Patent Application
20230026948
This invention pertains to the field of polyol and polyurethane compositions. More particularly, the invention pertains to polyol and polyurethane compositions comprising blends of polycarbonate polyols.
Polyurethane compositions, which are derived from the reaction between isocyanates and reactive polymers, are widely used, e.g., in adhesive and coating applications. There remains a need for polyurethane compositions with improved performance characteristics, e.g., strength, flexibility, elongation, etc., in particular for adhesive and coating applications.
In some aspects, the present invention provides compositions comprising blends of polycarbonate polyols derived from copolymerization of carbon dioxide and one or more epoxides. In some embodiments, such compositions are useful, e.g., when incorporated into polyurethane compositions, in particular for adhesive and coating applications.
As noted above, polyurethane compositions have been described. Many different combinations of polyols and isocyanates have been used in polyurethane compositions. For example, in certain applications, polyether polyols, polyester polyols, and polycarbonate polyols have been disclosed as preferred polyols in polyurethane compositions. However, each of these traditional polyols exhibits certain drawbacks when incorporated into polyurethane compositions, e.g., in adhesive compositions. For example, polyether polyols are a lower cost polyol used for their flexibility and hydrolytic stability, but polyurethane compositions derived from polyether polyols exhibit low strength and poor weather resistance. Polyester polyols are available in a wide variety structures and generally have good mechanical strength and flexibility; however, polyurethane compositions derived from polyester polyols exhibit low hydrolytic resistance. Although polyester polyols that result in improved hydrolytic resistance may be available, they come at a high cost. Lastly, polycarbonate diols exhibit good performance properties when incorporated into polyurethane compositions, but are the highest cost polyols. Accordingly, in certain aspects, there is a need to provide polyurethane compositions with improved performance characteristics, in particular for adhesive, elastomer, and coating applications.
The present invention encompasses the recognition that blends of polycarbonate polyols within a polyol component of a polyurethane composition can unexpectedly improve the performance profile (e.g., mechanical properties, adhesive properties, and/or shelf-life) of the resulting polyurethane composition. Accordingly, in some aspects, the present invention encompasses polyurethane compositions comprising the reaction product of a polyol component and a polyisocyanate composition. In particular, a polyol component comprises a blend of polycarbonate polyols.
Polycarbonate polyols derived from copolymerization of carbon dioxide and one or more epoxides include substantially alternating polycarbonate polyols. Such polyols, as a result of being derived from copolymerization of carbon dioxide and one or more epoxides, comprise a repeating unit having a structure:
wherein R1, R2, R3, and R4 are as described herein.
As shown by the above structure, polycarbonate polyols derived from copolymerization of carbon dioxide and one or more epoxides comprise repeating carbonate units separated by two carbons.
Furthermore, polyurethane compositions that comprise a polycarbonate polyol derived from copolymerization of carbon dioxide and one or more epoxides, and thus comprising repeating carbonate units separated by two carbons, have been described in, for example, PCT Publication Nos. WO 2010/028362, WO 2013/016331, and WO 2014/074706.
While PCT Publication No. WO 2010/028362 discloses polycarbonate polyols derived from copolymerization of carbon dioxide and one or more epoxides and their incorporation into polyurethane compositions, it is silent with respect to particular blends of polycarbonate polyols.
PCT Publication No. WO 2013/016331 discloses B-side mixtures for the formulation of polyurethane compositions that incorporate a polycarbonate polyol and one or more additional polyols (e.g., a polyether or polyester polyol). In addition, PCT Publication No. WO 2014/074706 discloses polyurethane foams derived from a polycarbonate polyol and a polyether or polyester polyol. However, neither of these disclosures recognizes that particular blends of polycarbonate polyols within a polyurethane composition provides a superior performing material in certain applications, e.g., coatings and adhesives.
In some aspects, the present invention provides the recognition that, for a particular polyurethane composition, a blend of polyols comprising two or more structurally different polycarbonate polyols derived from CO2 and one or more epoxides provides a polyurethane composition with superior performance properties.
When blending two or more polyols to provide a polyurethane composition, it is expected that the performance properties of the resulting polyurethane composition will be an average of the corresponding polyurethane compositions derived solely from each polyol. However, the present invention recognizes that the polyurethane compositions described herein (derived from a blend of polycarbonate polyols) display an unexpected synergistic improvement in performance profile (e.g., performance properties such as lap shear strength, tensile strength, tensile elongation, modulus, hydrolytic stability, and/or thermal stability), compared to the corresponding polyurethane compositions derived solely from each polycarbonate polyol. Additionally or alternatively, the present invention recognizes that the polyurethane compositions described herein (derived from a blend of polycarbonate polyols as described herein) display one or more improved performance properties without sacrificing a proportional decrease in another performance property (e.g., improved tensile strength without proportional decrease in tensile elongation).
In some aspects, the present invention encompasses compositions comprising:
wherein each of R10, R20, R30, R40, Y10, n10, and
is as described herein; and
wherein each of R11, R21, R31, R41, Y11, n11, and
is as described herein.
In some aspects, the present invention encompasses polyurethane compositions derived from the reaction product of compositions comprising a blend of polycarbonate polyols described herein, e.g., comprising polyol subcomponent (i) and polyol subcomponent (ii). The polyurethane compositions of the present invention are particularly useful in adhesive and coating applications. In one aspect, polyurethane compositions of the present invention unexpectedly demonstrate improved performance properties (e.g., strength, flexibility, or both), as compared to a reference polyurethane composition.
In some aspects, the present invention encompasses isocyanate-terminated prepolymers derived from a composition comprising a blend of polycarbonate polyols described here, e.g., comprising polyol subcomponent (i) and polyol subcomponent (ii).
In some aspects, the present invention encompasses methods of producing a polyurethane compositions, comprising the steps of:
In some embodiments, the present invention encompasses methods of producing a polyurethane composition comprising the steps of:
In some aspects, the present invention encompasses methods of improving a performance property of a polyurethane compositions comprising the reaction product of a polyol component and an isocyanate component, the method comprising the step of incorporating a blend of polycarbonate polyols into the polyol component, e.g., polyol subcomponent (i) and polyol subcomponent (ii).
Definitions of specific functional groups and chemical terms are described in more detail below. For purposes of this invention, the chemical elements are identified in accordance with the Periodic Table of the Elements, CAS version, Handbook of Chemistry and Physics, 75th Ed., inside cover, and specific functional groups are generally defined as described therein. Additionally, general principles of organic chemistry, as well as specific functional moieties and reactivity, are described in Organic Chemistry, Thomas Sorrell, University Science Books, Sausalito, 1999; Smith and March March's Advanced Organic Chemistry, 5th Edition, John Wiley & Sons, Inc., New York, 2001; Larock, Comprehensive Organic Transformations, VCH Publishers, Inc., New York, 1989; Carruthers, Some Modern Methods of Organic Synthesis, 3rd Edition, Cambridge University Press, Cambridge, 1987; the entire contents of each of which are incorporated herein by reference.
Certain molecules (e.g., polymers, epoxides, etc.) of the present invention can comprise one or more asymmetric centers, and thus can exist in various stereoisomeric forms, e.g., enantiomers and/or diastereomers. Thus, inventive molecules and compositions thereof may be in the form of an individual enantiomer, diastereomer or geometric isomer, or may be in the form of a mixture of stereoisomers. In certain embodiments, the molecules of the invention are enantiopure molecules. In certain embodiments, mixtures of enantiomers or diastereomers are provided.
Certain molecules described herein may have one or more double bonds that can exist as either the Z or E isomer, unless otherwise indicated. The invention additionally encompasses the molecules as individual isomers substantially free of other isomers and alternatively, as mixtures of various isomers, e.g., racemic mixtures of enantiomers. In addition to the above-mentioned molecules per se, this invention also encompasses compositions comprising one or more molecules.
As used herein, the term “about”, when used herein in reference to a value, refers to a value that is similar, in context to the referenced value. In general, those skilled in the art, familiar with the context, will appreciate the relevant degree of variance encompassed by “about” in that context. For example, in some embodiments, the term “about” may encompass a range of values that fall within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction (greater than or less than) of the stated reference value, unless otherwise stated or otherwise evident from the context (except where such number would exceed 100% of a possible value).
The term “isomers” includes any and all geometric isomers and stereoisomers. For example, “isomers” include cis- and trans-isomers, E- and Z-isomers, R- and S-enantiomers, diastereomers, (D)-isomers, (L)-isomers, racemic mixtures thereof, and other mixtures thereof, as falling within the scope of the invention. For instance, a stereoisomer may, in some embodiments, be provided substantially free of one or more corresponding stereoisomers, and may also be referred to as “stereochemically enriched.”
The term “epoxide”, as used herein, refers to a substituted or unsubstituted oxirane. Such substituted oxiranes include monosubstituted oxiranes, disubstituted oxiranes, trisubstituted oxiranes, and tetrasubstituted oxiranes. Such epoxides may be further optionally substituted as defined herein. In certain embodiments, epoxides comprise a single oxirane moiety. In certain embodiments, epoxides comprise two or more oxirane moieties.
The term “polymer”, as used herein, refers to a molecule of high relative molecular mass, the structure of which comprises the multiple repetitions of units derived, actually or conceptually, from molecules of low relative molecular mass. In certain embodiments, a polymer is comprised of substantially alternating units derived from CO2 and an epoxide (e.g., poly(ethylene carbonate). In certain embodiments, a polymer of the present invention is a copolymer, terpolymer, heteropolymer, block copolymer, or tapered heteropolymer incorporating two or more different epoxide monomers. With respect to the structural depiction of such higher polymers, the convention of showing enchainment of different monomer units separated by a slash may be used as depicted herein, e.g.,
These structures are to be interpreted to encompass copolymers incorporating any ratio of the different monomer units depicted unless otherwise specified. This depiction is also meant to represent random, tapered, block copolymers, and combinations of any two or more of these and all of these are implied unless otherwise specified.
The terms “halo” and “halogen” as used herein refer to an atom selected from fluorine (fluoro, —F), chlorine (chloro, —Cl), bromine (bromo, —Br), and iodine (iodo, —I).
The term “reference” as used herein, described a standard or control relative to which a comparison is performed. For example, in some embodiments, a polymer, composition, sample, or value of interest is compared with a reference or control polymer, composition, sample, or value. In some embodiments, a reference or control is tested and/or determined substantially simultaneously with the testing or determination of interest. In some embodiments, a reference or control is a historical reference or control, optionally embodied in a tangible medium. Typically, as would be understood by those skilled in the art, a reference or control is determined or characterized under comparable conditions or circumstances to those under assessment. Those skilled in the art will appreciate when sufficient similarities are present to justify reliance on and/or comparison to a particular possible reference or control.
In some aspects, the present invention encompasses polyol compositions comprising a blend of polycarbonate polyols that, when incorporated into a polyurethane composition, result in one or more improved performance characteristics, e.g., strength, flexibility, elongation, etc. In some embodiments, the present invention encompasses compositions comprising:
wherein each of R10, R20, R30, R40, Y10, n10, and
is as described herein; and
wherein each of R11, R21, R31, R41, Y11, n11, and
is as described herein.
Before describing these compositions in more detail, the polyols and isocyanates from which they are formulated will be more fully described.
In certain embodiments, compositions of the present invention comprise a polyol component, wherein the polyol component comprises a blend of polycarbonate polyols. Herein, a polycarbonate polyol refers to a substantially alternating aliphatic polycarbonate polyol. Examples of suitable aliphatic polycarbonate polyols, as well as methods of making them are disclosed in PCT publication WO 2010/028362, the entirety of which is incorporated herein by reference.
It will be appreciated that within the present disclosure, “aliphatic polycarbonate polyols” refers to a composition comprising a mixture of aliphatic polycarbonate polyol chains.
It is advantageous for many of the embodiments described herein that the aliphatic polycarbonate polyols used have a high percentage of reactive end groups. Such reactive end-groups are typically hydroxyl groups, but other reactive functional groups may be present if the polyols are treated to modify the chemistry of the end groups, such modified materials may terminate in amino groups, thiol groups, alkene groups, carboxylate groups, isocyanate groups, silyl groups, epoxy groups and the like. For purposes of this invention, the term “aliphatic polycarbonate polyol” includes both traditional hydroxy-terminated materials as well as these end-group modified compositions (e.g., isocyanate terminated prepolymers).
In certain embodiments, at least 90% of the end groups of the aliphatic polycarbonate polyol composition are reactive end groups. In certain embodiments, at least 95%, at least 96%, at least 97% or at least 98% of the end groups of the aliphatic polycarbonate polyol composition are reactive end groups. In certain embodiments, more than 99%, more than 99.5%, more than 99.7%, or more than 99.8% of the end groups of the aliphatic polycarbonate polyol composition used are reactive end groups. In certain embodiments, more than 99.9% of the end groups of the aliphatic polycarbonate polyol composition used are reactive end groups.
In certain embodiments, at least 90% of the end groups of the aliphatic polycarbonate polyol composition are —OH groups. In certain embodiments, at least 95%, at least 96%, at least 97% or at least 98% of the end groups of the aliphatic polycarbonate polyol composition are —OH groups. In certain embodiments, more than 99%, more than 99.5%, more than 99.7%, or more than 99.8% of the end groups of the aliphatic polycarbonate polyol composition are —OH groups. In certain embodiments, more than 99.9% of the end groups of the aliphatic polycarbonate polyol composition used are —OH groups.
Another way of expressing the —OH end-group content of a polyol composition is by reporting its OH #, which is measured using methods well known in the art. For example, OH # may be measured according to ASTM D4274 or ASTM E1899. In some embodiments, OH # is measured according to ASTM D4274. In some embodiments, OH # is measured according to ASTM E1899.
In certain embodiments, aliphatic polycarbonate polyol compositions used in the present invention have an OH # greater than about 20. In certain embodiments, aliphatic polycarbonate polyol compositions utilized in the present invention have an OH # greater than about 40. In certain embodiments, aliphatic polycarbonate polyol compositions have an OH # greater than about 50, greater than about 75, greater than about 100, or greater than about 120.
In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 40 and about 120. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 40 and about 100. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 40 and about 80. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 40 and about 70. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 50 and about 60. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 52 and about 60. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 54 and about 58. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 50. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 52. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 54. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 56. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 58. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 60.
In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 80 and about 120. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 100 and about 120. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 105 and about 115. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 108 and about 116. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of between about 110 and about 114. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 108. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 110. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 112. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 114. In some embodiments, aliphatic polycarbonate polyol compositions have an OH # of about 116.
In certain embodiments, it is advantageous if aliphatic polycarbonate polyol compositions have a substantial proportion of primary hydroxyl end groups. These are the norm for compositions comprising poly(ethylene carbonate), but for polyols derived from copolymerization of substituted epoxides with CO2, it is common for some or most of the chain ends to consist of secondary hydroxyl groups. In certain embodiments, such polyol compositions are treated to increase the proportion of primary —OH end groups. This may be accomplished by reacting the secondary hydroxyl groups with reagents such as ethylene oxide, reactive lactones, and the like. In certain embodiments, aliphatic polycarbonate polyol compositions are treated with beta lactones, caprolactone and the like to introduce primary hydroxyl end groups. In certain embodiments, aliphatic polycarbonate polyol compositions are treated with ethylene oxide to introduce primary hydroxyl end groups.
In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and one or more epoxides. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and ethylene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and propylene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and 1,2-butene oxide and/or 1,2-hexene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and cyclohexene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and cyclopentene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and 3-vinyl cyclohexene oxide. In certain embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and 3-ethyl cyclohexene oxide.
In certain embodiments, aliphatic polycarbonate polyols comprise a terpolymer of carbon dioxide and ethylene oxide along with one or more additional epoxides selected from the group consisting of propylene oxide, 1,2-butene oxide, 2,3-butene oxide, cyclohexene oxide, 3-vinyl cyclohexene oxide, 3-ethyl cyclohexene oxide, cyclopentene oxide, epichlorohydrin, glicydyl esters, glycidyl ethers, styrene oxides, and epoxides of higher alpha olefins. In certain embodiments, such terpolymers contain a majority of repeat units derived from ethylene oxide with lesser amounts of repeat units derived from one or more additional epoxides. In certain embodiments, terpolymers contain about 50% to about 99.5% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than about 60% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 75% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 80% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 85% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 90% ethylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 95% ethylene oxide-derived repeat units.
In some embodiments, aliphatic polycarbonate polyols comprise a copolymer of carbon dioxide and propylene oxide along with one or more additional epoxides selected from the group consisting of ethylene oxide, 1,2-butene oxide, 2,3-butene oxide, cyclohexene oxide, 3-vinyl cyclohexene oxide, cyclopentene oxide, epichlorohydrin, glicydyl esters, glycidyl ethers, styrene oxides, and epoxides of higher alpha olefins. In certain embodiments, such terpolymers contain a majority of repeat units derived from propylene oxide with lesser amounts of repeat units derived from one or more additional epoxides. In certain embodiments, terpolymers contain about 50% to about 99.5% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 60% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 75% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 80% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 85% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 90% propylene oxide-derived repeat units. In certain embodiments, terpolymers contain greater than 95% propylene oxide-derived repeat units.
In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn in the range of 500 g/mol to about 50,000 g/mol. In some embodiments, Mn is measured by size-exclusion chromatography. In some embodiments, Mn is measured by gel permeation chromatography. In some embodiments, gel permeation chromatography comprises a polystyrene standard.
In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 40,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn less than about 25,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 20,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 10,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 5,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 1,000 g/mol and about 5,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 5,000 g/mol and about 10,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 1,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 500 g/mol and about 2,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn between about 1,000 g/mol and about 3,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 5,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 4,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 3,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 2,500 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 2,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 1,500 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 1,000 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 750 g/mol. In certain embodiments, aliphatic polycarbonate polyol compositions have a Mn of about 500 g/mol.
In certain embodiments, aliphatic polycarbonate polyols used are characterized in that they have a narrow molecular weight distribution. This can be indicated by the polydispersity indices (PDI) of the polycarbonate polyols. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI less than 3. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI less than 2. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI less than 1.8. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI less than 1.5. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI less than 1.4. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI between about 1.0 and 1.2. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI between about 1.0 and 1.1.
In certain embodiments, aliphatic polycarbonate polyol compositions used do not have a narrow PDI. This can be the case if, for example, a polydisperse chain transfer agent is used to initiate an epoxide CO2 copolymerization, or if a plurality of polycarbonate polyol compositions with different molecular weights are blended. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI greater than 3. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI greater than 2. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI greater than 1.8. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI greater than 1.5. In certain embodiments, aliphatic polycarbonate polyol compositions (or a subcomponent thereof) have a PDI greater than 1.4.
In some embodiments, PDI is measured by size-exclusion chromatography. In some embodiments, PDI is measured by gel permeation chromatography. In some embodiments, gel permeation chromatography comprises a polystyrene standard.
In certain embodiments, aliphatic polycarbonate polyols contain a high percentage of carbonate linkages and a low content of ether linkages. In some embodiments, the percentage of carbonate linkages may be determined by 1H or 13C NMR spectroscopy. In some embodiments, the percentage of carbonate linkages may be determined by infrared (IR) or Raman spectroscopy.
In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention comprise substantially alternating polymers containing a high percentage of carbonate linkages and a low content of ether linkages. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 85% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 90% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 91% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 92% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 93% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 94% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 95% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 96% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 97% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 98% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 99% or greater. In certain embodiments, aliphatic polycarbonate polyol compositions of the present invention are characterized in that, on average in the composition, the percentage of carbonate linkages is 99.5% or greater. Unless otherwise stated, the percentages above exclude ether linkages present in polymerization initiators or chain transfer agents and refer only to the linkages formed during epoxide CO2 copolymerization.
In certain embodiments, aliphatic polycarbonate polyol compositions are characterized in that they contain essentially no ether linkages either within the polymer chains derived from epoxide CO2 copolymerization or within any polymerization initiators, chain transfer agents, or end groups that may be present in the polymer. In certain embodiments, aliphatic polycarbonate polyol compositions are characterized in that they contain, on average, less than one ether linkage per polymer chain within the composition. In certain embodiments, aliphatic polycarbonate polyol compositions are characterized in that they contain essentially no ether linkages.
In certain embodiments, where an aliphatic polycarbonate polyol is derived from mono-substituted epoxides (e.g. such as propylene oxide, 1,2-butylene oxide, epichlorohydrin, epoxidized alpha olefins, or a glycidol derivative), the aliphatic polycarbonate polyol is characterized in that it is regioregular. Regioregularity may be expressed as the percentage of adjacent monomer units that are oriented in a head-to-tail arrangement within the polymer chain. In certain embodiments, aliphatic polycarbonate polyols have a head-to-tail content higher than about 80%. In certain embodiments, the head-to-tail content is higher than about 85%. In certain embodiments, the head-to-tail content is higher than about 90%. In certain embodiments, the head-to-tail content is greater than about 91%, greater than about 92%, greater than about 93%, greater than about 94%, or greater than about 95%. In certain embodiments, the head-to-tail content of the polymer is as determined by proton or carbon-13 NMR spectroscopy.
In certain embodiments, aliphatic polycarbonate polyols have a structure P1:
wherein,
is a covalent bond or a multivalent moiety; and
In some embodiments, R1, R2, R3, and R4 are, independently at each occurrence in the polymer chain, selected from the group consisting of hydrogen and optionally substituted C1-C6 aliphatic. In some embodiments, R1, R2, R3, and R4 are, independently at each occurrence in the polymer chain, selected from the group consisting of hydrogen and methyl.
In some embodiments, Y is, at each occurrence, —H or the site of attachment to a chain-extending moiety. In some embodiments Y is —H.
It will be understood that when a composition that comprises an aliphatic polycarbonate polyol has a structure of formulae P1 through P2r-a, the composition may also comprise other polymer species, e.g., those with occurrences where n is 0 or 1.
In certain embodiments, the multivalent moiety
embedded within the aliphatic polycarbonate chain is derived from a polyfunctional chain transfer agent having two or more sites from which epoxide/CO2 copolymerization can occur. In certain embodiments, such copolymerizations are performed in the presence of polyfunctional chain transfer agents as exemplified in published PCT application WO 2010/028362. In certain embodiments, such copolymerizations are performed as exemplified in US 2011/0245424. In certain embodiments, such copolymerizations are performed as exemplified in Green Chem. 2011, 13, 3469-3475.
In certain embodiments, a polyfunctional chain transfer agent has a formula:
wherein each of
x, and y is as defined above and described in classes and subclasses herein.
In certain embodiments, aliphatic polycarbonate polyols are derived from the copolymerization of one or more epoxides with carbon dioxide in the presence of such polyfunctional chain transfer agents as shown in Scheme 1:
In certain embodiments, aliphatic polycarbonate polyols have a structure of Formula P2:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in the classes and subclasses herein.
In certain embodiments where aliphatic polycarbonate polyol chains have a structure P2,
is derived from a dihydric alcohol. In such instances
represents the carbon-containing backbone of the dihydric alcohol, while the two oxygen atoms adjacent to
are derived from the —OH groups of the diol. For example, if the polyfunctional chain transfer agent were ethylene glycol, then
would be —CH2CH2— and P2 would have the following structure:
In certain embodiments where
is derived from a dihydric alcohol, the dihydric alcohol comprises a C2-40 diol. In certain embodiments, the dihydric alcohol is selected from the group consisting of: 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethylpropane-1,3-diol, 2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol, 2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 2,2,4,4-tetramethylcyclobutane-1,3-diol, 1,3-cyclopentanediol, 1,2-cyclohexanediol, 1,3-cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, 1,4-cyclohexanediethanol, isosorbide, glycerol monoesters, glycerol monoethers, trimethylolpropane monoesters, trimethylolpropane monoethers, pentaerythritol diesters, pentaerythritol diethers, and alkoxylated derivatives of any of these.
In certain embodiments, where
is derived from a dihydric alcohol, the dihydric alcohol is selected from the group consisting of: diethylene glycol, triethylene glycol, tetraethylene glycol, higher poly(ethylene glycol), such as those having number average molecular weights of from 220 to about 2000 g/mol, dipropylene glycol, tripropylene glycol, and higher poly(propylene glycol), such as those having number average molecular weights of from 234 to about 2000 g/mol. In some embodiments,
is derived from dipropylene glycol.
In certain embodiments, where
is derived from a dihydric alcohol, the dihydric alcohol comprises an alkoxylated derivative of a compound selected from the group consisting of: a diacid, a diol, or a hydroxy acid. In certain embodiments, the alkoxylated derivatives comprise ethoxylated or propoxylated compounds.
In certain embodiments, where
is derived from a dihydric alcohol, the dihydric alcohol comprises a polymeric diol. In certain embodiments, a polymeric diol is selected from the group consisting of polyethers, polyesters, hydroxy-terminated polyolefins, polyether-copolyesters, polyether polycarbonates, polycarbonate-copolyesters, polyoxymethylene polymers, and alkoxylated analogs of any of these. In certain embodiments, a polymeric diol has an average molecular weight less than about 2000 g/mol. In some embodiments, a polymeric diol has an average molecular weight of between about 500 g/mol and about 1,500 g/mol. In some embodiments, a polymeric diol has an average molecular weight of between about 750 g/mol and about 1,250 g/mol. In some embodiments, a polymeric diol has an average molecular weight of between about 900 g/mol and about 1,100 g/mol. In some embodiments, a polymeric diol has an average molecular weight of about 1,000 g/mol.
In some embodiments, a polymeric diol is a polyether. In some embodiments, a polymeric diol is polyethylene glycol. In some embodiments, a polymeric diol is polypropylene glycol. In some embodiments, a polymeric diol is a polyester.
In certain embodiments,
is derived from a polyhydric alcohol with more than two hydroxy groups. In embodiments in which
is derived from a polyhydric alcohol with more than two hydroxyl groups, these >2 functional polyols are a component of a polyol mixture containing predominantly polyols with two hydroxyl groups. In certain embodiments, these >2 functional polyols are less than 20% of the total polyol mixture by weight. In certain embodiments, these >2 functional polyols are less than 10% of the total polyol mixture. In certain embodiments, these >2 functional polyols are less than 5% of the total polyol mixture. In certain embodiments, these >2 functional polyols are less than 2% of the total polyol mixture.
In certain embodiments, aliphatic polycarbonate polyol compositions comprise polycarbonate polyols where the moiety
is derived from a triol. In certain embodiments, such polycarbonate polyols have the structure P3:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in classes and subclasses herein.
In certain embodiments where
is derived from a triol, the triol is selected from the group consisting of: glycerol, 1,2,4-butanetriol, 2-(hydroxymethyl)-1,3-propanediol; hexane triols, trimethylol propane, trimethylol ethane, trimethylolhexane, 1,2,4-cyclohexanetrimethanol, pentaerythritol mono esters, pentaerythritol mono ethers, and alkoxylated analogs of any of these. In certain embodiments, such alkoxylated derivatives comprise ethoxylated or propoxylated compounds.
In certain embodiments,
is derived from an alkoxylated derivative of a trifunctional carboxylic acid or trifunctional hydroxy acid. In certain embodiments, alkoxylated derivatives comprise ethoxylated or propoxylated compounds.
In certain embodiments, where
is derived from a polymeric triol, the polymeric triol is selected from the group consisting of polyethers, polyesters, hydroxy-terminated polyolefins, polyether-copolyesters, polyether polycarbonates, polyoxymethylene polymers, polycarbonate-copolyesters, and alkoxylated analogs of any of these. In certain embodiments, the alkoxylated polymeric triols comprise ethoxylated or propoxylated compounds.
In certain embodiments,
is derived from a polyhydric alcohol with four hydroxy groups.
In certain embodiments, aliphatic polycarbonate polyol compositions comprise polycarbonate polyols where the moiety
is derived from a tetraol. In certain embodiments, polycarbonate polyols have the structure P4:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in classes and subclasses herein.
In certain embodiments,
is derived from a polyhydric alcohol with more than four hydroxy groups. In certain embodiments,
is derived from a polyhydric alcohol with six hydroxy groups. In certain embodiments, a polyhydric alcohol is dipentaerythritol or an alkoxylated analog or other derivative thereof. In certain embodiments, a polyhydric alcohol is sorbitol or an alkoxylated analog thereof.
In certain embodiments, aliphatic polycarbonate polyols have the structure P5:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in classes and subclasses herein.
In certain embodiments, aliphatic polycarbonate polyols comprise a combination of bifunctional chains (e.g. aliphatic polycarbonates of formula P2) in combination with higher functional chains (e.g. one or more aliphatic polycarbonates of formulae P3 to P5).
In certain embodiments,
is derived from a hydroxy acid. In certain embodiments, aliphatic polycarbonate polyols have the structure P6:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in classes and subclasses herein.
In such instances,
represents the carbon-containing backbone of the hydroxy acid, while ester and carbonate linkages adjacent to
are derived from the —CO2H group and the hydroxy group of the hydroxy acid. For example, if
were derived from 3-hydroxypropanoic acid, then
would be —CH2CH2+ and P6 would have the following structure:
In certain embodiments,
is derived from an optionally substituted C2-40 hydroxy acid. In certain embodiments,
is derived from a polyester. In certain embodiments, such polyesters have a molecular weight less than about 2000 g/mol.
In certain embodiments, a hydroxy acid is an alpha-hydroxy acid. In certain embodiments, a hydroxy acid is selected from the group consisting of: glycolic acid, DL-lactic acid, D-lactic acid, L-lactic, citric acid, and mandelic acid.
In certain embodiments, a hydroxy acid is a beta-hydroxy acid. In certain embodiments, a hydroxy acid is selected from the group consisting of: 3-hydroxypropionic acid, DL 3-hydroxybutryic acid, D-3 hydroxybutryic acid, L-3-hydroxybutyric acid, DL-3-hydroxy valeric acid, D-3-hydroxy valeric acid, L-3-hydroxy valeric acid, salicylic acid, and derivatives of salicylic acid.
In certain embodiments, a hydroxy acid is a α-θ hydroxy acid. In certain embodiments, a hydroxy acid is selected from the group consisting of: of optionally substituted C3-20 aliphatic α-ω hydroxy acids and oligomeric esters.
In certain embodiments, a hydroxy acid is selected from the group consisting of:
In certain embodiments,
is derived from a polycarboxylic acid. In certain embodiments, aliphatic polycarbonate polyols have the structure P7:
wherein each of R1, R2, R3, R4, Y,
and n is as defined above and described in classes and subclasses herein, and y′ is an integer from 1 to 5 inclusive.
In embodiments, where the aliphatic polycarbonate polyols have a structure P7,
represents the carbon-containing backbone (or a bond in the case of oxalic acid) of a polycarboxylic acid, while ester groups adjacent to
are derived from —CO2H groups of the polycarboxylic acid. For example, if
were derived from succinic acid (HO2CCH2CH2CO2H), then
would be —CH2CH2— and P7 would have the following structure:
wherein each of R1, R2, R3, R4, Y, and n is as defined above and described in classes and subclasses herein.
In certain embodiments,
is derived from a dicarboxylic acid. In certain embodiments, aliphatic polycarbonate polyols have the structure P8:
In certain embodiments,
is selected from the group consisting of: phthalic acid, isophthalic acid, terephthalic acid, maleic acid, succinic acid, malonic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, and azelaic acid.
In certain embodiments,
is derived from a diacid selected from the group consisting of:
In certain embodiments,
is derived from a phosphorous-containing molecule. In certain embodiments,
has a formula —P(O)(OR)k— where each R is independently an optionally substituted C1-20 aliphatic group or an optionally substituted aryl group and k is 0, 1, or 2.
For example, if
were derived from PhO—P(O)(OH)2, then
would be —P(O)(OPh)- and P7 would have the following structure:
wherein each of R1, R2, R3, R4, Y, and n is as defined above and described in classes and subclasses herein.
In certain embodiments,
is derived from a phosphorous-containing molecule selected from the group consisting of:
In certain embodiments,
has a formula —P(O)(R)— where R is an optionally substituted C1-20 aliphatic group or an optionally substituted aryl group and k is 0, 1, or 2. In certain embodiments,
is derived from a phosphorous-containing molecule selected from the group consisting of:
where each of R is as defined above and in the classes and subclasses herein; and Rd is optionally substituted C1-6 aliphatic.
In certain embodiments,
has a formula —PR— where R is an optionally substituted C1-20 aliphatic group or an optionally substituted aryl group.
In certain embodiments, each
in the structures herein is independently selected from the group consisting of:
In certain embodiments, each
in the structures herein is independently selected from the group consisting of:
wherein Rx is as defined above and described in classes and subclasses herein.
In certain embodiments, the moiety —Y in the structures herein is —H.
In certain embodiments, —Y comprises an ester linkage to an optionally substituted C2-40 linker comprising (e.g., terminated with) an —OH group. In certain embodiments, —Y is selected from the group consisting of:
In certain embodiments, —Y comprises an ester linkage to an optionally substituted C2-40 linker comprising (e.g., terminated with) an —CO2H group. In certain embodiments, —Y is selected from the group consisting of:
In certain embodiments, the moiety —Y in the structures herein comprises a hydroxy-terminated polymer. In certain embodiments, —Y comprises a hydroxy-terminated polyether. In certain embodiments, —Y comprises
where t is an integer from 1 to 20.
In certain embodiments, —Y comprises a hydroxy-terminated polyester. In certain embodiments, —Y is selected from the group consisting of:
where s is an integer from 2 to 20.
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate-polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
wherein each of —Y and n is as defined above and described in classes and subclasses herein.
In certain embodiments, aliphatic polycarbonate polyols comprise:
—Y, and n is as defined above and described in classes and subclasses herein.
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
—Y, and n are is as defined above and described in classes and subclasses herein; and each independently represents a single or double bond.
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, aliphatic polycarbonate polyols comprise:
—Y, and n is as defined above and described in classes and subclasses herein.
In certain embodiments, aliphatic polycarbonate polyols comprise:
In certain embodiments, in aliphatic polycarbonate polyols of structures P2a, P2c, P2d, P2f, P2h, P2j, P2l, P2l-a, P2n, P2p, and P2r,
is selected from the group consisting of: ethylene glycol; diethylene glycol, triethylene glycol, 1,3 propane diol; 1,4 butane diol, hexylene glycol, 1,6 hexane diol, neopentyl glycol, propylene glycol, dipropylene glycol, tripropylene glycol, and alkoxylated derivatives of any of these.
In certain embodiments, in aliphatic polycarbonates of structures P2a, through P2r-a, —Y is —H.
For polycarbonates comprising repeat units derived from two or more epoxides, such as those represented by structures P2f through P2r-a, depicted above, it is to be understood that the structures drawn may represent mixtures of positional isomers or regioisomers that are not explicitly depicted. For example, the polymer repeat unit adjacent to either end group of the polycarbonate chains can be derived from either one of the two epoxides comprising the copolymers. Thus, while the polymers may be drawn with a particular repeat unit attached to an end group, the terminal repeat units might be derived from either of the two epoxides and a given polymer composition might comprise a mixture of all of the possibilities in varying ratios. The ratio of these end-groups can be influenced by several factors including the ratio of the different epoxides used in the polymerization, the structure of the catalyst used, the reaction conditions used (i.e temperature pressure, etc.) as well as by the timing of addition of reaction components. Similarly, while the drawings above may show a defined regiochemistry for repeat units derived from substituted epoxides, the polymer compositions will, in some cases, contain mixtures of regioisomers. The regioselectivity of a given polymerization can be influenced by numerous factors including the structure of the catalyst used and the reaction conditions employed. To clarify, this means that the composition represented by structure P2r above, may contain a mixture of several compounds as shown in the diagram below. This diagram shows the isomers graphically for polymer P2r, where the structures below the depiction of the chain show each regio- and positional isomer possible for the monomer unit adjacent to the chain transfer agent and the end groups on each side of the main polymer chain. Each end group on the polymer may be independently selected from the groups shown on the left or right while the central portion of the polymer including the chain transfer agent and its two adjacent monomer units may be independently selected from the groups shown. In certain embodiments, the polycarbonate polyol composition comprises a mixture of all possible combinations of these. In other embodiments, the polycarbonate polyol composition is enriched in one or more of these.
In certain embodiments, aliphatic polycarbonate polyols are selected from the group consisting of Q1, Q2, Q3, Q4, Q5, Q6, and mixtures of any two or more of these.
In certain embodiments, an aliphatic polycarbonate polyol is selected from the group consisting of:
In certain embodiments, the
in the embedded chain transfer agent is a moiety derived from a polymeric diol or higher polyhydric alcohol. In certain embodiments, such polymeric alcohols are polyether or polyester polyols. In certain embodiments
is a polyether polyol comprising ethylene glycol or propylene glycol repeating units (—OCH2CH2O—, or —OCH2CH(CH3)O—) or combinations of these. In certain embodiments,
is a polyester polyol comprising the reaction product of a diol and a diacid, or a material derived from ring-opening polymerization of one or more lactones.
In certain embodiments where
comprises a polyether diol, an aliphatic polycarbonate polyol has a structure Q7:
In certain embodiments, an aliphatic polycarbonate polyol is selected from the group consisting of:
In certain embodiments, where aliphatic polycarbonate polyols comprise polymer chains conforming to structure Q7, the moiety
is derived from a commercially available polyether polyol such as those typically used in the formulation of polyurethane compositions.
In certain embodiments, where
comprises a polyester diol, an aliphatic polycarbonate polyol has a structure Q8:
In certain embodiments, an aliphatic polycarbonate polyol is selected from the group consisting of:
In certain embodiments, where aliphatic polycarbonate polyols comprise polymer chains conforming to structure Q8, the moiety
is derived from a commercially available polyester polyol such as those typically used in the formulation of polyurethane compositions.
In certain embodiments, aliphatic polycarbonate polyols have a structure PS1:
is selected from the group consisting of an optionally substituted bivalent C1-6 hydrocarbon chain and
In some embodiments, R10, R20, R30, and R40 are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and optionally substituted C1-6 aliphatic. In some embodiments, R10, R20, R30, and R40 are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and methyl. In some embodiments, each of R10, R20, R30, and R40 is hydrogen.
In some embodiments, each
in the structures herein is independently selected from the group consisting of:
wherein each Rx is as defined above and described herein.
In certain embodiments, each
in the structures herein is independently selected from the group consisting of:
wherein Rx is as defined above and described in classes and subclasses herein.
In certain embodiments, each
in the structures herein is
In certain embodiments, each
in the structures herein is
In certain embodiments, each
in the structures herein is
In some embodiments, Y10 is, at each occurrence, independently —H, a reactive group, or a site of attachment to any of the chain-extending moieties or isocyanates. In some embodiments, Y10 is, at each occurrence, independently —H or a site of attachment to a chain-extending moiety. In some embodiments, Y10 is, at each occurrence, independently —H. In some embodiments, Y10 is, at each occurrence, independently a reactive group. In some embodiments, Y10 is, at each occurrence, independently a site of attachment to a chain-extending moiety. In some embodiments, Y10 is, at each occurrence, independently a site of attachment to an isocyanate.
In some embodiments, each n10 is, at each occurrence, independently an integer from about 2 to about 20. In some embodiments, each n10 is, at each occurrence, independently an integer from about 2 to about 15. In some embodiments, each n10 is, at each occurrence, independently an integer from about 2 to about 10. In some embodiments, each n10 is, at each occurrence, independently an integer from about 3 to about 7. In some embodiments, each n10 is, at each occurrence, independently an integer from about 4 to about 5.
In some embodiments, the sum of the n10 moieties within each polymer chain is between about 6 to about 12. In some embodiments, the sum of the n10 moieties within each polymer chain is between about 7 to about 11. In some embodiments, the sum of the n10 moieties within each polymer chain is between about 8 to about 10. In some embodiments, the sum of the n10 moieties within each polymer chain is about 9.
In some embodiments,
is selected from the group consisting of an optionally substituted bivalent C1-6 hydrocarbon chain and
In some embodiments,
is an optionally substituted bivalent C1-6 hydrocarbon chain. In some embodiments,
is a bivalent C1-6 hydrocarbon chain. In some embodiments,
is a bivalent C1-4 hydrocarbon chain. In some embodiments,
is a bivalent C2-6 hydrocarbon chain. In some embodiments,
is a bivalent C3-6 hydrocarbon chain.
In some embodiments,
is
In some embodiments, R9b and R10b are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and optionally substituted C1-6 aliphatic. In some embodiments, R9b and R10b are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and methyl. In some embodiments, R9b is, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and methyl. In some embodiments, R9b is, at each occurrence in the polymer chain, independently hydrogen. In some embodiments, R9b is, at each occurrence in the polymer chain, independently methyl. In some embodiments, R10b is, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and methyl. In some embodiments, R10b is, at each occurrence in the polymer chain, independently hydrogen. In some embodiments, R10b is, at each occurrence in the polymer chain, independently methyl.
In some embodiments, each n″ is, at each occurrence within a polymer chain, independently an integer from 1 to 4. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently an integer from 2 to 4. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently an integer from 3 to 4. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently 1. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently 2. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently 3. In some embodiments, each n″ is, at each occurrence within a polymer chain, independently 4.
In some embodiments, each t″ is, at each occurrence within a polymer chain, independently an integer from 1 to 3. In some embodiments, each t″ is, at each occurrence within a polymer chain, independently an integer from 2 to 3. In some embodiments, each t″ is, at each occurrence within a polymer chain, independently 1. In some embodiments, each t″ is, at each occurrence within a polymer chain, independently 2. In some embodiments, each t″ is, at each occurrence within a polymer chain, independently 3.
In certain embodiments, where aliphatic polycarbonate polyol chains have a structure PS1,
is derived from a dihydric alcohol. In such instances,
represents the carbon-containing backbone of the dihydric alcohol, while the two oxygen atoms adjacent to
are derived from the —OH groups of the diol. For example, if the polyfunctional chain transfer agent were ethylene glycol, then
would be —CH2CH2— and PS1 would have the following structure:
In certain embodiments where
is derived from a dihydric alcohol, the dihydric alcohol comprises a C2-6 diol. In certain embodiments, the dihydric alcohol is selected from the group consisting of: 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethylpropane-1,3-diol, 2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol, 2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol, 1,6-hexanediol, and alkoxylated derivatives of any of these. In certain embodiments, the dihydric alcohol is selected from the group consisting of: 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethylpropane-1,3-diol, 2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol, 2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol, 1,6-hexanediol.
In certain embodiments, where
is derived from a dihydric alcohol, the dihydric alcohol is selected from the group consisting of: diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, and tripropylene glycol. In some embodiments,
is derived from dipropylene glycol.
It will be understood that when a composition that comprises an aliphatic polycarbonate polyol has a structure of formula PS1, the composition may also comprise other polymer species, e.g., those with occurrences where n10 is 0 or 1.
In certain embodiments, aliphatic polycarbonate polyols have a structure PS2:
is a polyether.
In some embodiments, R11, R21, R31, and R41 are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and optionally substituted C1-6 aliphatic. In some embodiments, R11, R21, R31, and R41 are, at each occurrence in the polymer chain, independently selected from the group consisting of hydrogen and methyl. In some embodiments, each of R11, R21, R31, and R41 is hydrogen.
In some embodiments, each
in the structures herein is independently selected from the group consisting of:
wherein each Rx is as defined above and described herein.
In certain embodiments, each
in the structures herein is independently selected from the group consisting of:
wherein Rx is as defined above and described in classes and subclasses herein.
In certain embodiments, each
in the structures herein is
In certain embodiments, each
in the structures herein is
In certain embodiments, each
in the structures herein is
In some embodiments, Y11 is, at each occurrence, independently —H, a reactive group, or a site of attachment to any of the chain-extending moieties or isocyanates. In some embodiments, Y11 is, at each occurrence, independently —H or a site of attachment to a chain-extending moiety. In some embodiments, Y11 is, at each occurrence, independently —H. In some embodiments, Y11 is, at each occurrence, independently a reactive group. In some embodiments, Y11 is, at each occurrence, independently a site of attachment to a chain-extending moiety. In some embodiments, Y11 is, at each occurrence, independently a site of attachment to an isocyanate.
In some embodiments, each n11 is, at each occurrence, independently an integer from about 2 to about 20. In some embodiments, each n11 is, at each occurrence, independently an integer from about 2 to about 15. In some embodiments, each n11 is, at each occurrence, independently an integer from about 2 to about 10. In some embodiments, each n11 is, at each occurrence, independently an integer from about 3 to about 7. In some embodiments, each n11 is, at each occurrence, independently an integer from about 4 to about 6. In some embodiments, each n11 is, at each occurrence, independently about 5.
In some embodiments, the sum of the n11 moieties within each polymer chain is between about 5 to about 15. In some embodiments, the sum of the n11 moieties within each polymer chain is between about 5 to about 10. In some embodiments, the sum of the n11 moieties within each polymer chain is between about 10 to about 15. In some embodiments, the sum of the n11 moieties within each polymer chain is between about 8 to about 12. In some embodiments, the sum of the n11 moieties within each polymer chain is between about 9 to about 11. In some embodiments, the sum of the n11 moieties within each polymer chain is about 10.
In some embodiments,
is a polyether. In some embodiments,
is polyethylene glycol. In some embodiments,
is derived from poly(ethylene glycol) having a Mn between about 234 and about 2000 g/mol. In some embodiments,
is derived from poly(ethylene glycol) having a Mn between about 900 g/mol and 1,100 g/mol. In some embodiments,
is derived from poly(ethylene glycol) having a Mn of about 1000 g/mol.
In some embodiments,
is polypropylene glycol. In some embodiments,
is derived from poly(propylene glycol) having a Mn between about 234 and about 2000 g/mol. In some embodiments,
is derived from poly(propylene glycol) having a Mn between about 900 g/mol and 1,100 g/mol. In some embodiments,
is derived from poly(propylene glycol) having a Mn of about 1000 g/mol.
It will be understood that when a composition that comprises an aliphatic polycarbonate polyol has a structure of formula PS2, the composition may also comprise other polymer species, e.g., those with occurrences where n11 is 0 or 1.
In certain embodiments, an aliphatic polycarbonate polyol has a structure of formula
wherein each n′ is, at each occurrence, independently an integer from about 2 to about 50.
In some embodiments, each n′ is, at each occurrence, independently an integer from about 2 to about 20. In some embodiments, each n′ is, at each occurrence, independently an integer from about 2 to about 15. In some embodiments, each n′ is, at each occurrence, independently an integer from about 2 to about 10. In some embodiments, each n′ is, at each occurrence, independently an integer from about 3 to about 7. In some embodiments, each n′ is, at each occurrence, independently an integer from about 4 to about 5.
In some embodiments, the sum of the n′ moieties within each polymer chain is between about 6 to about 12. In some embodiments, the sum of the n′ moieties within each polymer chain is between about 7 to about 11. In some embodiments, the sum of the n′ moieties within each polymer chain is between about 8 to about 10. In some embodiments, the sum of the n′ moieties within each polymer chain is about 9.
It will be understood that when a composition comprising an aliphatic polycarbonate polyol has a structure of formula Q10, the composition may also comprise other polymer species, e.g., those with occurrences where n′ is 0 or 1.
In some embodiments, an aliphatic polycarbonate polyol has a structure of formula Q10 and an OH # of between about 105 and about 120, or an OH # of about 112.
In certain embodiments, an aliphatic polycarbonate polyol has a structure of formula
wherein each a is, at each occurrence, independently an integer from about 2 to about 50; and each m′ is, at each occurrence, independently an integer from about 2 to about 50.
In some embodiments, each a is, at each occurrence, independently an integer from about 2 to about 20. In some embodiments, each a is, at each occurrence, independently an integer from about 2 to about 15. In some embodiments, each a is, at each occurrence, independently an integer from about 5 to about 12. In some embodiments, each a is, at each occurrence, independently an integer from about 6 to about 10. In some embodiments, each a is, at each occurrence, independently an integer from about 7 to about 9. In some embodiments, each a is, at each occurrence, about 8.
In some embodiments, the sum of the a moieties within each polymer chain is between about 12 and about 20. In some embodiments, the sum of the a moieties within each polymer chain is between about 14 and about 18. In some embodiments, the sum of the a moieties within each polymer chain is between about 15 and about 17. In some embodiments, the sum of the a moieties within each polymer chain is about 16.
In some embodiments, each m′ is, at each occurrence, independently an integer from about 2 to about 20. In some embodiments, each m′ is, at each occurrence, independently an integer from about 2 to about 10. In some embodiments, each m′ is, at each occurrence, independently an integer from about 3 to about 7. In some embodiments, each m′ is, at each occurrence, independently an integer from about 4 to about 6. In some embodiments, each m′ is, at each occurrence, independently about 5.
In some embodiments, the sum of the m′ moieties within each polymer chain is between about 5 and about 15. In some embodiments, the sum of the m′ moieties within each polymer chain is between about 5 and about 10. In some embodiments, the sum of the m′ moieties within each polymer chain is between about 10 and about 15. In some embodiments, the sum of the m′ moieties within each polymer chain is between about 8 and about 12. In some embodiments, the sum of the m′ moieties within each polymer chain is between about 9 and about 11. In some embodiments, the sum of the m′ moieties within each polymer chain is about 10.
It will be understood that when a composition comprising an aliphatic polycarbonate polyol has a structure of formula Q11, the composition may also comprise other polymer species, e.g., those with occurrences where m′ is 0 or 1.
In some embodiments, an aliphatic polycarbonate polyol has a structure of formula Q11 and an OH # of between about 50 and about 60, or an OH # of about 56.
As described above, compositions useful in the present invention may be combined with isocyanate reagents to form polyurethane compositions. The purpose of these isocyanate reagents is to react with the reactive end groups on the polyols to form isocyanate-terminated prepolymers or higher molecular weight structures through chain extension and/or cross-linking.
The art of polyurethane synthesis is well advanced and a very large number of isocyanates and related polyurethane precursors are known in the art. While this section of the specification describes isocyanates suitable for use in certain embodiments of the present invention, it is to be understood that it is within the capabilities of one skilled in the art of polyurethane formulation to use alternative isocyanates along with the teachings of this disclosure to formulate additional compositions of matter within the scope of the present invention. Descriptions of suitable isocyanate compounds and related methods can be found in: Chemistry and Technology of Polyols for Polyurethanes Ionescu, Mihail 2005 (ISBN 978-1-84735-035-0), and H. Ulrich, “Urethane Polymers,” Kirk-Othmer Encyclopedia of Chemical Technology, 1997 the entirety of each of which is incorporated herein by reference.
In certain embodiments, isocyanate reagents comprise two or more isocyanate groups per molecule. In certain embodiments, isocyanate reagents are diisocyanates. In other embodiments, isocyanate reagents are higher polyisocyanates such as triisocyanates, tetraisocyanates, isocyanate polymers or oligomers, and the like, which are typically a minority component of a mix of predominanetly diisocyanates. In certain embodiments, isocyanate reagents are aliphatic polyisocyanates or derivatives or oligomers of aliphatic polyisocyanates. In other embodiments, isocyanates are aromatic polyisocyanates or derivatives or oligomers of aromatic polyisocyanates. In certain embodiments, compositions may comprise mixtures of any two or more of the above types of isocyanates.
In certain embodiments, isocyanate reagents usable for the production of the polyurethane adhesive include aliphatic, cycloaliphatic and aromatic diisocyanate compounds.
Suitable aliphatic and cycloaliphatic isocyanate compounds include, for example, 1,3-trimethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethylhexamethylene diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, 1,9-nonamethylene diisocyanate, 1,10-decamethylene diisocyanate, 1,4-cyclohexane diisocyanate, isophorone diisocyanate (IPDI), 4,4,′-dicyclohexylmethane diisocyanate, 2,2′-diethylether diisocyanate, hydrogenated xylylene diisocyanate, and hexamethylene diisocyanate-biuret.
The aromatic isocyanate compounds include, for example, p-phenylene diisocyanate, tolylene diisocyanate, xylylene diisocyanate, 4,4′-diphenyl diisocyanate, 2,4′-diphenylmethane diisocyanate, 1,5-naphthalene diisocyanate, 4,4′-diphenylmethane diisocyanate (MDI), 3,3′-methyleneditolylene-4,4′-diisocyanate, tolylenediisocyanate-trimethylolpropane adduct, triphenylmethane triisocyanate, 4,4′-diphenylether diisocyanate, tetrachlorophenylene diisocyanate, 3,3′-dichloro-4,4′-diphenylmethane diisocyanate, and triisocyanate phenylthiophosphate.
In certain embodiments, an isocyanate compound employed comprises one or more of: 4,4′-diphenylmethane diisocyanate, 1,6-hexamethylene hexamethylene diisocyanate and isophorone diisocyanate (IPDI). In certain embodiments, an isocyanate compound employed is 4,4′-diphenylmethane diisocyanate. In certain embodiments, an isocyanate compound employed is IPDI. The above-mentioned diisocyanate compounds may be employed alone or in mixtures of two or more thereof.
In certain embodiments, an isocyanate reagent is selected from the group consisting of: 1,6-hexamethylaminediisocyanate (HDI), isophorone diisocyanate (IPDI), 4,4′ methylene-bis(cyclohexyl isocyanate) (H12MDI), 2,4-toluene diisocyanate (TDI), 2,6-toluene diisocyanate (TDI), diphenylmethane-4,4′-diisocyanate (MDI), diphenylmethane-2,4′-diisocyanate (MDI), xylylene diisocyanate (XDI), 1,3-Bis(isocyanatomethyl)cyclohexane (H6-XDI), 2,2,4-trimethylhexamethylene diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate (TMDI), m-tetramethylxylylene diisocyanate (TMXDI), p-tetramethylxylylene diisocyanate (TMXDI), isocyanatomethyl-1,8-ictane diisocyanate (TIN), triphenylmethane-4,4′,4″triisocyanate, Tris(p-isocyanatomethyl)thiosulfate, 1,3-Bis(isocyanatomethyl)benzene, 1,4-tetramethylene diisocyanate, trimethylhexane diisocyanate, 1,6-hexamethylene diisocyanate, 1,4-cyclohexyl diisocyanate, lysine diisocyanate, HDI allophonate trimer, HDI urethdione and HDI-trimer and mixtures of any two or more of these.
In certain embodiments, an isocyanate reagent is selected from the group consisting of 4,4′-diphenylmethane diisocyanate, 1,6-hexamethylene diisocyanate and isophorone diisocyanate. In certain embodiments, an isocyanate reagent is 4,4′-diphenylmethane diisocyanate. certain embodiments, an isocyanate reagent is 1,6-hexamethylene diisocyanate. In certain embodiments, an isocyanate reagent is isophorone diisocyanate (IPDI).
Isocyanates suitable for certain embodiments of the present invention are available commercially under various trade names. Examples of suitable commercially available isocyanates include materials sold under trade names: Desmodur® (Bayer Material Science), Tolonate® (Perstorp), Takenate® (Takeda), Vestanat® (Evonik), Desmotherm® (Bayer Material Science), Bayhydur® (Bayer Material Science), Mondur (Bayer Material Science), Suprasec (Huntsman Inc.), Lupranate® (BASF), Trixene (Baxenden), Hartben® (Benasedo), Ucopol® (Sapici), and Basonat® (BASF). Each of these trade names encompasses a variety of isocyanate materials available in various grades and formulations. The selection of suitable commercially available isocyanate materials as reagents to produce polyurethane compositions for a particular application is within the capability of one skilled in the art of polyurethane coating technology using the teachings and disclosure of this patent application along with the information provided in the product data sheets supplied by the above-mentioned suppliers.
Additional isocyanates suitable for certain embodiments of the present invention are sold under the trade name Lupranate® (BASF). In certain embodiments, isocyanates are selected from the group consisting of the materials shown in Table 1, and typically from the subset of isocyanates from this list with the functionality between 1.95 and 2.1.
Other isocyanates suitable for certain embodiments of the present invention are sold under the trade name Desmodur® available from Bayer Material Science. In certain embodiments, isocyanates are selected from the group consisting of the materials shown in Table 2, and typically from the subset of isocyanates with functionality between 1.95 and 2.1.
Additional isocyanates suitable for certain embodiments of the present invention are sold under the trade name Tolonate® (Perstorp). In certain embodiments, isocyanates are selected from the group consisting of the materials shown in Table 3, and typically from the subset of this list with functionality in the range of 1.95 and 2.1
Other isocyanates suitable for certain embodiments of the present invention are sold under the trade name Mondur® available from Bayer Material Science. In certain embodiments, isocyanates are selected from the group consisting of the materials shown in Table 4, and typically from the subset of isocyanates with functionality between 1.95 and 2.1.
In certain embodiments, one or more of the above-described isocyanate compositions is provided in a formulation typical of a mixture known in the art of polyurethane adhesives manufacture. Such mixtures may comprise prepolymers formed by the reaction of a molar excess of one or more isocyanates with reactive molecules comprising reactive functional groups such as alcohols, amines, thiols, carboxylates and the like. These mixtures may also comprise solvents, surfactants, stabilizers, and other additives known in the art.
In certain embodiments, the composition of the adhesive might comprise a blocked isocyanate and a polyol. Such a mixture of blocked isocyanate and a polyol do not react under normal conditions, even in the presence of water and the curing of this mixture is triggered by heating.
In another aspect, the present invention encompasses prepolymers comprising isocyanate-terminated polyols (“isocyanate-terminated prepolymers”) derived from compositions described herein. In certain embodiments, such isocyanate-terminated prepolymers comprise a plurality of polyol segments linked via urethane bonds formed by reaction with polyisocyanate compounds.
In certain embodiments, a prepolymer of the present invention is the result of a reaction between one or more of the polycarbonate polyols described above with a stoichiometric excess of any one or more of the diisocyanates described herein. The degree of polymerization of these prepolymers (i.e. the average number of polyol segments contained in the prepolymer chains) can be manipulated by controlling the relative amount of isocyanate, as well as the order of reagent addition and the reaction conditions.
In certain embodiments, prepolymers comprise compounds conforming to a formula:
wherein Q is 0 or an integer between 1 and about 50, each open rectangle, , represents a polyol moiety each of which may be the same or different, and where, the black rectangles
represent the carbon skeleton of the diisocyanate.
In certain embodiments, prepolymers comprise chains conforming to the formula:
wherein, ,
Q, R1, R2, R3, R4, and n are as defined above and in the classes and subclasses herein.
In certain embodiments, prepolymers comprises chains conforming to the formula:
wherein, ,
Q, R10, R20, R30, R40, and n10 are as defined above and in the classes and subclasses herein.
In certain embodiments, prepolymers comprises chains conforming to the formula:
wherein, ,
Q, R11, R21, R31, R41, and n11 are as defined above and in the classes and subclasses herein.
In certain embodiments, prepolymers comprise chains conforming to the formula:
wherein, ,
Q, and n are as defined above and in the classes and subclasses herein.
In certain embodiments, prepolymers comprise chains conforming to the formula:
wherein, ,
Q, a, and n are as defined above and in the classes and subclasses herein.
In other embodiments, a prepolymer may be formed by reacting a stoichiometric excess of polyol with a limited amount of isocyanate. In such embodiments, the inventive prepolymer has —OH end groups and contains two or more polyol units connected by urethane linkages. In certain embodiments, such prepolymers conform to a structure:
wherein ,
, and Q, are as defined above and in the classes and subclasses herein.
In certain embodiments, such prepolymers have structures conforming to:
wherein ,
Q, R1, R2, R3, R4, and n are as defined above and in the classes and subclasses herein.
It will be appreciated that, e.g., depending on the purpose or application, isocyanate terminated prepolymer compositions may also comprise residual isocyanate reagent. In some embodiments, an isocyanate terminated prepolymer composition comprises up to 50 weight percent residual isocyanate reagent.
Additionally or alternatively, it will be appreciated that, e.g., depending on the purpose or application, isocyanate terminated prepolymer compositions comprise unreacted NCO functionality. Unreacted NCO functionality refers to the weight percent of NCO from residual isocyanate reagent and unreacted NCO groups on the prepolymer in the mass of the isocyanate terminated prepolymer.
In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 0.5% to 20% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 2% to 18% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 6% to 16% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 0.5% to 10% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 0.5% to 8% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 0.5% to 6% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 0.5% to 4% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 2% to 6% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises between about 3% to 5% weight percent NCO functionality. In some embodiments, an isocyanate-terminated prepolymer composition comprises about 4% weight percent NCO functionality.
In some aspects, the present invention encompasses polyurethane compositions derived from polyurethane reaction mixtures provided herein. In certain embodiments, polyurethane reaction mixtures comprise additional reactive small molecules known as chain extenders such as amines, alcohols, thiols or carboxylic acids that participate in bond-forming reactions with isocyanates. In certain embodiments, additives are selected from the group consisting of: solvents, fillers, clays, blocking agents, stabilizers, thixotropes, plasticizers, compatibilizers, colorants, UV stabilizers, flame retardants, and the like.
In certain embodiments, polyurethane reaction mixtures include one or more small molecules reactive toward isocyanates. In certain embodiments, reactive small molecules included in polyurethane reaction mixtures comprise low molecular weight organic molecules having one or more functional groups selected from the group consisting of alcohols, amines, carboxylic acids, thiols, and combinations of any two or more of these.
In certain embodiments, polyurethane reaction mixtures include one or more alcohols. In certain embodiments, polyurethane reaction mixtures include polyhydric alcohols.
In certain embodiments, reactive small molecules included in polyurethane reaction mixtures comprise dihydric alcohols. In certain embodiments, the dihydric alcohol comprises a C2-40 diol. The polyol compound is selected from aliphatic and cycloaliphatic polyol compounds, for example, ethylene glycol, 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,2-propylene glycol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,9-nonane diol, 1,10-decane diol, neopentyl glycol, 3-methyl-1,5-pentane diol, 3,3-dimethylolheptane, 1,4-cyclohexane diol, 1,4-cyclohexanedimethanol and 1,4-dihydroxyethyl cyclohexane; and aliphatic and aromatic polyamine compounds, for example, ethylene diamine, 1,2-propylene diamine, 1,6-hexamethylene diamine, isophorone diamine bis(4-aminocyclohexyl)methane, piperazine and meta- or para-xylene diamine; aliphatic, cycloaliphatic and aromatic aminoalcohol compounds, for example, 2-ethanolamine, N-methyldiethanolamine, N-phenyldipropanolamine; hydroxyalkyl sulfamides, for example, hydroxyethyl sulfamide and hydroxyethylaminoethyl sulfamide; urea and water. Among the above-mentioned chain extending compounds, preferably 1,4-butane diol, 2-ethanolamine, and 1,2-propylenediamine are employed. In certain embodiments, the chain extender is selected from the group consisting of: 1,4-cyclohexanediethanol, isosorbide, glycerol monoesters, glycerol monoethers, trimethylolpropane monoesters, trimethylolpropane monoethers, pentaerythritol diesters, pentaerythritol diethers, and alkoxylated derivatives of any of these. The above-mentioned chain-extending compounds may be used alone or in a mixture of two or more thereof.
In certain embodiments, a reactive small molecule included in polyurethane reaction mixtures comprises a dihydric alcohol selected from the group consisting of: diethylene glycol, triethylene glycol, tetraethylene glycol, higher poly(ethylene glycol), such as those having number average molecular weights of from 220 to about 2000 g/mol, dipropylene glycol, tripropylene glycol, and higher poly(propylene glycols) such as those having number average molecular weights of from 234 to about 2000 g/mol.
In certain embodiments, a reactive small molecule included in polyurethane reaction mixtures comprises an alkoxylated derivative of a compound selected from the group consisting of: a diacid, a diol, or a hydroxy acid. In certain embodiments, the alkoxylated derivatives comprise ethoxylated or propoxylated compounds.
In certain embodiments, a reactive small molecule included in polyurethane reaction mixtures comprises a polymeric diol. In certain embodiments, a polymeric diol is selected from the group consisting of polyethers, polyesters, hydroxy-terminated polyolefins, polyether-copolyesters, polyether polycarbonates, polycarbonate-copolyesters, and alkoxylated analogs of any of these. In certain embodiments, the polymeric diol has an average molecular weight less than about 2000 g/mol.
In certain embodiments, a reactive small molecule comprises a hydroxy-carboxylic acid having the general formula (HO)xQ(COOH)y, wherein Q is a straight or branched hydrocarbon radical containing 1 to 12 carbon atoms, and x and y are each integers from 1 to 3. In certain embodiments, a coreactant comprises a diol carboxylic acid. In certain embodiments, a coreactant comprises a bis(hydroxylalkyl) alkanoic acid. In certain embodiments, a coreactant comprises a bis(hydroxylmethyl) alkanoic acid. In certain embodiments the diol carboxylic acid is selected from the group consisting of 2,2 bis-(hydroxymethyl)-propanoic acid (dimethylolpropionic acid, DMPA) 2,2-bis(hydroxymethyl) butanoic acid (dimethylolbutanoic acid; DMBA), dihydroxysuccinic acid (tartaric acid), and 4,4′-bis(hydroxyphenyl) valeric acid. In certain embodiments, a coreactant comprises an N,N-bis(2-hydroxyalkyl)carboxylic acid.
In certain embodiments, a reactive small molecule comprises a polyhydric alcohol comprising one or more amino groups. In certain embodiments, a reactive small molecule comprises an amino diol. In certain embodiments, a reactive small molecule comprises a diol containing a tertiary amino group. In certain embodiments, an amino diol is selected from the group consisting of: diethanolamine (DEA), N-methyldiethanolamine (MDEA), N-ethyldiethanolamine (EDEA), N-butyldiethanolamine (BDEA), N,N-bis(hydroxyethyl)-α-amino pyridine, dipropanolamine, diisopropanolamine (DIPA), N-methyldiisopropanolamine, Diisopropanol-p-toluidine, N,N-Bis(hydroxyethyl)-3-chloroaniline, 3-diethylaminopropane-1,2-diol, 3-dimethylaminopropane-1,2-diol and N-hydroxyethylpiperidine. In certain embodiments, a coreactant comprises a diol containing a quaternary amino group. In certain embodiments, a coreactant comprising a quaternary amino group is an acid salt or quaternized derivative of any of the amino alcohols described above. In some embodiments, a reactive small molecule is DMPA.
In certain embodiments, a reactive small molecule is selected from the group consisting of: inorganic or organic polyamines having an average of about 2 or more primary and/or secondary amine groups, polyalcohols, ureas, and combinations of any two or more of these. In certain embodiments, a reactive small molecule is selected from the group consisting of: diethylene triamine (DETA), ethylene diamine (EDA), meta-xylylenediamine (MXDA), aminoethyl ethanolamine (AEEA), 2-methyl pentane diamine, and the like, and mixtures thereof. Also suitable for practice in the present invention are propylene diamine, butylene diamine, hexamethylene diamine, cyclohexylene diamine, phenylene diamine, tolylene diamine, 3,3-dichlorobenzidene, 4,4′-methylene-bis-(2-chloroaniline), 3,3-dichloro-4,4-diamino diphenylmethane, and sulfonated primary and/or secondary amines. In certain embodiments, reactive small molecule is selected from the group consisting of: hydrazine, substituted hydrazines, hydrazine reaction products, and the like, and mixtures thereof. In certain embodiments, a reactive small molecule is a polyalcohol including those having from 2 to 12 carbon atoms, preferably from 2 to 8 carbon atoms, such as ethylene glycol, diethylene glycol, neopentyl glycol, butanediols, hexanediol, and the like, and mixtures thereof. Suitable ureas include urea and its derivatives, and the like, and mixtures thereof.
In certain embodiments, reactive small molecules containing at least one basic nitrogen atom are selected from the group consisting of: mono-, bis- or polyalkoxylated aliphatic, cycloaliphatic, aromatic or heterocyclic primary amines, N-methyl diethanolamine, N-ethyl diethanolamine, N-propyl diethanolamine, N-isopropyl diethanolamine, N-butyl diethanolamine, N-isobutyl diethanolamine, N-oleyl diethanolamine, N-stearyl diethanolamine, ethoxylated coconut oil fatty amine, N-allyl diethanolamine, N-methyl diisopropanolamine, N-ethyl diisopropanolamine, N-propyl diisopropanolamine, N-butyl diisopropanolamine, cyclohexyl diisopropanolamine, N,N-diethoxylaniline, N,N-diethoxyl toluidine, N,N-diethoxyl-1-aminopyridine, N,N′-diethoxyl piperazine, dimethyl-bis-ethoxyl hydrazine, N,N′-bis-(2-hydroxyethyl)-N,N′-diethylhexahydr op-phenylenediamine, N-12-hydroxyethyl piperazine, polyalkoxylated amines, propoxylated methyl diethanolamine, N-methyl-N,N-bis-3-aminopropylamine, N-(3-aminopropyl)-N,N′-dimethyl ethylenediamine, N-(3-aminopropyl)-N-methyl ethanolamine, N,N′-bis-(3-aminopropyl)-N,N′-dimethyl ethylenediamine, N,N′-bis-(3-aminopropyl)-piperazine, N-(2-aminoethyl)-piperazine, N, N′-bisoxyethyl propylenediamine, 2,6-diaminopyridine, diethanolaminoacetamide, diethanolamidopropionamide, N,N-bisoxyethylphenyl thiosemicarbazide, N,N-bis-oxyethylmethyl semicarbazide, p,p′-bis-aminomethyl dibenzyl methylamine, 2,6-diaminopyridine, 2-dimethylaminomethyl-2-methylpropanel, 3-diol. In certain embodiments, chain-extending agents are compounds that contain two amino groups. In certain embodiments, chain-extending agents are selected from the group consisting of: ethylene diamine, 1,6-hexamethylene diamine, and 1,5-diamino-1-methyl-pentane.
In certain embodiments, no catalysts are used in provided polyurethane reaction mixtures. In certain embodiments, in the polymerization reaction for a polyurethane, a conventional catalyst comprising an amine compound or tin compound can be employed to promote the reaction. These embodiments are most commonly found in reactive extrusion methods of polyurethane adhesive production. Any suitable urethane catalyst may be used, including tertiary amine compounds and organometallic compounds may be used. Exemplary tertiary amine compounds include triethylenediamine, N-methylmorpholine, N,N-dimethylcyclohexylamine, pentamethyldiethylenetriamine, tetramefhylefhylenediamine, 1-methyl-4-dimethylaminoethylpiperazine, 3-methoxy-N-dimethylpropylamine, N-ethylmorpholine, diethylethanolamine, N-cocomorpholine, N,N-dimethyl-N′,N′-dimethyl isopropylpropylenediamine, N,N-diethyl-3-diethylaminopropylamine and dimethylbenzylamine. Exemplary organometallic catalysts include organomercury, organolead, organoferric and organotin catalysts, with organotin catalysts being preferred among these. Suitable tin catalysts include stannous chloride, tin salts of carboxylic acids such as dibutyltin dilaurate, as well as other organometallic compounds such as are disclosed in U.S. Pat. No. 2,846,408. A catalyst for the trimerization of polyisocyanates, resulting in a polyisocyanurate, such as an alkali metal alkoxide may also optionally be employed herein. Such catalysts are used in an amount which measurably increases the rate of polyurethane or polyisocyanurate formation.
In certain embodiments, where polyurethane reaction mixtures comprise catalysts, the catalysts comprise tin based materials. In certain embodiments, tin catalysts are selected from the group consisting of: di-butyl tin dilaurate, dibutylbis(laurylthio)stannate, dibutyltinbis(isooctylmercapto acetate) and dibutyltinbis(isooctylmaleate), tin octanoate and mixtures of any two or more of these.
In certain embodiments, catalysts included in polyurethane reaction mixtures comprise tertiary amines. In certain embodiments, catalysts included in polyurethane reaction mixtures are selected from the group consisting of: DABCO, pentametyldipropylenetriamine, bis(dimethylamino ethyl ether), pentamethyldiethylenetriamine, DBU phenol salt, dimethylcyclohexylamine, 2,4,6-tris(N,N-dimethylaminomethyl)phenol (DMT-30), triazabicyclodecene (TBD), N-methyl TBD, 1,3,5-tris(3-dimethylaminopropyl)hexahydro-s-triazine, 4,4′-(Oxydi-2,1-ethanediyl) bismorpholine (DMDEE), ammonium salts and combinations or formulations of any of these.
In some embodiments, the catalyst is a non-Sn catalyst. In some embodiments, the catalyst is a zinc-catalyst. In some embodiments, a catalyst is a Bi-catalyst.
Typical amounts of catalyst are 0.001 to 10 parts of catalyst per 100 parts by weight of total polyol in polyurethane reaction mixtures. In certain embodiments, catalyst levels in the formulation, when used, range between about 0.001 pph (weight parts per hundred) and about 3 pph based on the amount of polyol present in polyurethane reaction mixtures. In certain embodiments, catalyst levels range between about 0.05 pph and about 1 pph, or between about 0.1 pph and about 0.5 pph.
In certain embodiments, monofunctional components are added to polyurethane reaction mixtures. Suitable monofunctional components can include molecules having a single isocyanate-reactive functional group such as an alcohol, amine, carboxylic acid, or thiol. A monofunctional component will serve as a chain termination which can be used to limit molecular weight or crosslinking if higher functionality species are used. U.S. Pat. No. 5,545,706 illustrates the use of a monofunctional alcohol in a substantially linear polyurethane formulation. The monofunctional alcohol can be any compound with one alcohol available for reaction with isocyanate such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol, pentanol, hexanol, heptanol, octanol, nonanol, decanol, dodecanol, phenol and the like. Additionally, the monofunctional component can be added as a low molecular weight polymer that has been initiated by or reacted with the monofunctional alcohol. The monofunctional alcohol can be a polyether such as polypropylene oxide or polyethylene oxide initiated with any of the monofunctional alcohols listed. The monofunctional alcohol can be a polyester polymer where the monofunctional alcohol is added to the recipe. The monofunctional alcohol can be a polycarbonate polymer such as polyethylene carbonate or polypropylene carbonate initiated with a monofunctional anion, such as halide, nitrate, azide, carboxylate, or a monohydric alcohol.
Similarly, the monofunctional component could be an isocyanate. Any monofunctional isocyanate could be added for this same function. Possible materials include phenyl isocyanate, naphthyl isocyanate, methyl isocyanate, ethyl isocyanate, propyl isocyanate, butyl isocyanate, hexyl isocyanate, octyl isocyanate and the like.
In addition to the above components, polyurethane reaction mixtures and/or polyurethane compositions of the present invention may optionally contain various additives as are known in the art of polyurethane technology. Such additives may include, but are not limited to solvents, fillers, clays, blocking agents, stabilizers, thixotropes, plasticizers, compatibilizers, colorants, UV stabilizers, flame retardants, and the like.
If desired, the polyurethanes or pre-polymers can be dispersed in a mixture of water and organic solvents known to those skilled in the art. Suitable solvents can include aliphatic, aromatic, or halogenated hydrocarbons, ethers, esters, ketones, lactones, sulfones, nitriles, amides, nitromethane, propylene carbonate, dimethyl carbonate and the like. Representative examples include, but are not limited to: acetone, acetonitrile, benzene, butanol, butyl acetate, g-butyrolactone, butyl carbitol acetate, carbitol acetate, chloroform, cyclohexane, 1,2-dichloromethane, dibasic ester, diglyme, 1,2-dimethoxyethane, dimethylacetamide, dimethylsulfoxide, dimethformamide, 1,4-dioxane, ethanol, ethyl acetate, ethyl ether, ethylene glycol, hexane, hydroxylmethyl methacrylate, isopropyl acetate, methanol, methyl acetate, methyl amyl ketone, methyl isobutyl ketone, methylene chloride, methyl ethyl ketone (MEK), monoglyme, methyl methacrylate, propylene carbonate, propylene oxide, styrene, alpha-terpineol, tetrahydrofuran, texanol, toluene, diethyl succinate, diethylene glycol methyl ether, ethylene glycol diacetate, triethyl phosphate and the like. In some embodiments, the solvent is MEK. In some embodiments, e.g., PUD compositions, a solvent is or includes water.
Optional components of polyurethane reaction mixtures and/or polyurethane compositions of the present invention include fillers. Such fillers are well known to those skilled in the art and include carbon black, titanium dioxide, calcium carbonate, surface treated silicas, titanium oxide, fume silica, talc, aluminum trihydrate and the like. In certain embodiments, fillers comprise carbon black. In certain embodiments, more than one reinforcing filler may be used, of which one is carbon black and a sufficient amount of carbon black is used to provide the desired black color to the adhesive. In certain embodiments, a reinforcing filler is used in sufficient amount to increase the strength of the adhesive and/or to provide thixotropic properties to the adhesive. The amounts of filler or other additives will vary depending on the desired application.
Among optional materials in polyurethane reaction mixtures and/or polyurethane compositions of the present invention are clays. Preferred clays useful in the present invention include kaolin, surface treated kaolin, calcined kaolin, aluminum silicates and surface treated anhydrous aluminum silicates. The clays can be used in any form which facilitates formulation of a pumpable adhesive. Preferably the clay is in the form of pulverized powder, spray-dried beads or finely ground particles.
One or more blocking agents are utilized to provide an induction period between the mixing of the two parts of the polyurethane adhesive composition and the initiation of the cure. The addition of the blocking agents provides an induction period which causes a reduction in the curing rate immediately after mixing of the components of the adhesive. The reduction in the curing rate results in lower initial tensile shear strengths and storage moduli immediately after mixing than those found in compositions that do not contain a blocking agent. Following the induction period the adhesive quickly cures so that the tensile shear strength and storage modulus are similar to those produced by adhesives that do not contain the blocking agent. Such thixotropes are well known to those skilled in the art and include hydroxyl containing compounds such as diethylene glycol, mono alkyl ethers, butanone oxime, methyl ethyle ketone oxime, nonylphenol, phenol and cresol; amine containing compounds such as caprolactam, diisopropyl amine, 1,2,4-triazole and 3,5-dimethyl pyrazole; and aliphatic containing compounds such as dialkyl malonate.
Polyurethane reaction mixtures and/or polyurethane compositions of the present invention may further comprise stabilizers which function to protect the polyurethane composition from moisture, thereby inhibiting advancement and preventing premature crosslinking of the isocyanates in the adhesive formulation. Included among such stabilizers are diethylmalonate and alkylphenol alkylates.
Optionally, polyurethane reaction mixtures and/or polyurethane compositions of the present invention may further comprise a thixotrope. Such thixotropes are well known to those skilled in the art and include alumina, limestone, talc, zinc oxides, sulfur oxides, calcium carbonate, perlite, slate flour, salt (NaCl), cyclodextrin and the like. The thixotrope may be added to the polyurethane composition in a sufficient amount to give the desired rheological properties.
Polyurethane reaction mixtures and/or polyurethane compositions of the present invention may further comprise plasticizers so as to modify the rheological properties to a desired consistency. Such materials should be free of water, inert to isocyanate groups and compatible with a polymer. Suitable plasticizers are well known in the art and preferable plasticizers include alkyl phthalates such as dioctylphthalate or dibutylphthalate, partially hydrogenated terpene commercially available as “HB-40”, trioctyl phosphate, epoxy plasticizers, toluene-sulfamide, chloroparaffins, adipic acid esters, castor oil, toluene and alkyl naphthalenes. The amount of plasticizer in the polyurethane composition is that amount which gives the desired rheological properties and/or which is sufficient to disperse any catalyst that may be present in the system.
In certain embodiments, polyurethane reaction mixtures and/or polyurethane compositions of the present invention comprise one or more suitable compatibilizers. Compatibilizers are molecules that allow two or more nonmiscible ingredients to come together and give a homogeneous liquid phase. Many such molecules are known to the polyurethane industry, these include: amides, amines, hydrocarbon oils, phthalates, polybutyleneglycols, and ureas.
In certain embodiments, polyurethane reaction mixtures and/or polyurethane compositions of the present invention comprise one or more suitable colorants. Typical inorganic coloring agents included titanium dioxide, iron oxides and chromium oxide. Organic pigments originated from the azo/diazo dyes, phthalocyanines and dioxazines, as well as carbon black. Recent advances in the development of polyol-bound colorants are described in:
In certain embodiments, polyurethane reaction mixtures and/or polyurethane compositions of the present invention comprise one or more suitable UV stabilizers. Polyurethanes based on aromatic isocyanates will typically turn dark shades of yellow upon aging with exposure to light. A review of polyurethane weathering phenomena is presented in: Davis, A.; Sims, D. Weathering Of Polymers; Applied Science: London, 1983, 222-237. Light protection agents, such as hydroxybenzotriazoles, zinc dibutyl thiocarbamate, 2,6-ditertiary butylcatechol, hydroxybenzophenones, hindered amines and phosphites have been used to improve the light stability of polyurethanes. Color pigments have also been used successfully.
In certain embodiments, polyurethane reaction mixtures and/or polyurethane compositions of the present invention comprise one or more suitable flame retardants. Flame retardants are often added to reduce flammability. The choice of flame retardant for any specific polyurethane adhesive often depends upon the intended service application of that adhesive and the attendant flammability testing scenario governing that application. Aspects of flammability that may be influenced by additives include the initial ignitability, burning rate and smoke evolution.
The most widely used flame retardants are the chlorinated phosphate esters, chlorinated paraffins and melamine powders. These and many other compositions are available from specialty chemical suppliers. A review of this subject has been published: Kuryla, W. C.; Papa, A. J. Flame Retardancy of Polymeric Materials, Vol. 3; Marcel Dekker: New York, 1975, 1-133.
As described above and herein, in some aspects, the present invention encompasses compositions comprising a blend of polycarbonate polyols. In some embodiments, such a “blend” refers to two or more polycarbonate polyols which are structurally different from one another. In some embodiments, a provided composition comprises any of the polyols described above and herein.
In some embodiments, polyol subcomponent (i) comprises a polycarbonate polyol as described above and herein. In some embodiments, polyol subcomponent (ii) comprises a polycarbonate polyol as described above and herein. In some embodiments, polyol subcomponent (i) and polyol subcomponent (ii) each comprise a polycarbonate polyol. In some embodiments, polyol subcomponent (i) and polyol subcomponent (ii) each comprise a polycarbonate polyol, wherein a polycarbonate polyol present within polyol subcomponent (i) is structurally different than a polycarbonate polyol present in polyol subcomponent (ii).
In some embodiments, the present invention provides compositions comprising:
In some embodiments, the present invention provides compositions comprising:
In some embodiments, the present invention provides compositions comprising:
In some embodiments, polyol subcomponent (i) (e.g, having formula PS1, P2b, or Q10) has a Mn between about 500 g/mol and about 1,500 g/mol. In some embodiments, polyol subcomponent (i) (e.g, having formula PS1, P2b, or Q10) has a Mn of about 1,000 g/mol.
In some embodiments, polyol subcomponent (i) (e.g., having formula PS2, Q7, or Q11) has a Mn between about 500 g/mol and about 2,500 g/mol. In some embodiments, polyol subcomponent (i) (e.g., having formula PS2, Q7, or Q11) has a Mn of about 2,000 g/mol.
In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 9:1 to about 1:9. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 7:1 to about 1:7. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 5:1 to about 1:5. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 4:1 to about 1:4. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 3:1 to about 1:3. In certain embodiments, a provided compositions comprise polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 2:1 to about 1:2. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 1:1.
In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 2:3 to about 3:2. In certain embodiments, a provided composition comprises polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11) in a weight ratio between about 4:3 to about 3:4.
In some embodiments, a provided composition comprises about 0.1-60 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 40-99.9 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 10-50 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 50-90 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 25-50 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 50-75 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11).
In some embodiments, a provided composition comprises about 0.1-60 weight percent of polycarbonate polyols of formula PS1 and about 40-99.9 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 10-50 weight percent of polycarbonate polyols of formula PS1 and about 50-90 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 25-50 weight percent of polycarbonate polyols of formula PS1 and about 50-75 weight percent of polycarbonate polyols of formula PS2.
In some embodiments, a provided composition comprises about 0.1-60 weight percent of polycarbonate polyols of formula P2b and about 40-99.9 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 10-50 weight percent of polycarbonate polyols of formula P2b and about 50-90 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 25-50 weight percent of polycarbonate polyols of formula P2b and about 50-75 weight percent of polycarbonate polyols of formula Q7.
In some embodiments, a provided composition comprises about 0.1-60 weight percent of polycarbonate polyols of formula Q10 and about 40-99.9 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 10-50 weight percent of polycarbonate polyols of formula Q10 and about 50-90 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 25-50 weight percent of polycarbonate polyols of formula Q10 and about 50-75 weight percent of polycarbonate polyols of formula Q11.
In some embodiments, a provided composition comprises about 5-15 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 85-95 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 7-13 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 87-93 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 10 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 90 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 5-15 weight percent of polycarbonate polyols of formula PS1 and about 85-95 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 7-13 weight percent of polycarbonate polyols of formula PS1 and about 87-93 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 10 weight percent of polycarbonate polyols of formula PS1 and about 90 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 5-15 weight percent of polycarbonate polyols of formula P2b and about 85-95 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 7-13 weight percent of polycarbonate polyols of formula P2b and about 87-93 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 10 weight percent of polycarbonate polyols of formula P2b and about 90 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 5-15 weight percent of polycarbonate polyols of formula Q10 and about 85-95 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 7-13 weight percent of polycarbonate polyols of formula Q10 and about 87-93 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 10 weight percent of polycarbonate polyols of formula Q10 and about 90 weight percent of polycarbonate polyols of formula Q11.
In some embodiments, a provided composition comprises about 20-30 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 70-80 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 22-28 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 72-78 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 25 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 75 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 20-30 weight percent of polycarbonate polyols of formula PS1 and about 70-80 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 22-28 weight percent of polycarbonate polyols of formula PS1 and about 72-78 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 25 weight percent of polycarbonate polyols of formula PS1 and about 75 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 20-30 weight percent of polycarbonate polyols of formula P2b and about 70-80 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 22-28 weight percent of polycarbonate polyols of formula P2b and about 72-78 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 25 weight percent of polycarbonate polyols of formula P2b and about 75 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 20-30 weight percent of polycarbonate polyols of formula Q10 and about 70-80 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 22-28 weight percent of polycarbonate polyols of formula Q10 and about 72-78 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 25 weight percent of polycarbonate polyols of formula Q10 and about 75 weight percent of polycarbonate polyols of formula Q11.
In some embodiments, a provided composition comprises about 45-55 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 45-55 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 47-53 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 47-53 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 50 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 50 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 45-55 weight percent of polycarbonate polyols of formula PS1 and about 45-55 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 47-53 weight percent of polycarbonate polyols of formula PS1 and about 47-53 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 50 weight percent of polycarbonate polyols of formula PS1 and about 50 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 45-55 weight percent of polycarbonate polyols of formula P2b and about 45-55 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 47-53 weight percent of polycarbonate polyols of formula P2b and about 47-53 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 50 weight percent of polycarbonate polyols of formula P2b and about 50 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 45-55 weight percent of polycarbonate polyols of formula Q10 and about 45-55 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 47-53 weight percent of polycarbonate polyols of formula Q10 and about 47-53 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 50 weight percent of polycarbonate polyols of formula Q10 and about 50 weight percent of polycarbonate polyols of formula Q11.
In some embodiments, a provided composition comprises about 55-65 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 35-45 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 57-63 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 37-43 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 60 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 40 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 55-65 weight percent of polycarbonate polyols of formula PS1 and about 35-45 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 57-63 weight percent of polycarbonate polyols of formula PS1 and about 37-43 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 60 weight percent of polycarbonate polyols of formula PS1 and about 40 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 55-65 weight percent of polycarbonate polyols of formula P2b and about 35-45 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 57-63 weight percent of polycarbonate polyols of formula P2b and about 37-43 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 60 weight percent of polycarbonate polyols of formula P2b and about 40 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 55-65 weight percent of polycarbonate polyols of formula Q10 and about 35-45 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 57-63 weight percent of polycarbonate polyols of formula Q10 and about 37-43 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 60 weight percent of polycarbonate polyols of formula Q10 and about 40 weight percent of polycarbonate polyols of formula Q11.
In some embodiments, a provided composition comprises about 65-75 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 25-35 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 67-73 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 27-33 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 70 weight percent of polyol subcomponent (i) (e.g., having formula PS1, P2b, or Q10) and about 30 weight percent of polyol subcomponent (ii) (e.g., having formula PS2, Q7, or Q11). In some embodiments, a provided composition comprises about 65-75 weight percent of polycarbonate polyols of formula PS1 and about 25-35 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 67-73 weight percent of polycarbonate polyols of formula PS1 and about 27-33 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 70 weight percent of polycarbonate polyols of formula PS1 and about 30 weight percent of polycarbonate polyols of formula PS2. In some embodiments, a provided composition comprises about 65-75 weight percent of polycarbonate polyols of formula P2b and about 25-35 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 67-73 weight percent of polycarbonate polyols of formula P2b and about 27-33 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 70 weight percent of polycarbonate polyols of formula P2b and about 30 weight percent of polycarbonate polyols of formula Q7. In some embodiments, a provided composition comprises about 65-75 weight percent of polycarbonate polyols of formula Q10 and about 25-35 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 67-73 weight percent of polycarbonate polyols of formula Q10 and about 27-33 weight percent of polycarbonate polyols of formula Q11. In some embodiments, a provided composition comprises about 70 weight percent of polycarbonate polyols of formula Q10 and about 30 weight percent of polycarbonate polyols of formula Q11.
It will be understood that each of the above weight percentages refer to the weight percentage of polyols within a provided composition, exclusive of other co-reactives and additives, e.g., those listed above and herein.
As described above and herein, in some aspects, the present invention encompasses polyurethane compositions derived from compositions provided herein. In some embodiments, the present invention encompasses polyurethane compositions comprising the reaction product of a composition comprising a blend of polycarbonate polyols described above and herein and an isocyanate component.
In certain embodiments, polyurethane compositions of the present invention are derived by combining two-components: a first component comprising one or more isocyanate reagents, optionally containing diluents, solvents, coreactants and the like, and a second component comprising one or more polyol reagents optionally with additional reactants, solvents, catalysts, or additives. These components may be formulated separately and then combined or all components of the finished polyurethane composition may be combined in a single step. In some embodiments, polyurethane compositions of the present invention were prepared from a two-component formulation, wherein the first component comprises one or more isocyanates; and the second component comprises one or more polyols.
In certain embodiments, polyurethane compositions of the present invention were prepared from a one-component formulation comprising one or more polyurethane prepolymers. In some embodiments, a polyurethane prepolymer is synthesized from one or more polyols. In some embodiments, the present invention encompasses polyurethane compositions comprising the reaction product of an isocyanate-terminated prepolymer, wherein the isocyanate terminated prepolymer is derived from compositions described above and herein.
It will be appreciated that within the present disclosure, a reference to a polyurethane composition also refers to a waterborne polyurethane dispersion (PUD) composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, or a hot-melt polyurethane composition. Additionally or alternatively, it will also be appreciated that such references to, for example, a waterborne polyurethane dispersion (PUD) composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, or a hot-melt polyurethane composition, refer to a polyurethane composition derived from a particular curing method (e.g., a one-component polyurethane composition refers to a polyurethane composition derived from a one-component curing method). In some embodiments, a polyurethane composition is a waterborne polyurethane dispersion composition. In some embodiments, a polyurethane composition is a one-component polyurethane composition. In some embodiments, a polyurethane composition is a two-component polyurethane composition. In some embodiments, a polyurethane composition is a hot-melt polyurethane composition. In some embodiments, a polyurethane composition is a solvent-borne polyurethane composition. In some embodiments, a polyurethane composition is a one-component hot-melt polyurethane composition. In some embodiments, a polyurethane composition is a two-component hot-melt polyurethane composition.
II. Polyurethane Compositions with Improved Properties
Polyurethane compositions of the present invention may be useful in adhesive and coating applications. In some embodiments, a substrate is coated with a polyurethane composition, and the water or solvent is evaporated, leaving behind a polyurethane film. The polyurethane film may be lifted from the substrate and its properties measured.
It will be appreciated that within the present disclosure, a reference to a polyurethane composition also refers to a waterborne polyurethane dispersion (PUD), composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, a hot-melt polyurethane composition, a one-component hot-melt polyurethane composition, or a two-component hot-melt polyurethane composition.
In one aspect, polyurethane compositions of the present invention unexpectedly demonstrate improved performance properties (e.g., strength, flexibility, elongation or combinations thereof), as compared to a reference polyurethane composition. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (i) as described above and herein (e.g., having formula PS1, P2b, or Q10). In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (ii) as described above and herein (e.g., having formula PS2, Q7, or Q11). In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polycarbonate polyol that is structurally different from either polyol subcomponent (i) as described above and herein (e.g., having formula PS1, P2b, or Q10) or polyol subcomponent (ii) as described above and herein (e.g., having formula PS2, Q7, or Q11). In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polyether polyol. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polyester polyol.
In some embodiments, the improved performance property is tensile strength measure according to ASTM D412. In some embodiments, the improved performance property is tensile elongation measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 100% measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 200% measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 300% measured according to ASTM D412. In some embodiments, the improved property is lap shear strength measured according to ASTM D1002 or ISO 4587. In some embodiments, the improved property is lap shear strength measured according to ASTM D1002. In some embodiments, the improved property is lap shear strength measured according to ISO 4587. In some embodiments, the improved property is peel strength measured according to ASTM D1876.
In some embodiments, the present invention provides polyurethane compositions characterized in that the tensile strength measured according to ASTM D412 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the tensile strength measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the tensile elongation measured according to ASTM D412 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the tensile elongation measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition.
In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is improved, and the tensile elongation measured according to ASTM D412 is about the same, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is improved by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300%, and the tensile elongation measured according to ASTM D412 is within 10%, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is about the same, and the tensile elongation measured according to ASTM D412 is improved, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is within 10%, and the tensile elongation measured according to ASTM D412 is improved by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300%, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 and the tensile elongation measured according to ASTM D412 are improved, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, and the tensile elongation measured according to ASTM D412 is about the same, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is about the same, and the tensile elongation measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the tensile strength measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, and the tensile elongation measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides a polyurethane composition characterized in that the modulus at 100% measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the modulus at 200% measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides a polyurethane composition characterized in that the modulus at 300% measured according to ASTM D412 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ASTM D1002 or ISO 4587 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ASTM D1002 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ISO 4587 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ASTM D1002 or ISO 4587 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater as compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ASTM D1002 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater as compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the lap shear strength measured according to ISO 4587 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater as compared to a reference polyurethane composition.
In some embodiments, the present invention provides polyurethane compositions characterized in that the peel strength measured according to ASTM D1876 is improved compared to a reference polyurethane composition. In some embodiments, the present invention provides polyurethane compositions characterized in that the peel strength measured according to ASTM D1876 is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition.
In some embodiments, the present invention provides a polyurethane composition characterized in that it is about the same density as compared to a reference polyurethane composition.
In another aspect, the present invention encompasses methods of improving a performance property of a polyurethane compositions comprising the reaction product of a polyol component and a polyisocyanate component, the method comprising the step of incorporating into the polyol component a blend of polycarbonate polyols. In some embodiments, such blends comprise polyol subcomponent (i) as described above and herein (e.g., having formula PS1, P2b, or Q10) and polyol subcomponent (ii) as described above and herein (e.g., having formula PS2, Q7, or Q11).
It will be appreciated that within the present disclosure, a reference to a polyurethane composition also refers to a waterborne polyurethane dispersion (PUD) composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, a hot-melt polyurethane composition, a one-component hot-melt polyurethane composition, or a two-component hot-melt polyurethane composition.
In one aspect, methods of the present invention unexpectedly demonstrate improved performance properties (e.g., strength, flexibility, elongation or a combination thereof) of polyurethane compositions, as compared to a reference polyurethane composition. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (i) as described above and herein. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (ii) as described above and herein. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polycarbonate polyol that is structurally different from either polyol subcomponent (i) as described above and herein or polyol subcomponent (ii) as described above and herein. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polyether polyol. In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polyester polyol.
In some embodiments, the improved performance property is tensile strength measure according to ASTM D412. In some embodiments, the improved performance property is tensile elongation measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 100% measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 200% measured according to ASTM D412. In some embodiments, the improved performance property is modulus at 300% measured according to ASTM D412. In some embodiments, the improved property is lap shear strength measured according to ASTM D1002 or ISO 4587. In some embodiments, the improved property is lap shear strength measured according to ASTM D1002. In some embodiments, the improved property is lap shear strength measured according to ISO 4587. In some embodiments, the improved property is peel strength measured according to ASTM D1876.
In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile elongation measured according to ASTM D412 of a polyurethane composition compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile elongation measured according to ASTM D412 of a polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition as compared to a reference polyurethane composition, and the tensile elongation measured according to ASTM D412 of the polyurethane composition is about the same, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile elongation measured according to ASTM D412 of a polyurethane composition as compared to a reference polyurethane composition, and the tensile strength measured according to ASTM D412 of the polyurethane composition is about the same, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 and the tensile elongation measured according to ASTM D412 of a polyurethane composition, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition, and the tensile elongation measured according to ASTM D412 of the polyurethane composition is about the same as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition, and the tensile elongation measured according to ASTM D412 of the polyurethane composition is within about 10% as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile elongation measured according to ASTM D412 of the polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% as compared to a reference polyurethane composition, and the tensile strength measured according to ASTM D412 of the polyurethane composition is about the same as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile elongation measured according to ASTM D412 of the polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% as compared to a reference polyurethane composition, and the tensile strength measured according to ASTM D412 of the polyurethane composition is within about 10% as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the tensile strength measured according to ASTM D412 of a polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% as compared to a reference polyurethane composition, and the tensile elongation measured according to ASTM D412 of the polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods of improving the modulus at 100% measured according to ASTM D412 of the polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the modulus at 200% measured according to ASTM D412 of the polyurethane composition by at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the modulus at 300% measured according to ASTM D412 of the polyurethane composition at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods of improving the lap shear strength measured according to ASTM D1002 or ISO 4587 of the polyurethane composition at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the lap shear strength measured according to ASTM D1002 of the polyurethane composition at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater, as compared to a reference polyurethane composition. In some embodiments, the present invention provides methods of improving the lap shear strength measured according to ISO 4587 of the polyurethane composition at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, 300, 350, 400, 450, or 500% greater, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods of improving the peel strength measured according to ASTM D1876 of the polyurethane composition at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 125, 150, 200, 250, or 300% greater, as compared to a reference polyurethane composition.
In some embodiments, the present invention provides methods characterized in that the polyurethane composition has about the same density as compared to a reference polyurethane composition.
In some aspects, the present invention encompasses methods of producing a polyurethane composition, the method comprising the steps of:
In some aspects, the present invention encompasses methods of producing a polyurethane composition, the method comprising the steps of:
In some aspects, the present invention encompasses methods of producing a polyurethane composition, the method comprising the steps of:
In some aspects, the present invention encompasses methods of producing a polyurethane composition, the method comprising the steps of:
It will be appreciated that within the present disclosure, a reference to a polyurethane composition also refers to a waterborne polyurethane dispersion (PUD) composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, a hot-melt polyurethane composition, a one-component hot-melt polyurethane composition, or a two-component hot-melt polyurethane composition.
In some embodiments, catalysts are not added. In some embodiments, the catalyst is 4,4′-(Oxydi-2,1-ethanediyl) bismorpholine (DMDEE). In some embodiments, the solvent is methyl ethyl ketone (MEK). In some embodiments, the base is triethylamine (TEA). In some embodiments, the chain extender is 1,2-ethylene diamine (EDA).
V. Coatings with Improved Properties
In some embodiments, the present invention provides polyurethane compositions for use as coatings. In some embodiments, the present invention provides polyurethane coating compositions.
It will be appreciated that within the present disclosure, a reference to a polyurethane coating composition also refers to such a waterborne polyurethane dispersion (PUD) composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, a hot-melt polyurethane composition, a one-component hot-melt polyurethane composition, or a two-component hot-melt polyurethane composition. In some embodiments, a polyurethane coating composition is a waterborne polyurethane dispersion (PUD) coating composition. In some embodiments, a polyurethane coating composition is a one-component polyurethane composition. In some embodiments, a polyurethane coating composition is a two-component polyurethane composition. In some embodiments, a polyurethane coating composition is a hot-melt polyurethane composition. In some embodiments, a polyurethane coating composition is a one-component hot-melt polyurethane composition. In some embodiments, a polyurethane coating composition is a two-component hot-melt polyurethane composition.
Polyurethane coating compositions of the present invention may exhibit improved performance as defined herein, for example they may exhibit improved hardness, flexibility, corrosion resistance and/or outdoor durability. The cured coatings resulting from compositions present invention may exhibit a broad range of protective properties like one or more of: excellent hardness, flexibility, processability, resistance against solvent, stain, corrosion and/or dirt pick up, thermal stability, hydrolytic stability against humidity and/or sterilization and/or outdoor durability.
Such improved properties may be in at least one, preferably a plurality, more preferably three of more of those properties labeled numerically below. Preferred polymers and/or compositions and/or coating compositions may exhibit comparable properties in one or more, preferably a plurality, more preferably three or more, most preferably in the rest of those properties labelled numerically herein.
Hardness (Konig, Persoz and/or pencil hardness measured as described DIN 53157/1-87 (Konig), DIN 53157/11-87 (Persoz) and/or ISO 3270-1984, DIN EN 13523-4, ECCA T4 and/or ISO 15184:1998 (pencil hardness) and/or otherwise as described herein).
Flexibility (may be measured using the T-bend test as described in European standard EN 13523-7:2001 and/or otherwise as described herein).
Corrosion resistance (measured as described herein) is visually determined as described herein and rated from 1-5.
Hydrolysis resistance (according to the methods described herein to determine hydrolysis of coatings as described herein). Hydrolysis resistance is a general property useful for all coatings while sterilization is usually only useful for specific types of coatings such as those used to coat cans.
Outdoor durability (for example with respect to UV-A and UV-B resistance such as in the QUV-test (a laboratory simulation of the damaging forces of weather, for the purpose of predicting the relative durability of coatings/materials exposed to the outdoor environment and described in ASTMG 53-95 and/or otherwise as described herein)).
Chemical resistance (to methyl ethyl ketone (MEK) in the MEK double rubs test as described herein).
The degree of damage to a coating in various tests herein is determined visually based on the following ratings where 5 is the best and 0 is the worse:
König hardness is determined following DIN 53157 NEN5319 using Erichsen hardness measuring equipment. The values are given in seconds and the higher the value is the harder is the coating. A Koenig hardness above 100 and combined with a T-bend of 1T or lower is considered very good.
Pencil hardness was determined following ISO 15184:1998 using a set of KOH-I-NOR drawing pencils in the following range: 6B-5B-4B-3B-2B-B-HB-F-H-2H-3H-4H-5H-6H (soft to hard). The hardest lead which does not penetrate the coating determines the degree of hardness. The minimum needed hardness is 1H. When at least 3H is obtained combined with a T-bend of 1T or lower, this is considered very good.
May be measured using the T-bend test as described in European standard EN 13523-7:2001. A T-bend of 1T or lower is considered very flexible. In general a flexibility 1.5T or lower is aimed for.
The degree of cross-linking of a coating is determined by means of its resistance against wiping a cloth which is wetted with a strong organic solvent. The apparatus used is a DJH Designs MEK rub test machine and Greenson 4×4 pads. The reagent used is methyl ethyl ketone (MEK). The coated panel to be tested is at least 13×3 cm and is taped or clamped onto the machine. The pad is wetted automatically with approx 2 mL MEK. The wet pad is moved automatically over a length of about 12 cm forwards and backward in one movement, which is repeated continuously with a pressure of 3 kg and a cycle time of about 1 second. One double rub is one cycle and the procedure is repeated for 100 cycles or until the coating is ruptured or dissolved and the bare metal (or the primer layer) becomes visible. Matt coatings become glossy during the MEK test but this is not rated as coating damage. After the test the coating is visually examined in the middle of the rubbed area and given a rating from 5 to 1 as indicated above. To be acceptable for use in many applications typically coatings have chemical resistance of at least 100 MEK double rubs. For coating cans MEK resistance is not a relevant criteria.
The QUV-test is a laboratory simulation of the damaging forces of weather, for the purpose of predicting the relative durability of coatings/materials exposed to the outdoor environment according to ASTMG 53-95. Apparatus used is a Q.U.V. accelerated weathering tester and eight fluorescent UV-B 313 lamps. Reagent used is demineralised water. Test panels/materials of 75×150 mm size were coated with the test coatings and exposed to test cycles for four hours of UV radiation at 50° C., relative humidity 40%. The test panels/materials are mounted in the specimen racks with the test surfaces facing the UV lamps. Empty spaces are filled with blank panels to maintain the test conditions within the chamber. The total time of exposure is measured by the apparatus. The gloss 20°, 60° and L*, a*, b* values are measured and the test is finished when for high gloss coatings: 200 gloss is <20% and for semi gloss coatings: 600 gloss is 50% of original gloss. According to ECCA T10, 2000 hrs QUV-A is obtained for a good outdoor durable system. According to ECCA T10, 1000 hrs QUV-B is obtained for a good outdoor durable system.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a higher Konig hardness relative to a corresponding reference polyurethane composition, wherein the Konig hardness is measured in accordance with DIN 53157/1-87. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a Konig hardness that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 200%, higher relative to a corresponding reference polyurethane composition, wherein the Konig hardness is measured in accordance with DIN 53157/1-87.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a higher Persoz hardness relative to a corresponding reference polyurethane composition, wherein the Persoz hardness is measured in accordance with DIN 53157/11-87. In some embodiments, a polyurethane composition is characterized in that, after curing, the coating composition has a Persoz hardness that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 200%, higher relative to a corresponding reference polyurethane composition, wherein the Persoz hardness is measured in accordance with DIN 53157/11-87.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a higher Pencil hardness relative to a corresponding reference polyurethane composition, wherein the Pencil hardness is measured in accordance with ISO 15184:1998. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a Pencil hardness that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 200%, higher relative to a corresponding reference polyurethane composition, wherein the Pencil hardness is measured in accordance with ISO 15184:1998.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a lower T-bend flexibility relative to a corresponding reference polyurethane composition, wherein the T-bend flexibility is measured in accordance with EN 13523-7:2001. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a T-bend flexibility that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or about 100% lower relative to a corresponding reference polyurethane composition, wherein the T-bend flexibility is measured in accordance with EN 13523-7:2001.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a higher corrosion resistance relative to a corresponding reference polyurethane composition, wherein the corrosion resistance is measured as described above. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a corrosion resistance that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or about 100% lower relative to a corresponding reference polyurethane composition, wherein the corrosion resistance is measured as described above.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has an improved hydrolysis resistance relative to a corresponding reference polyurethane composition, wherein the hydrolysis resistance is measured as described above. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a hydrolysis resistance that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or about 100% lower relative to a corresponding reference polyurethane composition, wherein the hydrolysis resistance is measured as described above.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has an improved outdoor durability relative to a corresponding reference polyurethane composition, wherein the outdoor durability is measured in accordance with the QUV-test. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has an outdoor durability that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or about 100% lower relative to a corresponding reference polyurethane composition, wherein the outdoor durability is measured in accordance with the QUV-test.
In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has an improved chemical resistance relative to a corresponding reference polyurethane composition, wherein the chemical resistance is measured in accordance with the salt-spray test described above. In some embodiments, a polyurethane composition is characterized in that, after curing, the polyurethane composition has a chemical resistance that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, or about 100% lower relative to a corresponding reference polyurethane composition, wherein the chemical resistance is measured in accordance with the salt-spray test described above.
VI. Adhesives with Improved Properties
In another aspect, a polyurethane composition of the present invention is an adhesive composition. In certain embodiments, the polyurethane adhesive compositions comprise the reaction product of an isocyanate component and a composition, as described above and herein; or an isocyanate-terminated prepolymer composition as described above and herein.
It will be appreciated that within the present disclosure, a reference to a polyurethane adhesive composition also refers to such a waterborne polyurethane dispersion (PUD) adhesive composition, a solvent-borne polyurethane composition, a one-component polyurethane composition, a two-component polyurethane composition, a hot-melt polyurethane composition, a one-component hot-melt polyurethane composition, or a two-component hot-melt polyurethane composition. In some embodiments, a polyurethane adhesive composition is a waterborne polyurethane dispersion (PUD) coating composition. In some embodiments, a polyurethane adhesive composition is a one-component polyurethane composition. In some embodiments, a polyurethane adhesive composition is a two-component polyurethane composition. In some embodiments, a polyurethane adhesive composition is a hot-melt polyurethane composition. In some embodiments, a polyurethane adhesive composition is a one-component hot-melt polyurethane composition. In some embodiments, a polyurethane adhesive composition is a two-component hot-melt polyurethane composition.
In one aspect, the present invention encompasses reactive one-component adhesives. In certain embodiments, such one-component adhesive compositions are derived from a composition as defined above and in the embodiments and examples herein.
In certain embodiments the one-component adhesives are prepolymers made with one or more polyols; these prepolymers typically have low isocyanate values and are produced by reacting an excess of isocyanate with a relatively high molecular weight polyol. These adhesives are typically cured with water which can be added or which is present in the atmosphere or the material being bonded.
In some embodiments, MDI is the isocyanate reacted with a polyol component as described above. In some embodiments requiring unique adhesive performance properties, TDI and/or aliphatic isocyanates are used in place of, or in addition to, MDI. In some embodiments, isophorone diisocyanate (IPDI) is the isocyanate reacted with a polyol component described above and herein.
In certain embodiments the one-component adhesives comprise 100% solids (e.g. no solvent is present at the time of application). In certain embodiments, the one-component adhesives formulations may be dissolved, dispersed, and/or emulsified in a solvent or water to reduce viscosity or otherwise improve the applicability of the one-component adhesive in these applications.
In certain embodiments no catalysts are used. In certain embodiments catalysts are included in the formulation to increase the reaction rate of free isocyanate and water.
In certain embodiments, hydroxyethyl acrylate groups may be included in the polycarbonate polyol, other polyols, and/or the derivative prepolymers to introduce ultraviolet light curing properties.
In certain embodiments, fatty acid groups and/or other molecules with unsaturation functionality may be included in polyols and/or the derivative prepolymers to enable cross linking via oxidation.
In certain embodiments, the one-component adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In another aspect, the present invention encompasses reactive two-component adhesive compositions. In certain embodiments, such two-component adhesive compositions are derived from a composition as defined above and in the embodiments and examples herein.
In certain embodiments the two-component adhesives include prepolymers derived from one or more polyols. These prepolymers can be produced with excess isocyanate and/or excess hydroxyl content and are then mixed with one or more of the isocyanates, polyols, and other components described above.
In certain embodiments, the two-component adhesives are formulated to an isocyanate index range of 90 to 150. In certain embodiments, isocyanate indexes above 100 are used to increase hardness of the adhesive and to improve bonding to substrates, in particular those substrates with hydroxyl groups on their surfaces. In certain embodiments, isocyanate indexes below 100 are used to produce softer and more flexible adhesives.
In certain embodiments, MDI is the isocyanate used in the formulation of the two-component adhesives. In certain embodiments, TDI is the isocyanate used in the formulation of the two-component adhesives. In certain embodiments, IPDI is the isocyanate used in the formulation of the two-component adhesives. In certain embodiments, these isocyanates have a functionality greater than two, and may be polymeric. In certain embodiments, other isocyanates are used, including aliphatic isocyanates in cases where resistance to ultraviolet light is a requirement.
In certain embodiments, the two-component adhesives are formulated with isocyanates and/and or polyols which are 2.0 functional or lower. In certain embodiments the adhesives are formulated with isocyanates and/or polyols functionality greater than 2.0 (in other words, some degree of branching) to introduce cross-linking in the cured two-component adhesives. In certain embodiments, the total level of crosslinking is relatively high to produce adhesives with high modulus, high hardness, and good tensile, shear stress, and peel strength properties. In certain embodiments, the total level of crosslinking is relatively low to produce adhesives with greater elasticity.
In certain embodiments the two-component adhesives are applied as 100% solids. In certain embodiments, the two-component adhesives may be dissolved, dispersed, and/or emulsified in a solvent or water to reduce viscosity or otherwise improve their applicability. In certain embodiments, solvents such as acetone, methyl ethyl ketone, ethylacetate, toluene, or xylene are preferred.
In certain embodiments no fillers are present in the two-component adhesives. In other embodiments calcium carbonate, talc, clays, or the like are added as fillers to control rheology, reduce shrinkage, reduce cost, and/or for other reasons. In certain embodiments the two-component adhesives include thixotropic agents, flow agents, film-forming additives, and/or catalysts to achieve the processing and finished adhesives properties required.
In certain embodiments, the two-component adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In one aspect, the present invention also encompasses reactive hot-melt adhesives. In certain embodiments, such reactive hot-melt adhesive compositions are derived from a composition as defined above and in the embodiments and examples herein. In some embodiments, a polyurethane composition for use in a hot-melt adhesive comprises a composition described above and herein.
In certain embodiments the hot-melt adhesives include prepolymers derived from one or more polyols. These prepolymers can be produced with excess isocyanate and/or excess hydroxyl content and are then mixed with one or more of the isocyanates, polyols, and other components described above. In certain embodiments the molar ratio of isocyanate to polyol is between 1.5:1 and 4:1, preferably between 1.9:1 and 3:1, and often very near 2:1.
In certain embodiments, MDI is the isocyanate to react with a polyol component as described above. In certain embodiments, IPDI is the isocyanate to react with a polyol component as described above. In certain embodiments requiring unique hot-melt adhesive performance properties, TDI and/or aliphatic isocyanates are used in place of or in addition to MDI.
In certain embodiments the reactive hot-melt adhesive prepolymers are produced by reacting an excess of isocyanate with a relatively high molecular weight polyol. These prepolymers thus have an excess of isocyanate, or “free” isocyanate groups, which react with atmospheric moisture to improve the finished properties of the reactive hot-melt adhesive. In certain embodiments the amount of free isocyanate is about 1-5 percent by weight.
In certain embodiments the polyols, isocyanates, and/or prepolymers comprising the primary components of the reactive hot-melt adhesive are formulated such that the viscosity of the adhesive formulation is sufficiently low at the application temperature to enable efficient application to the substrate. The reactive hot-melt viscosity increases as it cools to rapidly provide good adhesive properties.
In certain embodiments, the reactive hot-melt polyurethane adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In another aspect, the present invention encompasses non-reactive solvent-borne adhesives. In certain embodiments, such solvent-borne adhesive compositions are derived a composition comprising a composition as defined above and in the embodiments and examples herein.
In some embodiments, a polyurethane composition for use in a non-reactive solvent-borne adhesive comprises a composition described above and herein.
In certain embodiments the solvent-borne adhesives are produced by reacting one or more polyols with one or more isocyanates and/or all other additives described above to create higher molecular weight prepolymers and/or polyurethane adhesives. These high molecular weight polyurethanes are then dissolved in one or more solvents for application onto various substrates. In these embodiments the solvent-borne adhesive is described as a one-component system. Additional fillers and performance enhancing additives may be included in the formulation.
In certain embodiments, solvent-borne cross-linkers are added to solvent-born polyurethane adhesives as described above to improve the strength and resistance of the finished adhesive. The crosslinkers may be any combination polyols and isocyanates described above and may also be other types of thermosetting components. In these embodiments the solvent-borne adhesive is described as a two-component reactive system and are thus similar and/or equivalent to the two-component reactive adhesives described above, in the embodiments in which these systems are dissolved in one or more solvents.
In certain embodiments, the non-reactive solvent-borne adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In one aspect, the present invention encompasses reactive water-borne adhesives. In certain embodiments, such water-borne adhesive compositions are derived from a composition as defined above and in the embodiments and examples herein.
In certain embodiments the water-borne adhesives are produced by reacting one or more polyols with one or more isocyanates and/or all other additives described above to create higher molecular weight prepolymers and/or polyurethane adhesives, which are then dispersed in water and known as polyurethane dispersions (PUDs). In certain embodiments, they may contain low levels of solvents to help stabilize the polymers in water.
In certain embodiments, the solids content of the final PUD adhesive is in the range of 25-75%, preferably in the range of 35-50%. In certain embodiments, the water-borne adhesives are formulated to be on the very high or low end of these ranges depending on viscosity requirements, other processing considerations, and finished adhesive properties required.
In certain embodiments, water-borne cross-linkers are added to water-born PUDs as described above to improve the performance of the finished adhesive. The crosslinkers may be any combination of polyols and isocyanates described above and may also be other types of thermosetting components. In these embodiments the water-borne adhesive is akin to the two-component reactive system described above (except it is dispersed in an aqueous system) in the embodiments in which these systems are dispersed or emulsified in water.
In certain embodiments, the non-reactive water-borne adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In one aspect, the present invention encompasses non-reactive hot-melt adhesives. In certain embodiments, such non-reactive hot-melt adhesive compositions are derived from a composition as defined above and in the embodiments and examples herein. In some embodiments, a polyurethane composition for use in a hot-melt adhesive comprises a composition described above and herein.
In certain embodiments the non-reactive hot-melt adhesives are produced by reacting one or more polyols with one or more isocyanates and/or all other additives described above to create higher molecular weight polymers and/or polyurethane adhesives. Additional fillers and performance enhancing additives may be included in the formulation.
In certain embodiments the polyols, isocyanates, prepolymers and/or polyurethane adhesives comprising the primary components of the non-reactive hot-melt adhesive are formulated such that the viscosity of the adhesive formulation is sufficiently low at the application temperature to enable efficient application to the substrate. The non-reactive hot-melt viscosity increases as it cools to rapidly provide good adhesive properties. In certain applications, they are formulated to have melt viscosities between 25,000 and 500,000 mPa*s, more preferable between 50,000 to 250,000 mPa*s.
In certain embodiments, the non-reactive hot-melt adhesive mixture forms a final, cured polyurethane adhesive with the following composition:
In certain embodiments, any of the above reactive and non-reactive adhesive formulations are combined with other adhesive chemistries in hybrid systems. In certain embodiments, the finished adhesives are urethane acrylic systems which can take a number of forms, including aqueous systems using water-dispersable isocyanates with PUDs and acrylic emulsion polymers, mixing acrylic and hydroxyl polyols to create co-polymerized resins, and the like. In certain embodiments, vinyl-terminated acrylic polymers are used to improve impact resistance. In certain embodiments, polyurethanes with acrylic functionality are also used in anaerobic or radiation-cured adhesives to increase toughness. In certain embodiments, urethanes are combined with epoxy chemistries using amine curing systems to create fast-curing adhesives for structural and heavy duty applications.
In one aspect, the present invention encompasses adhesive compositions derived from compositions as defined above and in the embodiments and examples herein that are used for joining substrates. Exemplary substrates include, but are not limited to, metals (e.g., aluminum, stainless steel, etc), ceramics, textiles, woven and/or non-woven fabrics, foams, polyesters, polyolefins, polystyrenes, polyvinyl chlorides (PVC), polycarbonates (PC), acrylonitrile butadiene styrenes (ABS), acrylics, rubbers, plastics, glasses, woods (e.g., pine, maple, etc), and combinations thereof (e.g., metal to plastic, PVC to ABS, etc). In some embodiments, a substrate is selected from the group consisting of a metal (e.g., aluminum, stainless steel, etc), ceramic, textile, woven and/or non-woven fabric, foam, polyester, polyolefin, polystyrene, polyvinyl chloride (PVC), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), acrylic, rubber, plastic, glass, wood (e.g., pine, maple, etc), and combinations thereof (e.g., metal to plastic, PVC to ABS, etc). In some embodiments, a substrate is selected from the group consisting of metal, PVC, PC, ABS, plastic substrates, and combinations thereof (e.g., metal to plastic, PVC to ABS, etc). In some embodiments, a substrate is selected from the group consisting of aluminum, PVC, PC, ABS, plastic substrates, and combinations thereof (e.g., aluminum to plastic, PVC to ABS, etc). In some embodiments, a substrate is selected from the group consisting of metal, PVC, and PC substrates. In some embodiments, a substrate is selected from the group consisting of aluminum, PVC, and PC substrates. In some embodiments, a substrate is a metal substrate. In some embodiments, a substrate is an aluminum substrate. In some embodiments, a substrate is a stainless steel substrate. In some embodiments, a substrate is a ceramic substrate. In some embodiments, a substrate is a textile substrate. In some embodiments, a substrate is a woven and/or non-woven fabric substrate. In some embodiments, a substrate is a woven fabric substrate. In some embodiments, a substrate is a non-woven fabric substrate. In some embodiments, a substrate is a foam substrate. In some embodiments, a substrate is a polyester substrate. In some embodiments, a substrate is a polyolefin substrate. In some embodiments, a substrate is a polystyrene substrate. In some embodiments, a substrate is a PVC substrate. In some embodiments, a substrate is a PC substrate. In some embodiments, a substrate is an ABS substrate. In some embodiments, a substrate is an acrylic substrate. In some embodiments, a substrate is a rubber substrate. In some embodiments, a substrate is a plastic substrate. In some embodiments, a substrate is a glass substrate. In some embodiments, a substrate is a wood (e.g., pine, maple, etc) substrate. In some embodiments, a substrate is a pine substrate. In some embodiments, a substrate is a maple substrate. In some embodiments, a substrate is a combination of substrates described above and herein. In some embodiments, a substrate is a combination of metal and plastic substrates. In some embodiments, a substrate is a combination of aluminum and plastic substrates. In some embodiments, a substrate is a combination of stainless steel and plastic substrates. In some embodiments, a substrate is a combination of PVC and ABS substrates.
Adhesives provided by the present invention have unique and unexpected properties. In certain embodiments, the present invention encompasses adhesives comprising a polyurethane composition as described herein, and characterized in that the cured adhesives have unexpectedly high strength at elevated temperatures. The high strength at elevated temperature can be demonstrated by measuring the strength of the cured adhesive strength on metal substrate using, e.g., the ASTM D1002 or ISO 4587 lap sheer test at ambient temperature and then performing the same measurement at one or more elevated temperatures.
In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (i). In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition lacking polyol subcomponent (ii). In some embodiments, a reference polyurethane composition is a corresponding polyurethane composition composed solely of a polycarbonate polyol that is structurally different from either polyol subcomponent (i) or polyol subcomponent (ii). In some embodiments, a reference polyurethane composition is a polyurethane composition composed solely of a polyether polyol. In some embodiments, a reference polyurethane composition is a polyurethane composition composed solely of a polyester polyol.
In certain embodiments, adhesives of the present invention (i.e., any of the adhesive compositions described above and herein derived from a compound described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens of the substrate has a greater strength relative to a corresponding adhesive composition derived from a reference polyurethane composition, wherein the strength is measured by an ASTM D1002 or ISO 4587 lap sheer test. In some embodiments, adhesives of the present invention (i.e., any of the adhesive compositions described above and herein derived from a compound described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens of the substrate has a greater strength relative to a corresponding adhesive composition derived from a reference polyurethane composition, wherein the strength is measured by an ASTM D1002 lap sheer test. In some embodiments, adhesives of the present invention (i.e., any of the adhesive compositions described above and herein derived from a compound described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens of the substrate has a greater strength relative to a corresponding adhesive composition derived from a reference polyurethane composition, wherein the strength is measured by an ISO 4587 lap sheer test. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured is least 5%, is least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 100%, at least 150%, at least 200%, at least 250%, at least 300%, at least 350%, at least 400%, at least 450%, or at least 500% greater than the corresponding adhesive composition derived from a reference polyurethane composition. In certain embodiments, the strengths compared above are indicated by a measurement selected from the group consisting of: Load at Failure; Tensile Energy to Break; Stress at Yield; and Strain at Yield.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens retains at least 50% of its room temperature strength when heated to a temperature of 50° C. In some embodiments the strength is measured using ASTM D1002 or ISO 4587. In some embodiments the strength is measured using ASTM D1002. In some embodiments the strength is measured using ISO 4587. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens measured at 50° C. is least 5%, least 10%, least 20%, least 30%, least 40%, least 50%, least 60%, least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98%; or between about 5% and about 10%, about 5% and about 25%, about 5% and about 50%, about 5% and about 75%, about 5% and about 100%, about 10% and about 100%, about 25% and about 100%, about 50% and about 100%, about 75% and about 100%, about 20% and about 80%, and about 40% and about 60% of the strength measured using the same procedure at room temperature. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens measured at 70° C. is least 5%, least 10%, least 20%, least 30%, least 40%, least 50%, least 60%, least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98%; or between about 5% and about 10%, about 5% and about 25%, about 5% and about 50%, about 5% and about 75%, about 5% and about 100%, about 10% and about 100%, about 25% and about 100%, about 50% and about 100%, about 75% and about 100%, about 20% and about 80%, and about 40% and about 60% of the strength measured using the same procedure at room temperature. In certain embodiments, the strengths compared above are indicated by a measurement selected from the group consisting of: Load at Failure; Tensile Energy to Break; Stress at Yield; and Strain at Yield.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ASTM D1002 or ISO 4587 at 50° C. is at least 60% of the Load at Failure measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ASTM D1002 at 50° C. is at least 60% of the Load at Failure measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ISO 4587 at 50° C. is at least 60% of the Load at Failure measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured at 50° C. is least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the Load at Failure measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured at 50° C. is between 50 and 100% of the Load at Failure measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured at 50° C. is between 50% and 80%, between 70% and 80%, between 60% and 80%, between 70% and 100%, or between 80% and 100% of the Load at Failure measured using the same procedure at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ASTM D1002 or ISO 4587 at 50° C. is at least 60% of the Tensile Energy to Break measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ASTM D1002 at 50° C. is at least 60% of the Tensile Energy to Break measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ISO 4587 at 50° C. is at least 60% of the Tensile Energy to Break measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured at 50° C. is least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the Tensile Energy to Break measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured at 50° C. is between 50 and 100% of the Tensile Energy to Break measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured at 50° C. is between 50% and 80%, between 70% and 80%, between 60% and 80%, between 70% and 100%, or between 80% and 100% of the Tensile Energy to Break measured using the same procedure at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Stress at Yield or Strain at Yield measured using ASTM D1002 or ISO 4587 at 50° C. is at least 60% of the corresponding parameter measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Stress at Yield or Strain at Yield measured using ASTM D1002 at 50° C. is at least 60% of the corresponding parameter measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Stress at Yield or Strain at Yield measured using ISO 4587 at 50° C. is at least 60% of the corresponding parameter measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Stress at Yield or Strain at Yield of the cured adhesive measured at 50° C. is least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 92%, at least 95%, or at least 98% of the corresponding parameter measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Stress at Yield or Strain at Yield of the cured adhesive measured at 50° C. is between 50 and 100% of the corresponding parameter measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Stress at Yield or Strain at Yield of the cured adhesive measured at 50° C. is between 50% and 80%, between 70% and 80%, between 60% and 80%, between 70% and 100%, or between 80% and 100% of the corresponding parameter measured using the same procedure at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ASTM D1002 or ISO 4587 at 50° C. is greater than the strength at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ASTM D1002 at 50° C. is greater than the strength at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ISO 4587 at 50° C. is greater than the strength at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured using ASTM D1002 or ISO 4587 at 50° C. is at least 10% higher than the strength measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured using ASTM D1002 at 50° C. is at least 10% higher than the strength measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured using ISO 4587 at 50° C. is at least 10% higher than the strength measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive at 50° C. is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the strength measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured at 50° C. is between 100% and 200%, between 100% and 150%, between 120% and 180%, between 120% and 150%, or between 100% and 120% of the strength measured using the same procedure at 25° C. In certain embodiments, the strengths compared above are indicated by a measurement selected from the group consisting of: Load at Failure; Tensile Energy to Break; Stress at Yield; and Strain at Yield. In certain embodiments, the strengths compared above are indicated by a measurement selected from the group consisting of: Load at Failure; Tensile Energy to Break; and Strain at Yield.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ASTM D1002 or ISO 4587 at 50° C. is greater than the Load at Failure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ASTM D1002 at 50° C. is greater than the Load at Failure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by Load at Failure measured using ISO 4587 at 50° C. is greater than the Load at Failure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured using ASTM D1002 or ISO 4587 at 50° C. is at least 10% higher than the Load at Failure measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured using ASTM D1002 at 50° C. is at least 10% higher than the Load at Failure measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured using ISO 4587 at 50° C. is at least 10% higher than the Load at Failure measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive at 50° C. is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the Load at Failure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Load at Failure of the cured adhesive measured at 50° C. is between 100% and 200%, between 100% and 150%, between 120% and 180%, between 120% and 150%, or between 100% and 120% of the Load at Failure measured using the same procedure at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ASTM D1002 or ISO 4587 at 50° C. is greater than the Tensile Energy to Break at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ASTM D1002 at 50° C. is greater than the Tensile Energy to Break at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Tensile Energy to Break measured using ISO 4587 at 50° C. is greater than the Tensile Energy to Break at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured using ASTM D1002 or ISO 4587 at 50° C. is at least 10% higher than the Tensile Energy to Break measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured using ASTM D1002 at 50° C. is at least 10% higher than the Tensile Energy to Break measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured using ISO 4587 at 50° C. is at least 10% higher than the Tensile Energy to Break measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive at 50° C. is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the Tensile Energy to Break the adhesive at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Tensile Energy to Break the cured adhesive measured at 50° C. is between 100% and 200%, between 100% and 150%, between 120% and 180%, between 120% and 150%, or between 100% and 120% of the Tensile Energy to Break the adhesive at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ASTM D1002 or ISO 4587 at 50° C. is greater than the Strain at Yield at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ASTM D1002 at 50° C. is greater than the Strain at Yield at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ISO 4587 at 50° C. is greater than the Strain at Yield at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ASTM D1002 or ISO 4587 at 50° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ASTM D1002 at 50° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ISO 4587 at 50° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive at 50° C. is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the Strain at Yield of the adhesive at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured at 50° C. is between 100% and 200%, between 100% and 150%, between 120% and 180%, between 120% and 150%, or between 100% and 120% of the Strain at Yield of the adhesive at 25° C.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ASTM D1002 or ISO 4587 at 70° C. retains at least 40% of the strength measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ASTM D1002 at 70° C. retains at least 40% of the strength measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured adhesive measured using ISO 4587 at 70° C. retains at least 40% of the strength measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured at 50° C. is least 55%, at least 60%, at least 65%, at least 70%, at least 75%, or at least 80% of the strength measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured at 70° C. is between 40% and 100% of the strength measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the strength of the cured adhesive measured at 70° C. is between 40% and 80%, between 40% and 60%, between 50% and 80%, between 50% and 70%, or between 70% and 90% of the strength measured using the same procedure at 25° C. In certain embodiments, the strengths compared above are indicated by a measurement selected from the group consisting of: Load at Failure; Tensile Energy to Break; Stress at Yield; and Strain at Yield.
In certain embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ASTM D1002 or ISO 4587 at 70° C. is greater than the Strain at Yield at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ASTM D1002 at 70° C. is greater than the Strain at Yield at 25° C. In some embodiments, adhesives of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are characterized in that the strength of the cured bond formed by the adhesive composition between two specimens indicated by the Strain at Yield measured using ISO 4587 at 70° C. is greater than the Strain at Yield at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ASTM D1002 or ISO 4587 at 70° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ASTM D1002 at 70° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In some embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured using ISO 4587 at 70° C. is at least 10% higher than the Strain at Yield measured using the same procedure at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive at 70° C. is at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 75%, at least 100%, or at least 150% greater than the Strain at Yield of the adhesive at 25° C. In certain embodiments, adhesives of the present invention are characterized in that the Strain at Yield of the cured adhesive measured at 70° C. is between 100% and 200%, between 100% and 150%, between 120% and 180%, between 120% and 150%, or between 100% and 120% of the Strain at Yield of the adhesive at 25° C.
In another aspect, the present invention encompasses adhesive compositions (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) characterized in that the cured adhesive is highly resistant to solvents. Such solvent resistance properties are unexpected since analogous adhesives formulated with commercially available polycarbonate polyols (e.g. those having more than two carbon atoms enchained between adjacent carbonate linkages) are degraded by solvent to a greater degree than the adhesives of the present invention.
In certain embodiments, adhesive compositions of the present invention (i.e. any of the adhesive compositions described above and herein derived from a composition described above and herein) are further characterized in that they have excellent resistance to hydrocarbon solvents. In certain embodiments, adhesive compositions of the present invention are characterized in that they have superb resistance to aromatic hydrocarbons. In certain embodiments, the present invention comprises epoxide-CO2-based polyols characterized in that they gain less than 5% mass when immersed in aromatic hydrocarbon liquid for 1 week. In certain embodiments, they gain less than 5% mass when immersed in toluene for 1 week. In certain embodiments, they gain less than 1% mass when immersed in xylenes for 1 week.
The present invention is illustrated by the following examples. It is to be understood that the particular examples, materials, amounts, and procedures are to be interpreted broadly in accordance with the scope and spirit of the invention as set forth herein.
PC Polyol 1 and PC Polyol 2 were prepared by methods disclosed in, for example, PCT publication WO2010/028362, using a polymerization catalyst. Polymerization catalysts include those disclosed in, for example, R.-R. Ang et al., Journal of Cleaner Production. 102 (2015) 1-17; Zhang, et al., Chem. Rev. 2018 (118), 839-885; Liu et al., Current Opinion in Green and Sustainable Chemistry 2017 (3), 61-66; or Quin, et. al., Journal of CO2 Utilization 2015 (11), 3-9; U.S. Pat. Nos. 7,304,172 and 6,870,004; EP Patent No. EP 2258745B1; PCT Publication Nos. WO 2010/022388, WO 2008/136591, WO 2008/150033, WO 2009/137540, WO 2010/013948, WO 2010/147421, WO 2012/037282, WO 2013/022932, WO 2013/012895, WO 2013/096602, WO 2014/031811, WO 2016/012785, WO 2016/012786, and WO 2010/028362; and in Chinese Patent Publication Nos. CN 2007/10010706 and 2008/10229276. PC Polyol 1 was prepared from a polyol(propylene glycol) initiator and comprises polymer chains of formula:
where, on average within the composition, the sum of the a moieties within each polymer chain is about 16, and the sum of the m′ moieties within each polymer chain is about 10.
PC Polyol 1 has an OH # of about 56, a functionality of 2.0, and a wt % of CO2 of about 20. The number average molecular weight of PC Polyol 1 is about 2,000 g/mol.
PC Polyol 2 was prepared from a dipropylene glycol initiator and comprises polymer chains of formula:
where, on average within the composition, the sum of the n′ moieties within each polymer chain is about 9.
PC Polyol 2 has an OH # of about 112, a functionality of 2.0, and a wt % of CO2 of about 40.
Polyols (see Table 5) were first added to the reactor and maintained at 90° C. under vacuum for an hour to remove dissolved gas and water. Then, MDI was added to the polyol at 70° C. and the reaction was carried out at 90° C. until the target NCO content of 4% was achieved.
An initial screen was performed to identify initial blends for further study. The prepolymers were cast as thin films and a minimum of three test bars were prepared for each prepolymer. The test bars were used to measure tensile strength and ultimate elongation on the Instron according to ASTM D412.
Sample Preparation: 20 g of 4% NCO-terminated prepolymers were weighed into a 50-mL vial. Next, surfactant BYK-A530 (0.01 wt %) and catalyst 4,4′-(Oxydi-2,1-ethanediyl) bismorpholine (DMDEE, 0.1%) were added to the vial. The mixture was blended at 600 rpm at 90° C. for 2-3 minutes. The mixture was then held under vacuum at 90° C. for 2-4 hours to degas. Samples were used for making joints after complete degassing, which was determined by observing bubbles no longer forming in the mixture.
Substrate Preparation: Aluminum, polyvinyl chloride (PVC), and polycarbonate (PC) were used as substrates. Substrate dimension was (101.6 mm length and 25.4 mm width) as recommended in ASTM D1002. To prepare the substrates, each was wiped with isopropanol and then placed in the oven at 70° C. for 2-3 hours. Lap shear samples were prepared by using a 0.5 mm thick piece of Teflon sheet to ensure uniform adhesive thickness. Overlap length between substrate was kept around 0.5 inch as shown in
Curing Conditions: Samples were cured at 40° C. with 40% humidity for 8-10 days. Completion of curing was confirmed using FTIR by observing the absorbance around 2200 cm1. Uncured samples exhibit a larger absorbance, which reduces in intensity as the curing takes place. The completion of curing can also be visually observed by carefully checking the dryness or tackiness on the broken samples. If the sample is wet or tacky after breaking the joint on Instron, it is not completely cured. A completely cured sample should be dry and show no tackiness after joint break.
ASTM Method: ASTM D1002 was used for lap shear strength measurement. Lap shear joint strength was measured using a crosshead speed of 1.3 mm/min. Shear stress (lap shear strength) present in the adhesive layer was measured by the dividing the load at failure by the shear area. It will be appreciated that actual shear area dimensions can vary, and may be normalized in accordance with ASTM D1002.
Shear Stress=Load/Shear Area
Shear Area=Overlap Length*Substrate Width
Failure Mode: As is understood, when measuring lap shear strength, there are different types of failure modes, e.g., cohesive failure, adhesive failure, and substrate failure.
Cohesive Failure (CF): Cohesive Failure is characterized by failure of the adhesive sample itself and is associated with a breakdown of intermolecular bonding forces within the adhesive sample. Cohesive failure is observed where the interfacial strength (i.e., bond between the adhesive sample and the substrate) is materially greater than the cohesive strength of the adhesive sample.
Adhesive Failure (AF): Adhesive Failure is characterized by failure of the joint at the adhesive-substrate interface and is observed when the cohesive strength of the adhesive sample is materially greater than the interfacial strength (i.e., bond between the adhesive sample and substrate).
Substrate Failure (SF): Substrate Failure is characterized by failure of the adherent (e.g., substrate) instead of the adhesive sample and is associated with a breakdown of bonding forces within the substrate. Substrate Failure is observed when the interfacial strength (i.e., bond between the adhesive sample and substrate) is materially greater than the strength of the substrate itself.
As is understood, mixed failure modes, e.g., samples that exhibit some cohesion failure and some adhesion failure, can be observed. Additionally or alternatively, a mixed failure mode is a result of partial failure of the joint at the adhesive-substrate interface.
Alternative method(s) of measuring lap shear strength: Additionally or alternatively, lap shear strength is measured by other methods known in the field. For example, in some aspects, lap shear strength is measured according to ISO 4587.
Initial studies were performed to assess strength of polyurethane adhesives derived from blends of certain polycarbonate polyols and compared to polyurethane adhesives derived form conventional polyols. PUs 1-8 were prepared according to Example 1, as disclosed in Table 6, and characterized according to Example 2, as disclosed in Table 7. PUs 1-8 were also compared to a conventional hotmelt polyurethane based adhesive, Henkel's Technomelt PUR 3631, as disclosed in Table 7 as PU-A. In this initial study, lap shear strength was measured on three substrates: aluminum, PVC and PC, as indicated in Table 7.
Example 3 demonstrates that the addition of PC Polyol 2, even as low as 10%, to PC Polyol 1 significantly improves lap shear strength on aluminum and PVC substrates. The lap shear strength of the samples for polycarbonate are comparable and often result in substrate failure. Without wishing to be bound be a particular theory, it is hypothesized that an increase in wettability or surface interaction between the adhesive and substrate leads to the improved lap shear strength when using blends of PC Polyol 1 and PC Polyol 2, which is supported by the observed change in failure mode from adhesive failure to cohesive failure.
Example 3 also demonstrates that PUs 1-4, derived from PC Polyol 1 or a blend of PC Polyol 1 and 2, displayed high lap shear strengths when compared to convention polyols used in PUs 5-8 or a traditional hot melt polyurethane adhesive (PU-A), which was observed across multiple substrates.
aAll weight percents represent the weight percent of total polyols exclusive of other co-reactives and additives.
bViscosity values were obtained from the corresponding polyurethane prepolymers.
Based on the preliminary studies shown in Example 4, further studies were performed to assess the optimal blends of PC Polyol 1 and PC Polyol 2. PUs 9-11 were prepared according to Example 1, as disclosed in Table 8 and characterized according to Example 2 using aluminum as a substrate, as also disclosed in
When developing polyurethane adhesives derived from blends of polyols, it is generally expected that the adhesive comprised of a blend will consist of a weighted average of the properties of adhesives derived from a single polyol (e.g., adhesives derived solely from PC Polyol 1 (PU1) or PC Polyol 2 (PU11)).
Here, it was observed that in some instances, the polyurethane adhesive derived from a blend displayed strengths that are unexpectedly improved as compared to the adhesives composed solely of PC Polyol 1 or PC Polyol 2, as shown in
aAll weight percents represent the weight percent of total polyols exclusive of other co-reactives and additives.
The following numbered embodiments, while non-limiting, are exemplary of certain aspects of the present disclosure:
1. A composition comprising:
is derived from a dihydric alcohol selected from the group consisting of 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 2,2-dimethylpropane-1,3-diol, 2-butyl-2-ethylpropane-1,3-diol, 2-methyl-2,4-pentane diol, 2-ethyl-1,3-hexane diol, 2-methyl-1,3-propane diol, 1,5-hexanediol, and 1,6-hexanediol.
5. The composition according to any one of embodiments 1-3, wherein
is derived from a dihydric alcohol selected from the group consisting of diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, and tripropylene glycol.
6. The composition according to embodiment 5, wherein
is derived from dipropylene glycol.
7. The composition according to any one of embodiments 1-6, wherein
is derived from poly(propylene glycol) having a Mn between about 234 and about 2000 g/mol.
8. The composition according to embodiment 7, wherein
is derived from poly(propylene glycol) having a Mn between about 900 g/mol and 1,100 g/mol.
9. The composition according to embodiment 8, wherein
is derived from poly(propylene glycol) having a Mn of about 1000 g/mol.
10. The composition according to any one of embodiments 1-3 and 5-9, wherein one or more aliphatic polycarbonate polyols of formula PS1 are of formula Q10:
wherein,
wherein,
All material cited in this application, including, but not limited to, patents and patent applications, regardless of the format of such literature and similar materials, are expressly incorporated herein by reference in their entirety. In the event that one or more of the incorporated literature and similar materials differs from or contradicts this application, including but not limited to defined terms, term usage, described techniques, or the like, this application controls.
This application claims priority to U.S. Provisional Application No. 63/214,198 filed on Jun. 23, 2021, the entirety of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63214198 | Jun 2021 | US |
