Bio-Based Waterborne Polyurethane Hybrid for Stable Fluorine-Free Repellency
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Solution Overview
Problem
Existing fluorine-free water repellents face issues such as high production costs, complex synthesis processes, poor dispersion, low stability, limited fabric versatility, color differences, and low biomass content, with many products failing to meet environmental and performance standards.
Innovation Solution
A method is developed to prepare a bio-based polyurethane-acrylic hybrid fluorine-free water repellent through a two-step process involving homogeneous polymerization and polymerization, using bio-based isocyanate, sorbitol, fatty acid-substituted glycolipid, and dihydroxyl-terminated polydialkylsiloxane to create a stable waterborne polyurethane intermediate, which is then combined with an acrylic-based fluorine-free water repellent to achieve a high biomass content and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluorine-free water repellents (acrylic polymers, dendrimers, waterborne polyurethane) are used, then water-repellent effect is achieved, but production cost is high and synthesis process is complicated
Solution Approach 1:
The patent changes the chemical parameters by using bio-based isocyanate compounds instead of conventional petrochemical isocyanates, and employs polycondensation reaction under controlled conditions to synthesize waterborne polyurethane with improved biomass content (above 60%) while simplifying the synthesis process and reducing production costs
Solution Approach 2:
The patent creates a composite water-repellent system by combining waterborne polyurethane (with biomass content above 60%) and acrylic polymer in specific ratios, achieving both high biomass content and satisfactory water-repellent performance while maintaining cost-effectiveness
2Reliability
If waterborne polyurethane is produced under severe reaction conditions and specific dispersion technique, then water-repellent performance is achieved, but production cost increases
Solution Approach 1:
The patent modifies the reaction parameters by using bio-based isocyanate compounds and controlling polycondensation under milder conditions, eliminating the need for severe reaction conditions and specific dispersion techniques while maintaining water-repellent performance
Solution Approach 2:
The patent employs cost-effective bio-based isocyanate compounds and standard polycondensation techniques instead of expensive conventional materials and specialized dispersion processes, significantly reducing production costs while achieving comparable performance
3Ease of manufacture
If dendrimers and acrylic polymers are used, then production cost is low, but application selectivity is high and fabric versatility is limited
Solution Approach 1:
The patent develops a water-repellent formulation based on waterborne polyurethane with broad applicability across different fabric types (cotton, polyester, nylon, leather, paper), achieving universal water-repellent effect without the selectivity limitations of dendrimers and acrylic polymers, while maintaining cost-effectiveness
Solution Approach 2:
The patent creates a composite system combining waterborne polyurethane (above 60% biomass) and acrylic polymer that leverages the cost advantage of acrylic while adding the versatility of polyurethane, achieving both low cost and broad fabric applicability
4Reliability
If polyurethane polymers are used, then water-repellent effect is achieved, but dispersion and storage stability are poor
Solution Approach 1:
The patent changes the physical parameters by synthesizing waterborne polyurethane with controlled molecular weight and using bio-based isocyanate compounds that improve dispersion properties, achieving both water-repellent effect and enhanced storage stability without precipitation or phase separation
Solution Approach 2:
The patent formulates a composite system combining waterborne polyurethane (above 60% biomass) with acrylic polymer and appropriate dispersants, where the synergistic effect improves dispersion stability and storage characteristics while maintaining water-repellent performance
5Quantity of substance
If extra bio-based ingredients (glycerin, starch, saccharide) are added to increase biomass content, then biomass content increases, but water-repelling performance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by using bio-based isocyanate compounds as core building blocks and controlling polycondensation to achieve above 60% biomass content through meaningful chemical bonds in the polyurethane structure, rather than adding unrelated bio-based fillers
Solution Approach 2:
The patent extracts and eliminates unnecessary bio-based fillers (glycerin, starch, saccharide) that dilute performance, focusing instead on incorporating bio-based isocyanate compounds that form functional polyurethane chains, achieving high biomass content with sustained water-repelling performance
6Object-affected harmful factors
If conventional fluorine-free water repellents are used, then environmental protection is improved by eliminating fluorine, but fabric color difference and washability are poor
Solution Approach 1:
The patent changes the chemical composition by using bio-based isocyanate compounds and controlling polycondensation to create waterborne polyurethane with improved washability and color retention, eliminating fluorine while maintaining or enhancing fabric durability and appearance
Solution Approach 2:
The patent creates a composite water-repellent system combining waterborne polyurethane (above 60% biomass) and acrylic polymer that eliminates fluorine while achieving satisfactory washability and minimal fabric color change through the synergistic properties of the components
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 method results in a water repellent with high biomass content, superior stability, and enhanced water-repelling performance, maintaining effectiveness even after multiple washes and without significant color change, surpassing commercially available products in terms of performance and versatility.
Implementation Method 1
adding 0.05 to 0.3 part by weight of a first initiator to a mixture of step (a) to carry out polymerization
Implementation Method 2
adding 50.0 to 70.0 parts by weight of water, 1.0 to 4.0 parts by weight of an emulsifier, and 0.2 to 0.8 part by weight of acetic acid to the product of step (b) to form the bio-based waterborne polyurethane intermediate
Data Source
AI summary
The present disclosure provides a method of preparing a bio-based waterborne polyurethane intermediate. The method comprises the following steps: (a) mixing bio-based isocyanate compound, sorbitol, fatty acid-substituted glycolipid, dihydroxyl-terminated polydialkylsiloxane, and a solvent; (b) adding a first initiator to a mixture of step (a) to carry out polymerization; and (c) adding water, an emulsifier, and acetic acid to the product of step (b) to form the bio-based waterborne polyurethane intermediate. The present disclosure also provides a method of preparing a bio-based polyurethane-acrylic hybrid fluorine-free water repellent. The bio-based polyurethane-acrylic hybrid fluorine-free water repellent is derived from aforesaid bio-based waterborne polyurethane intermediate and an acrylic-based fluorine-free water repellent.