Ultra-High Solid Polyurethane Dispersion via Continuous Processing
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Solution Overview
Problem
Current methods fail to produce aqueous polyurethane dispersions with ultra-high solid contents, resulting in unacceptable shrinkage upon drying, limited filler incorporation, and longer drying times, while also increasing shipping and storage costs.
Innovation Solution
A continuous process merging a first polyurethane prepolymer stream with a second polyurethane prepolymer or seed latex stream in the presence of a chain extender, achieving a solid content of at least 60% and viscosity below 5000 cps, facilitating reduced shrinkage and faster drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aqueous polyurethane dispersions with low solid contents are used, then ease of manufacture is improved, but shrinkage upon drying increases and drying time increases
Solution Approach 1:
The invention changes the solid content parameter from conventional low levels (30-50%) to ultra-high levels (60-80%), fundamentally altering the dispersion composition to reduce shrinkage upon drying while maintaining manufacturability through continuous processing
2Ease of manufacture
If aqueous polyurethane dispersions with low solid contents are used, then ease of manufacture is improved, but drying time increases
Solution Approach 1:
The invention changes the solid content parameter from conventional low levels to ultra-high levels (60-80%), which directly reduces drying time by minimizing the amount of water that needs to be evaporated, while maintaining ease of manufacture through continuous processing
3Loss of substance
If ultra-high solid content polyurethane dispersions are produced, then shrinkage upon drying is reduced and drying time is shortened, but manufacturing complexity increases
Solution Approach 1:
The invention employs continuous processing where polyurethane prepolymer and aqueous phase are continuously mixed and emulsified, eliminating batch processing steps and reducing manufacturing complexity despite achieving ultra-high solid contents (60-80%)
Solution Approach 2:
The invention uses emulsifiers as intermediary substances to stabilize the ultra-high solid content dispersion during continuous processing, enabling the formation and maintenance of fine particle sizes without increasing manufacturing complexity
4Quantity of substance
If ultra-high solid content polyurethane dispersions are produced, then shipping and storage costs are reduced, but viscosity increases
Solution Approach 1:
The invention changes multiple parameters including solid content (60-80%), particle size (0.1-10 micrometers), and particle size distribution to achieve ultra-high solid contents while controlling viscosity through continuous emulsification processes
Solution Approach 2:
The invention creates a dispersed phase with fine particle sizes (0.1-10 micrometers) that distributes more evenly throughout the aqueous phase, reducing interparticle interactions and viscosity despite high solid content (60-80%)
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 process produces ultra-high solid content polyurethane dispersions with reduced shrinkage, enhanced filler loading, and shorter drying times, thereby optimizing production efficiency and cost-effectiveness.
Implementation Method 1
The ultra-high solid content polyurethane dispersion includes the reaction product of: (1) a first component, wherein the first component is a first polyurethane prepolymer or a first polyurethane prepolymer emulsion; (2) a second component, wherein the second component is a second polyurethane prepolymer, a second polyurethane prepolymer emulsion, a low solid content polyurethane dispersion, a seed latex, or combinations thereof; (3) and a chain extender.
Data Source
AI summary
The instant invention is an ultra-high solid content polyurethane dispersion, and a continuous process for producing ultra-high solid content polyurethane dispersions. The ultra-high solid content polyurethane dispersion includes the reaction product of: (1) a first component, wherein the first component is a first polyurethane prepolymer or a first polyurethane prepolymer emulsion; (2) a second component, wherein the second component is a second polyurethane prepolymer, a second polyurethane prepolymer emulsion, a low solid content polyurethane dispersion, a seed latex, or combinations thereof; (3) and a chain extender. The ultra-high solid content polyurethane dispersion has a solid content of at least 60 percent by weight of the solid, based on the total weight of the ultra-high solid content polyurethane dispersion, and a viscosity in the range of less than 5000 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer. The method for producing a high-solid content polyurethane dispersion includes the following steps: (1) providing a first stream, wherein said first stream comprising a first polyurethane prepolymer or a first polyurethane prepolymer emulsion; (2) providing a second stream, wherein said second stream being a media phase selected from the group consisting of a second polyurethane prepolymer, a second polyurethane prepolymer emulsion, a polyurethane prepolymer dispersion, a seed latex emulsion, or combinations thereof; (3) continuously merging said first stream with said second stream in the presence of a chain extender; and (4) thereby forming a polyurethane dispersion having a solid content of at least 60 percent by weight of the solid, based on the total weight of the ultra-high solid content polyurethane dispersion, and a viscosity in the range of less than 5000 cps at 20 rpm at 21° C. using spindle #4 with Brookfield viscometer.