for said rotational shaft for said rotor section, a distance between the surface (a) and a top of the multiple stator teeth of the stator section (A) is longer than a distance between the surface (a) and a top of the multiple rotor teeth of the rotor section (B), and the stator section (B) has a supply inlet which is positioned in the smallest circle of the stator section (A), and an outlet, which is positioned at a side portion of the stator section (A),
a first step of supplying a stream containing the urethane prepolymer into the emulsifying apparatus and separately supplying a stream containing water into the emulsifying apparatus so as to form an emulsion of the urethane prepolymer in water, from the inlet and continuously emulsifying them by having a peripheral velocity of a rotor tooth located at the outermost periphery among multiple rotor teeth of the emulsifying apparatus be within a range from 30 to 70 m/second so as to obtain an emulsion of the urethane prepolymer having an average particle size of 0.1 to 2.5 μm, and discharging the emulsion from the outlet, and
a second step of reacting the emulsion of the urethane prepolymer obtained in the first step with a chain extender, thereby completing chain extension of the urethane prepolymer.

2 more elements

a preliminary step of assembling an emulsifying apparatus comprising one pair of a stator section (A) having a surface (a) and a rotor section (B) having a surface (b), in which the surfaces (a) and (b) face and are parallel to each other, the stator section (A) being fixed inside a cylindrical casing and the rotor section (B) being fixed to a rotational shaft provided in the casing,
the stator section (A) has the surface (a) wherein multiple stator teeth are arranged on the surface along with two or more concentric circles, and
the rotor section (B) has the surface (b) wherein multiple rotor teeth are arranged on the surface along with two or more concentric circles, in which a ring axis of the circles is the same as the ring axis of the circles of the stator section (A), but diameters of the concentric circles of the rotor section (B) are different from those of the stator section (A), side surfaces of said rotor teeth being parallel to an axis of rotation for said rotational shaft for said rotor section, a distance between the surface (a) and a top of the multiple stator teeth of the stator section (A) is longer than a distance between the surface (a) and a top of the multiple rotor teeth of the rotor section (B), and the stator section (B) has at least two inlets for supplying the streams independently, which are positioned at a side portion of the stator section (A),
a first step of supplying a stream containing the urethane prepolymer into the emulsifying apparatus and separately supplying a stream containing water into the emulsifying apparatus so as to form an emulsion of the urethane prepolymer in water, continuously emulsifying them by having a peripheral velocity of a rotor tooth located at the outermost periphery among multiple rotor teeth of the emulsifying apparatus be within a range from 30 to 70 m/second so as to obtain an emulsion of the urethane prepolymer having an average particle size of 0.1 to 2.5 μm, and discharging the emulsion from the outlet, and
a second step of reacting the emulsion of the urethane prepolymer obtained in the first step with a chain extender, thereby completing chain extension of the urethane prepolymer.

2 more elements

Dependencies are inferred from the claim text.

Description6,840 words

Summary1,364 words

#1. Field of the Invention

#The present invention relates to a process for producing a polyurethane emulsion having excellent storage stability by continuously emulsifying a urethane prepolymer containing substantially no organic solvent with water and reacting the urethane prepolymer with a chain extender.

#This application is filed under 35 USC 371 based on the National Stage of International Application No. PCT/JP03/03627, filed on Mar. 25, 2003, the content of which is incorporated herein by reference. Priority is claimed on Japanese Patent Application No. 2002-91266, filed Mar. 28, 2002, the content of which is incorporated herein by reference.

Brief description of the drawings7 figures

#FIG. 1 is a schematic view showing an emulsifying apparatus used in the present invention.

#FIG. 2 is a sectional side view showing a rotor section 3 and a stator section 5 of an emulsifying apparatus used in the present invention.

#FIG. 3 is a sectional view taken along lines A-A in FIG. 2 of the rotor section 3 of the emulsifying apparatus used in the present invention. In FIG. 3, comb-shaped teeth 5a on the stator and slits 5b between the comb-shaped teeth on the stator are omitted. Also the section of a casing 1 is omitted.

Detailed description5,250 words

#The present invention will now be described in detail.

#The process for producing a polyurethane emulsion of the present invention comprises supplying a urethane prepolymer, which contains substantially no organic solvent and also has at least two isocyanate groups per one molecule, and water in a specific emulsifying apparatus, continuously emulsifying the urethane prepolymer with water to obtain an emulsion of the urethane prepolymer having an average particle size of 0.1 to 2.5 μm, and continuously reacting the emulsion with a chain extender, thereby completing chain extension of the urethane prepolymer.

#The specific emulsifying apparatus used in the present invention will now be described in detail.

Facts

Application

10/491,889Filed 25 Mar 2003

Priority

JP 2002-09126628 Mar 2002

Published

US 2004/0242764 A12 Dec 2004

Granted

7 Aug 2007

Term ended

25 Mar 2023

Estimated · how

20 years from earliest known nonprovisional domestic filing plus recorded patent term adjustment. Maintenance-fee lapses, terminal disclaimers and statutory extensions have not been checked. The continuity chain may be incomplete; this is not an enforceability determination.

Classification8 codes

B01F 27/271
Mixers with stator-rotor systems, e.g. with intermeshing teeth or cylinders or having orifices: with means for moving the materials to be mixed…
C08J 3/03
Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques: in aqueous media
B01F 27/2711
With means for moving the materials to be mixed radially between the surfaces of the rotor and the stator: provided with intermeshing elements
B01F 2215/0427
Geometrical information: numerical distance values, e.g. separation, position

Method for producing polyurethane emulsion

Life of this patent

Method for producing polyurethane emulsion

Life of this patent

Life of this patent

Abstract

Drawings

Drawings

Claims5

Description6,840 words

Drawings

Classification8 codes

Life of this patent

Description6,840 words