Plate containing non-isocyanate polyurethane

Abstract

A sheet material containing non-isocyanate polyurethane includes at least a core layer, a decorative layer, a wear-resistant layer, and a paint layer. The wear-resistant layer comprises non-isocyanate-based polyurethane, and the non-isocyanate-based polyurethane is prepared from 40%-60% of cyclic carbonate, 20%-30% of amine, 5%-15% of a chain extender, 1%-5% of an ultraviolet-proof additive and 10%-20% of bio-based polyol. The non-isocyanate polyurethane is generated through the reaction of cyclic carbonate and amine, the synthesis method avoids the use of isocyanate and is green and environment-friendly, and compared with isocyanate, the cyclic carbonate has the characteristics of nonporous property, insensitivity to moisture, low toxicity and the like, and the non-isocyanate polyurethane can be used for preparing the non-isocyanate polyurethane. According to the invention, the polyurethane which is nonporous, insensitive to moisture and free of isocyanate can be prepared, so that the obtained product has the advantages of good hydrolysis resistance, good mechanical resistance, low VOC content and the like.

Description

Technical Field

[0001] The invention relates to the technical field of building boards, in particular to a board containing non-isocyanate polyurethane. Background Art

[0002] As a decorative and home furnishing material, flooring is widely used in people's lives and work. Moreover, with the improvement of people's living standards, people's functional requirements for flooring are getting higher and higher, and different needs are generated. Polyurethane is produced in the form of rigid and flexible foaming and non-porous materials (such as coatings, adhesives, sealants, thermoplastics, elastomers or thermosetting plastics). They have excellent mechanical, chemical and physical properties, including elasticity, wear resistance, biocompatibility, durability or tensile strength.

[0003] Isocyanates are a class of highly reactive compounds that react with alcohol-based compounds to form polyurethane polymers. Isocyanates contribute to the durability, chemical resistance and longevity of floor coatings. As a result, conventional polyurethanes used in traditional flooring applications rely on isocyanates, but their production must use hazardous and toxic byproducts and requires complex safety measures and large investment processes to produce these monomers. In addition, isocyanates have significant toxicity and moisture sensitivity, and are synthesized from the more toxic precursor phosgene, which can harm the environment.

[0004] Exterior decking is also a concern as it is susceptible to UV degradation due to prolonged exposure to sunlight. UV degradation therefore poses a serious threat to coatings used on exterior decking as it adversely affects both aesthetics and structural integrity. When exposed to sunlight’s UV radiation, these coatings can photodegrade, causing fading, discoloration and loss of gloss, ultimately reducing the visual appeal of the panels. Additionally, UV exposure can cause the coating to become brittle, crack or peel, compromising its ability to protect the underlying substrate from environmental factors such as moisture and abrasion. Summary of the invention

[0005] In view of this, the present invention provides a board containing non-isocyanate polyurethane to solve the above problems.

[0006] A board containing non-isocyanate polyurethane comprises at least one core layer, at least one decorative layer arranged on the core layer, a wear-resistant layer arranged on the decorative layer, and a paint layer arranged on the wear-resistant layer, wherein the wear-resistant layer contains non-isocyanate polyurethane, and the non-isocyanate polyurethane is composed of 40-60% of cyclic carbonate, 20-30% of amine, 5-15% of chain extender, 1-5% of UV protection additive, and 10-20% of bio-based polyol.

[0007] Furthermore, the base layer is a SPC or PP board.

[0008] Furthermore, the amine may be a primary amine, a secondary amine, an aliphatic diamine or a cycloaliphatic polyamine.

[0009] Furthermore, the molecular weight of the non-isocyanate polyurethane is 22000 g / mol.

[0010] Furthermore, the viscosity of the non-isocyanate based polyurethane at room temperature is at least 2000 mPa-s, preferably at least 5000 mPa-s to 10000 mPa-s.

[0011] Furthermore, the chain extender is selected from ethylene glycol, 1,3-propylene glycol, 1,4-butanediol or 1,6-hexanediol or a mixture thereof.

[0012] Furthermore, the bio-based polyol is extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof.

[0013] Compared with the prior art, the non-isocyanate polyurethane of the plate containing non-isocyanate polyurethane of the present invention is composed of 40-60% cyclic carbonate, 20-30% amine, 5-15% chain extender, 1-5% UV protection additive, and 10-20% bio-based polyol. Non-isocyanate polyurethane is formed by the reaction of cyclic carbonate and amine to generate non-isocyanate polyurethane. This synthesis method avoids the use of isocyanate, which is not only green and environmentally friendly, but also compared with isocyanate, cyclic carbonate has the characteristics of non-porous, insensitive to moisture, and low toxicity. It can produce non-porous, moisture-insensitive, isocyanate-free polyurethane, so that the obtained product has the advantages of good hydrolysis resistance, mechanical resistance and low VOC content. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 The present invention provides a cross-sectional view of a plate containing non-isocyanate polyurethane. DETAILED DESCRIPTION

[0015] The specific embodiments of the present invention are further described in detail below. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the protection scope of the present invention.

[0016] like Figure 1As shown, it is a schematic diagram of the structure of a plate containing non-isocyanate polyurethane provided by the present invention. The plate containing non-isocyanate polyurethane includes at least one core layer 10, at least one decorative layer 20 arranged on the core layer 10, a wear-resistant layer 30 arranged on the decorative layer 20, and a paint layer 40 arranged on the wear-resistant layer 30. It can be imagined that the plate containing non-isocyanate polyurethane also includes some other functional components, such as a snap-on structure, a waterproof layer, etc., which are well known to those skilled in the art and will not be described in detail here.

[0017] The base layer 10 is an SPC or PP board. The SPC board is a new type of floor, also known as stone plastic floor. Its base material is a composite board made of stone powder and thermoplastic polymer material that are evenly mixed and then extruded at high temperature. It has the properties and characteristics of both wood and plastic, has a certain degree of flexibility, and ensures the strength and toughness of the floor.

[0018] The decorative layer 20 mainly provides aesthetic effects. The decorative layer is usually made of various materials such as wood, stone, and ceramic tile, and its color and texture can be selected according to personal preference and interior design style.

[0019] The wear-resistant layer 30 comprises non-isocyanate-based polyurethane, which is composed of 40-60% cyclic carbonate, 20-30% amine, 5-15% chain extender, 1-5% UV protection additive, and 10-20% bio-based polyol.

[0020] Non-isocyanate polyurethane (NIPU) refers to a polyurethane that does not contain isocyanate monomers during its preparation process. NIPU is usually formed by the reaction of cyclic carbonates and amines to form non-isocyanate polyurethanes, provided that both reagents carry at least two corresponding reactive parts. At the beginning of the reaction, the amine group performs a nucleophilic attack on the electropositive carbonyl carbon in the cyclic carbonate to form an intermediate with a tetrahedral structure. Then, another amine molecule captures the hydrogen ion (H+) on the N atom in the tetrahedral intermediate. Due to the high electron cloud density on the N atom, the CO bond is unstable, resulting in the breakage of the CO bond and the generation of oxygen anions.

[0021] The oxygen anion quickly combines with the previously lost proton (H+) to form an alcohol. In this step, the final product is a carbamate structure with -OH, that is, polyhydroxycarbamate. Polyhydroxycarbamate is an important intermediate product in the preparation process of NIPU or it can be said to be a specific type of NIPU. Therefore, NIPU can also be called polyhydroxycarbamate. These hydroxycarbamates have additional primary or secondary hydroxyl groups in their side chains. Therefore, with the formation of each carbamate bond, primary or secondary hydroxyl groups are also formed. These generated hydroxyl groups can establish intermolecular and intramolecular hydrogen bonds with carbamate carbonyl groups. Hydrogen bonds are a relatively strong non-covalent interaction that can form stable structures between or within molecules. This interaction can significantly enhance the structural stability of the molecule, making it less susceptible to changes in the external environment and improving the stability of the board.

[0022] By reacting cyclic carbonate with amine, polyhydroxyurethane can be generated. This synthesis method avoids the use of isocyanate, which is not only green and environmentally friendly, but also because cyclic carbonate is usually prepared by reacting epoxy resin and carbon dioxide. Compared with isocyanate, the most important characteristics of cyclic carbonate are non-porous characteristics, insensitivity to moisture, and low toxicity. This unique chemical substance does not produce gas during reaction and does not react with moisture in the air. It can produce non-porous, moisture-insensitive, isocyanate-free polyurethane, so that the resulting product has good hydrolysis resistance, mechanical resistance and low VOC content. The amine can be a primary amine, a secondary amine, an aliphatic diamine or a cycloaliphatic polyamine. The molecular weight of the non-isocyanate polyurethane is as high as 22,000 g / mol. In contrast, the molecular weight of traditional polyurethane based on isocyanate is 40,000 g / mol to 80,000 g / mol. The viscosity of the non-isocyanate polyurethane at room temperature is at least 2,000 mPa-s, preferably at least 5,000 mPa-s to 10,000 mPa-s.

[0023] The chain extender is selected from ethylene glycol, 1,3-propylene glycol, 1,4-butanediol or 1,6-hexanediol or a mixture thereof, preferably 1,3-propylene glycol or 1,4-butanediol or a mixture thereof. During the preparation of NIPU, the chain extender can react with the functional groups on the polymer chain to extend the molecular chain, thereby increasing the molecular weight of the polymer. Moreover, certain characteristic group structures in the chain extender molecule can be introduced into the polyurethane main chain, thereby affecting certain properties of the polyurethane, and can improve the hardness, resilience, shear strength and tear strength of the NIPU product.

[0024] The anti-ultraviolet additive is mainly used to improve the stability of the material under ultraviolet irradiation. Anti-ultraviolet additives include compounds such as ultraviolet absorbers and hindered amine stabilizers. These additives can effectively absorb or scatter ultraviolet rays, reducing their destructive effects on polyurethane materials. In addition, isocyanate-based polyurethanes are more sensitive to ultraviolet rays because aromatic ether groups directly absorb ultraviolet radiation, ultimately leading to photo-oxidative degradation. Aromatic ether groups are usually introduced into the polyurethane structure through aromatic polyols or isocyanate components containing aromatic rings. Isocyanate-based polyurethanes usually use aromatic isocyanates, such as toluene diisocyanate (TDI) or diphenylmethane diisocyanate (MDI), which can react with aromatic ether-containing polyols to form polyurethanes and aromatic ether backbones. Non-isocyanate-based polyurethanes, which are mainly prepared using polycyclic carbonates and at least one amine, usually do not contain aromatic structures, so the content of aromatic ether groups in non-isocyanate-based polyurethanes will be relatively low, so that the coating has a stronger anti-ultraviolet ability.

[0025] The bio-based polyols are extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof. These resources have a shorter growth cycle and high renewability. Compared with traditional petrochemical-based polyols, bio-based polyols reduce dependence on non-renewable resources, making them more sustainable. At the same time, bio-based polyols have good compatibility with other polymer components, which helps to create a more uniform and consistent material structure, thereby enhancing the overall flexibility of the material.

[0026] The non-isocyanate based polyurethane is cured at a curing temperature of 80-120° C. to form the wear resistant layer 30 to accommodate the slow reaction rate of the cyclocarbonate, which helps to form a non-isocyanate based polyurethane having a molecular weight of about 22,000 g / mol.

[0027] The paint layer 40 is formed by UV or EB curing and has a light transmittance of 60%-100%. The paint layer 40 can also be provided with textures to improve the anti-slip property and aesthetics of the board surface.

[0028] Compared with the prior art, the non-isocyanate polyurethane of the plate containing non-isocyanate polyurethane of the present invention is composed of 40-60% cyclic carbonate, 20-30% amine, 5-15% chain extender, 1-5% UV protection additive, and 10-20% bio-based polyol. Non-isocyanate polyurethane is formed by the reaction of cyclic carbonate and amine to generate non-isocyanate polyurethane. This synthesis method avoids the use of isocyanate, which is not only green and environmentally friendly, but also compared with isocyanate, cyclic carbonate has the characteristics of non-porous, insensitive to moisture, and low toxicity. It can produce non-porous, moisture-insensitive, isocyanate-free polyurethane, so that the obtained product has the advantages of good hydrolysis resistance, mechanical resistance and low VOC content.

[0029] The above are only preferred embodiments of the present invention and are not intended to limit the protection scope of the present invention. Any modification, equivalent substitution or improvement within the spirit of the present invention is included in the scope of the claims of the present invention.

Claims

1. A sheet containing non-isocyanate polyurethane, characterized in that: The board containing non-isocyanate polyurethane comprises at least one core layer, at least one decorative layer arranged on the core layer, a wear-resistant layer arranged on the decorative layer, and a paint layer arranged on the wear-resistant layer, wherein the wear-resistant layer contains non-isocyanate polyurethane, and the non-isocyanate polyurethane is composed of 40-60% of cyclic carbonate, 20-30% of amine, 5-15% of chain extender, 1-5% of UV protection additive, and 10-20% of bio-based polyol.

2. The sheet material containing non-isocyanate polyurethane according to claim 1, characterized in that: The base layer is SPC or PP board.

3. The sheet material containing non-isocyanate polyurethane according to claim 1, characterized in that: The amine may be a primary amine, a secondary amine, an aliphatic diamine or a cycloaliphatic polyamine.

4. The sheet material containing non-isocyanate polyurethane according to claim 1, characterized in that: The molecular weight of the non-isocyanate polyurethane is 22000 g / mol.

5. The sheet material containing non-isocyanate polyurethane as claimed in claim 1, characterized in that: The viscosity of the non-isocyanate based polyurethane at room temperature is at least 2000 mPa-s, preferably at least 5000 mPa-s to 10000 mPa-s.

6. The sheet material containing non-isocyanate polyurethane according to claim 1, characterized in that: The chain extender is selected from ethylene glycol, 1,3-propylene glycol, 1,4-butanediol or 1,6-hexanediol or a mixture thereof.

7. The sheet material containing non-isocyanate polyurethane as claimed in claim 1, characterized in that: The bio-based polyol is extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof.

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