Acrylated Hyperbranched Polyurethane Oligomer for Low-Temperature Curing
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Solution Overview
Problem
Conventional thermosetting powder coatings require high curing temperatures, leading to thermal deformation and discoloration on substrates like plastics and wood, and have low reactivity, making them unsuitable for thermal-sensitive materials, while radiation-curable coatings face challenges with low curing rates and complex synthesis methods.
Innovation Solution
A radiation-curable acrylated semi-crystalline hyperbranched polyurethane oligomer is developed through a two-step process, forming hydroxy-terminated hyperbranched polyurethane and modifying it with methacrylic and/or acrylic double bonds and long carbon chains or benzene rings, enabling easier leveling and rapid curing at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermosetting powder coatings are used to achieve high reactivity and fast curing, then curing speed is improved, but curing temperature must be increased to 160-180°C which causes thermal deformation and discoloration on substrates
Solution Approach 1:
The patent changes the chemical composition parameters of the oligomer by incorporating hyperbranched polyurethane structure with specific functional groups (carboxyl, hydroxyl, isocyanate) and controlling molecular weight distribution. This enables the coating to cure at lower temperatures (100-150°C) while maintaining high reactivity, thus resolving the contradiction between curing speed and substrate damage
Solution Approach 2:
The patent creates a composite oligomer system combining hyperbranched polyurethane with acrylic or methacrylic functional groups. This composite structure provides both the reactivity needed for fast curing and the thermal sensitivity for low-temperature processing, eliminating the need for high curing temperatures that cause substrate deformation
2Reliability
If conventional thermosetting powder coatings use high curing temperature to ensure complete curing, then curing completeness is improved, but energy consumption increases and application to thermal-sensitive substrates becomes difficult
Solution Approach 1:
The patent modifies the oligomer's chemical parameters by introducing hyperbranched structure with multiple reactive functional groups per molecule. This increases the number of crosslinking sites, enabling complete curing at lower temperatures (100-150°C) with reduced energy consumption while maintaining curing completeness
Solution Approach 2:
The patent replaces the thermal energy-intensive curing mechanism with a chemically-driven curing process. The hyperbranched oligomer's inherent reactivity and functional group density enable curing to proceed efficiently at lower temperatures, substituting chemical reactivity for thermal energy input
3Stability of the object's composition
If radiation-curable oligomers use amorphous polyurethane acrylate with high glass transition temperature to achieve thermal resistance, then thermal stability is improved, but melt viscosity decreases very slowly above Tg making it difficult to level
Solution Approach 1:
The patent creates a composite hyperbranched polyurethane structure combining rigid segments (for thermal stability) and flexible segments (for low viscosity). The hyperbranched architecture with distributed functional groups provides both thermal resistance and excellent leveling properties by maintaining low melt viscosity above Tg
Solution Approach 2:
The patent introduces local flexibility into the polymer structure by incorporating flexible diol segments and hyperbranched architecture between the rigid functional groups. This local flexibility allows the material to maintain overall thermal stability while exhibiting low viscosity and good flow characteristics above Tg for easy leveling
4Adaptability or versatility
If dendritic polyurethane oligomer is synthesized to achieve radiation curability, then radiation curing capability is improved, but synthesis becomes complicated and expensive limiting application
Solution Approach 1:
The patent extracts the essential radiation-curable functional groups (acrylic or methacrylic double bonds) from the complex dendritic structure and attaches them to a simpler hyperbranched polyurethane backbone. This maintains radiation curability while dramatically simplifying the synthesis pathway and reducing production costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The oligomer achieves faster viscosity decrease at higher temperatures, facilitating smoother film formation, higher curing rates, and energy efficiency, making it suitable for a wide range of substrates and suitable for large-scale industrial production.
Implementation Method 1
radiation-curable acrylated semi-crystallinehyperbranched polyurethane oligomer
Data Source
AI summary
The present invention relates to an acrylated semi-crystalline hyperbranched polyurethane oligomer and a preparation method thereof, which is characterized in that on the basis of the synthesis of hyperbranched polyurethane oligomer, it adopts a two-step process to make modifications to form a methacrylic and/or acrylic double bond and a long carbon chain with a carbon atom number higher than 10 or a benzene ring or a naphthalene ring at the terminals. The obtained oligomer has a lower melting point and a higher glass transition temperature and can be cured by means of radiation, and the curing rate is high enough to effectively improve production efficiency and save energy to form a cured film having a higher hardness and excellent thermal stability. The raw materials used in the method of the invention are easily obtained, and the method is suitable for large-scale production in industry.