Plate containing bio-based polyurethane

Abstract

The invention relates to a plate containing bio-based polyurethane. The plate comprises a core layer and a bio-based coating, the bio-based coating comprises bio-based polyurethane and 15%-75% of bio-based resin. The bio-based polyurethane is formed by carrying out condensation polymerization on bio-based isocyanate, bio-based polyol or bio-based polyamine and a bio-based additive. The bio-based isocyanate may be a glucose-derived isocyanate or a vegetable oil-derived isocyanate, or a combination of both. The glucose-derived isocyanate is a main reactant for forming polyurethane connection with the polyol, and the vegetable oil-derived isocyanate has the effects of secondary crosslinking, flexibility improvement and thermal stability and hydrophobicity enhancement. The content of the bio-based resin is divided into two dosages according to different applications, the flexibility and the adhesive force can be enhanced when the content is 15-30%, and the bio-based resin is suitable for floors subjected to small impact force. When the content is 30-75%, the crosslinking density can be increased, so that the hardness and the mechanical stability are improved.

Description

Technical Field

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

[0002] As a decorative and home furnishing material, flooring is widely used in people's lives and work. Moreover, as people's living standards improve, their functional requirements for flooring are getting higher and higher. Traditional floor panels usually use wood, vinyl or composite materials, which can cause damage to the environment. The main causes are the loss of natural resources, high energy consumption in the production process, and the emission of volatile organic compounds (VOCs) that cause indoor air pollution.

[0003] In recent years, building materials have begun to shift towards more sustainable development, driven by growing environmental awareness and strict regulations to reduce the carbon footprint of building construction. This trend has led to the development of a variety of eco-friendly materials and production technologies that aim to minimize environmental impact while maintaining or improving the performance and aesthetics of the product.

[0004] One of the most promising developments in this area is the use of bio-based polyurethanes. Unlike conventional polyurethanes, which are derived from petrochemical feedstocks, bio-based polyurethanes are synthesized from renewable feedstocks such as vegetable oils. These bio-based materials offer a variety of benefits, including reduced reliance on fossil fuels, lower greenhouse gas emissions, and biodegradability potential. Incorporating bio-based polyurethanes into decorative flooring panels addresses the environmental issues associated with conventional flooring materials while maintaining durability, versatility, and aesthetics. Summary of the invention

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

[0006] A board containing bio-based polyurethane, comprising at least one core layer and a bio-based coating disposed on the core layer, wherein the bio-based coating 20 comprises bio-based polyurethane and 15%-75% of bio-based resin. The bio-based polyurethane is formed by polycondensation reaction of at least one bio-based isocyanate, at least one bio-based polyol or at least one bio-based polyamine, and at least one bio-based additive. The bio-based isocyanate may be glucose-derived isocyanate or plant oil-derived isocyanate or a combination of the two, wherein the glucose-derived isocyanate accounts for 20-40% of the bio-based polyurethane, and the plant oil-derived isocyanate accounts for 10-20% of the bio-based polyurethane. The bio-based polyol may be plant oil-derived polyol or lignin-derived polyol or a combination of the two, wherein the plant oil-derived polyol accounts for 30-50% of the bio-based polyurethane, and the lignin-derived polyol accounts for 10-30% of the bio-based polyurethane.

[0007] Furthermore, the core layer is composed of 20-40wt% of bio-based polyurethane, 50-70wt% of filler, and 10-20wt% of reinforcing fiber, the filler is calcium carbonate or wood fiber, and the reinforcing fiber is glass fiber or natural fiber.

[0008] Furthermore, the bio-based polyol is extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof.

[0009] Furthermore, castor oil is modified with silane to form a castor oil-modified silane-based hybrid polyurethane coating.

[0010] Furthermore, the bio-based additive includes at least one chain extender 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.

[0011] Furthermore, the bio-based polyurethane is formed by reacting for 4-6 hours at a temperature of 60-120 degrees Celsius.

[0012] Compared with the prior art, the bio-based coating of the board containing bio-based polyurethane of the present invention includes bio-based polyurethane and 15%-75% of bio-based resin. The bio-based polyurethane is formed by polycondensation reaction of at least one bio-based isocyanate, at least one bio-based polyol or at least one bio-based polyamine, and at least one bio-based additive. The bio-based isocyanate can be glucose-derived isocyanate or vegetable oil-derived isocyanate or a combination of the two. The glucose-derived isocyanate is the main reactant for forming a polyurethane connection with the polyol, and the vegetable oil-derived isocyanate plays a role of secondary cross-linking, improving flexibility, enhancing thermal stability and hydrophobicity. The content of the bio-based resin can be further divided into two dosages according to different applications. When the content is 15-30%, it can enhance flexibility and adhesion, and is suitable for floors with less impact. When the content is 30-75%, the cross-linking density can be increased, thereby improving hardness and mechanical stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A cross-sectional view of a board containing bio-based polyurethane provided by the present invention. DETAILED DESCRIPTION

[0014] 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.

[0015] like Figure 1 As shown, it is a schematic diagram of the structure of a board containing bio-based polyurethane provided by the present invention. The board containing bio-based polyurethane includes at least one core layer 10 and a bio-based coating 20 disposed on the core layer 10. It is conceivable that the board containing bio-based polyurethane also includes 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.

[0016] The core layer 10 is composed of 20-40wt% of bio-based polyurethane, 50-70wt% of filler, and 10-20wt% of reinforcing fiber. The filler mainly plays the role of increasing volume, reducing cost, improving processing performance and improving physical properties in the board. The filler is an inorganic filler such as calcium carbonate and an organic filler such as wood fiber. The reinforcing fiber is used to improve the strength and rigidity of the core layer 10. By adding high-strength, high-modulus fibers such as glass fibers or natural fibers to the bio-based polyurethane, the mechanical properties of the board can be significantly improved. The bio-based polyurethane is the same as the bio-based polyurethane in the bio-based coating 20, which will be described in detail below.

[0017] The bio-based coating 20 includes bio-based polyurethane and 15%-75% bio-based resin.

[0018] The bio-based polyurethane is formed by polycondensation of at least one bio-based isocyanate, at least one bio-based polyol or at least one bio-based polyamine, and at least one bio-based additive.

[0019] The bio-based isocyanate can be glucose-derived isocyanate or vegetable oil-derived isocyanate or a combination of the two. The glucose-derived isocyanate accounts for 20-40% of the bio-based polyurethane. The vegetable oil-derived isocyanate accounts for 10-20% of the bio-based polyurethane.

[0020] The glucose-derived isocyanate is the main reactant for forming a polyurethane connection with a polyol. The synthesis process of the glucose-derived isocyanate is to convert the carbohydrate structure of glucose into intermediates such as furan, and then functionalize these intermediates to generate glucose-derived isocyanates. These glucose-derived isocyanates retain the basic skeleton of the glucose molecule and introduce active isocyanate groups, so that these compounds have certain properties of glucose molecules, such as hydrophilicity and biocompatibility, and retain reaction characteristics similar to traditional isocyanates. Its -NCO functional group can react with polyols to generate polyurethane. Polyurethanes extracted from glucose-based isocyanates can be used to manufacture highly durable, wear-resistant and firmly bonded floor coatings with various substrates. These properties are crucial for high-traffic areas such as industrial or commercial floors that require extremely high wear resistance.

[0021] The vegetable oil-derived isocyanate plays a role in secondary cross-linking, improving flexibility, and enhancing thermal stability and hydrophobicity.

[0022] The bio-based polyol can be a plant oil-derived polyol or a lignin-derived polyol or a combination of the two, and the plant oil-derived polyol accounts for 30-50% of the bio-based polyurethane. The lignin-derived polyol accounts for 10-30% of the bio-based polyurethane. The bio-based polyol is extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof. The fatty acid chain in the plant oil-derived polyol is an important structural component of this type of polyol. They are mainly derived from triglycerides in plant oil molecules, which are formed by esterification of glycerol and three fatty acid side chains. The self-oxidation of the double bond residues of triglycerides helps to increase the cross-linking density of the polyurethane coating and improve chemical resistance, hardness and solvent resistance. The fatty acid chains in the plant oil can also increase the flexibility of the coating and show lower tensile strength, tensile modulus and chemical resistance. The main technologies for converting vegetable oil into polyols are hydroformylation, transesterification / amidation, epoxidation / ethylene oxide ring opening and ozonolysis.

[0023] Compared with the unmodified polyurethane batches, the NCO content in the lignin bio-polyurethane was reduced, indicating that the addition of lignin to the bio-polyurethane can achieve efficient cross-linking and allow the monomer to be present in the final system. The lignin-derived polyol can improve the hardness, tensile strength and elastic modulus due to its aromatic structure. It helps to increase the molecular weight and cross-linking density. The aromatic structure of the lignin-derived polyol mainly originates from its original lignin structure. This aromatic structure gives the lignin-derived polyol many unique properties and application potential. Due to the hydrophobicity of the aromatic ring, the lignin-derived polyol can also be used to improve the waterproof properties of the material, thereby improving the waterproofness of the board. There are two ways to use lignin as a bio-polyurethane prepolymer, using lignin directly without chemical modification or combining it with other polymers or using lignin that has been chemically modified (such as esterification and etherification reactions) to ensure that the hydroxyl groups are more reactive.

[0024] Different combinations of bio-based polyols and different bio-based isocyanates will have different effects. For example, castor oil modified with silane to form a castor oil-modified silane-based hybrid polyurethane coating has good thermal stability, stronger hydrophobicity and lower swelling, making it suitable for flooring applications. Castor oil contains three hydroxyl groups and approximately 3.04 unsaturated / triglycerides, making it a suitable candidate for synthesizing polyurethane materials using cross-linking monomers. Most importantly, the structural factors of castor oil make it suitable for use as a polyol to prepare polyurethane coatings with appropriate properties. In addition, long-chain fatty acids can also improve the hydrophobicity, impact resistance and flexibility of the resulting coating.

[0025] The bio-based additive includes at least one chain extender 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. The bio-based polyurethane is formed by reacting for 4-6 hours at a temperature of 60-120 degrees Celsius.

[0026] The bio-based resin preferably has a content of 15-75%, which can be further divided into two dosages according to different applications. When the content is 15-30%, it can enhance flexibility and adhesion, and is suitable for floors with less impact. When the content is 30-75%, it can increase the cross-linking density, thereby improving hardness and / or mechanical stability. The increase in cross-linking density is due to the increase in resin content, which increases the availability of functional groups (-OH and -NCO), which react to form a dense three-dimensional polymer network.

[0027] Different types of ingredients also affect the hardness of the polymer network. Lignin-derived polyols can provide aromatic structures to the polyurethane matrix, thereby improving stiffness and hardness. As the amount of resin increases, the crosslink density also increases, making the material harder, and the tensile strength and elastic modulus also increase. Vegetable oil-derived polyols, especially long-chain fatty acids, can produce flexibility, but the secondary hydroxyl groups can produce moderate crosslinking. At higher concentrations closer to 75%, the resin forms a denser network by crosslinking with isocyanates, thereby balancing flexibility and hardness. Bio-based isocyanates (derived from glucose or vegetable oils) react with polyols to form polyurethane links, which have inherent rigidity and help improve hardness. Increasing the resin content ensures more urethane links, making the material harder. Bio-succinic acid can be used as a renewable component for polyurethanes. Bio-succinic acid can be used as part of the polyol component to react with glucose-derived isocyanates to form polyurethanes for flooring applications.

[0028] The bio-based coating 20 can be used as a wear-resistant protective surface. The coating can be evenly applied at room temperature or UV or heat cured at a temperature of 120-140 degrees Celsius to enhance adhesion and durability. The bio-based coating 20 can also be used as a bio-based impregnant for decorative paper or film, with an impregnation amount of 15-30wt%. The bio-based coating 20 can also be used as a core layer for polymer adhesives, and when used as a core layer, 50-70wt% fillers such as calcium carbonate or wood fiber and 10-20wt% reinforcing fibers such as glass fiber need to be added.

[0029] Compared with the prior art, the bio-based coating 20 of the board containing bio-based polyurethane of the present invention includes bio-based polyurethane and 15%-75% of bio-based resin. The bio-based polyurethane is formed by polycondensation reaction of at least one bio-based isocyanate, at least one bio-based polyol or at least one bio-based polyamine, and at least one bio-based additive. The bio-based isocyanate can be glucose-derived isocyanate or vegetable oil-derived isocyanate or a combination of the two. The glucose-derived isocyanate is the main reactant for forming a polyurethane connection with the polyol, and the vegetable oil-derived isocyanate plays a role of secondary cross-linking, improving flexibility, enhancing thermal stability and hydrophobicity. The content of the bio-based resin can be further divided into two dosages according to different applications. When the content is 15-30%, it can enhance flexibility and adhesion, and is suitable for floors with less impact. When the content is 30-75%, the cross-linking density can be increased, thereby improving hardness and mechanical stability.

[0030] 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 board containing bio-based polyurethane, characterized in that: The board material containing bio-based polyurethane comprises at least one core layer and a bio-based coating disposed on the core layer, wherein the bio-based coating comprises bio-based polyurethane and 15%-75% of bio-based resin, wherein the bio-based polyurethane is formed by polycondensation reaction of at least one bio-based isocyanate, at least one bio-based polyol or at least one bio-based polyamine, and at least one bio-based additive, wherein the bio-based isocyanate may be glucose-derived isocyanate or plant oil-derived isocyanate or a combination of the two, wherein the glucose-derived isocyanate accounts for 20-40% of the bio-based polyurethane, and the plant oil-derived isocyanate accounts for 10-20% of the bio-based polyurethane, wherein the bio-based polyol may be plant oil-derived polyol or lignin-derived polyol or a combination of the two, wherein the plant oil-derived polyol accounts for 30-50% of the bio-based polyurethane, and the lignin-derived polyol accounts for 10-30% of the bio-based polyurethane.

2. The board containing bio-based polyurethane according to claim 1, characterized in that: The core layer is composed of 20-40 wt% of bio-based polyurethane, 50-70 wt% of filler, and 10-20 wt% of reinforcing fiber. The filler is calcium carbonate or wood fiber, and the reinforcing fiber is glass fiber or natural fiber.

3. The board containing bio-based polyurethane according to claim 1, characterized in that: The bio-based polyol is extracted from vegetable oil, castor oil, vegetable oil, soybean oil or a mixture thereof.

4. The sheet material containing bio-based polyurethane according to claim 1, characterized in that: Castor oil is modified with silane to form castor oil-modified silane-based hybrid polyurethane coating.

5. The board containing bio-based polyurethane according to claim 1, characterized in that: The bio-based additive comprises at least one chain extender 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.

6. The board containing bio-based polyurethane according to claim 1, characterized in that: The bio-based polyurethane is formed by reacting for 4-6 hours at a temperature of 60-120 degrees Celsius.

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